The shedding problem of Tencel solid color carpet is essentially a result of insufficient bonding between fibers and the substrate, accumulated mechanical damage, and environmental interactions. Its production process requires coordinated optimization across seven dimensions: fiber pretreatment, weaving process optimization, finishing reinforcement, improved substrate compatibility, environmental control, mechanical damage avoidance, and a comprehensive quality inspection system, forming a complete process management solution.
Fiber pretreatment is fundamental to reducing the shedding rate. Due to its uniform cross-section and weak fibrillation, Tencel fibers require low-temperature plasma treatment or a silane coupling agent coating before weaving to create a micro-nano-scale rough structure on the fiber surface, enhancing the mechanical interlocking force between fibers. Simultaneously, a bio-enzyme polishing process replaces traditional chemical polishing, precisely removing burrs from the fiber surface and avoiding excessive damage that could lead to fiber breakage, thus reducing the risk of shedding from the source.
Optimizing the weaving process requires balancing density and stress distribution. In the hand-tufting process, a specially designed German tufting needle combined with a three-dimensional CNC needle system is used to achieve precise control of pile height, avoiding localized stress concentration caused by differences in pile height. Woven solid-color carpets utilize adjusted warp-to-weft density ratios, with the warp density slightly higher than the weft density. This warp tension counteracts the lateral tensile forces during use, reducing pile shedding caused by structural deformation. Furthermore, during tufting or weaving, pre-curing fiber nodes with a water-based adhesive enhances initial structural stability.
Post-treatment reinforcement is crucial for improving bonding strength. In the desizing process, room-temperature enzymatic desizing replaces alkaline desizing, preventing strength loss due to the poor alkali resistance of Tencel fibers. During stretching and setting, a composite finishing process using BF resin and silicone softener forms an elastic protective film on the fiber surface through a cross-linking reaction, enhancing fiber abrasion resistance while maintaining the original soft feel of Tencel. In the pre-shrinking process, a combined process of blanket drying and steam pre-shrinking ensures dimensional stabilization of the solid-color carpet under humid heat, preventing pile shedding due to shrinkage stress later.
Improved substrate compatibility enhances structural stability. To address the characteristics of Tencel fiber, high-puncture-strength PP nonwoven fabric is selected as the primary substrate, with a puncture strength exceeding 800N to ensure no tearing occurs during tufting needle penetration. The adhesive layer uses water-based PU adhesive, processed through a 65℃ hot-melt penetration process to evenly coat the fiber roots, forming a mechanically interlocking structure. The reinforcing layer is made of 12×12 jute mesh fabric; its natural fiber's rough surface enhances the bonding strength with the adhesive layer, forming a three-dimensional support system.
Environmental control is implemented throughout the entire production process. During spinning, a static eliminator and humidification system are linked to maintain workshop humidity at 60%±5%, preventing fiber entanglement damage due to electrostatic adsorption. After weaving or tufting, a low-temperature, slow-drying process is used to prevent fiber structural loosening due to sudden heat shrinkage. During storage, solid color carpet must be laid flat in a temperature- and humidity-controlled warehouse to avoid creases from folding becoming stress concentration points.
Mitigating mechanical damage requires attention to equipment maintenance and operating procedures. Regularly inspect the wear of the tufting needles and replace dulled needles promptly to prevent fiber breakage due to increased puncture resistance. In the cutting process, use laser cutting instead of mechanical cutting to avoid fiber fraying caused by blade pressure. During transportation, solid color carpet must be wound onto paper tubes with a diameter ≥30cm to prevent permanent fiber deformation due to excessive bending.
A comprehensive quality inspection system is a closed-loop guarantee for process optimization. Establish a dynamic monitoring mechanism for pile shedding rate, using a Martindale abrasion tester to simulate daily use and quantify pile shedding amount by weighing. Perform microscopic observation on each batch of solid color carpet, recording fiber breakage patterns and substrate peeling to trace deviations in process parameters. Incorporate customer feedback data to adjust weaving density or adhesive dosage in areas with high-frequency shedding, forming a continuous improvement mechanism.
