Yarns
Carpets are only as good as the raw materials from which they are made and the expertise with which they are constructed.
All carpets are made with raw fibre and this is normally spun into a yarn which is then woven or tufted into a fabric that you see in the shops.
Spinning the yarn itself is a skilled job and one which has created its own specialist companies.
Carr’s is one such company.
Attention to detail and exceptional quality control standards are the secrets of perfect yarn. 
Stages in Yarn Spinning.
Carr’s use raw wool from the best British and New Zealand fleeces. This is blended together in precise proportions according to the `character’ and `handle’ of the yarn required.
Continued.........

The Blend is scoured, pulled and teased (the technical term is `carded’) until it is straighter, whiter and free of natural burrs and foreign bodies
Continued.........

The Fibre is systematically opened up and layered and then cross layered and eventually this web or bat is split into slubbings which are then pulled and twisted on a spinning frame which adds strength to the single strand of yarn.
Two or more of these strands are then twisted together, or `doubled’, and this results in a yarn with a high tensile strength capable of being woven or tufted by the latest high tech machinery with the maximum efficiency and at the lower production cost, thereby providing the optimum combination of quality raw materials, exceptional yarns and most economical prices.

Continued.........

The Colour is introduced either at the raw fibre stage or when the yarn is spun into the thickness weight and length for the particular carpet. Thomas Carr continually invest in state-of-the-art machinery and their success is founded upon a continuous programme of research and development, designed to anticipate technical, performance and aesthetic requirements demanded by the market. The results of this investment, new yarn trends, process innovation and carpet product development are regularly introduced to the carpet market.

One of the first spinners to perceive the growing need for improved performance in the field of lasting good looks, Carr developed the process. Woolbond incorporates a small amount (up to 10%) or `low melt’ polyester, which, under normal dying temperatures, fuses with the other components to create a web like structure throughout the yarn. This improves the performance of the resultant carpet. It inhibits shedding of loose fluff contributes to better tuft definition, resilience and resistance to crushing.
Carr’s colour palette is much sought after for its clear soft shades but they have also created a growing bank of subtle heather and wool tweed effects which are providing a practical alternative to fashionable floors the world over.

Meltbond A yarn and spinning system which incorporates a small amount of low melt fibre, usually 10% polyester, with other fibres, usually wool and nylon. The yarn is subjected to a low heat during manufacture which fuses the polyester to the adjacent fibres. This creates a web like structure through the yarn which helps to reduce the shedding of fluff and improve the long term appearance of the carpet.

There are various trade names for this and similar processes: Woolbond, Wool Loc, Tuft-Loc, Twist-Loc, Texture-Loc, Yarn-Loc, Fibre-Loc, Superbond, Fibrebond and Tuftbond.

Anchor Coat

A latex or adhesive coating applied to the back of a carpet, usually tufted, to the tufts and prevent them pulling out.

Heat Setting

This is the process in which heat is used to set a permanent twist into the yarn. The most commonly used are:- Suessen, Superbra and autoclave. If this process has been left out, you may get a problem with pile bursting.