Carpet yarns makes up a third of our Dundee factory production, therefore quality testing is of extreme importance.

 

Development

Bonar Yarns has been manufacturing an outstanding range of polypropylene backing yarns for Axminster and Wilton woven carpets since 1970. All of our carpet backing yarns have been developed and produced at our factory at Dundee, Scotland and from there, our yarns are distributed worldwide.

We have the resources to put in the effort needed to keep our product range at top level and to offer the market the next generation of yarns they are looking for. The network between our organization and the market (our customers/ institutions/ laboratories) is very strong, helping us to understand future market needs.

Over the years Bonar Yarns has developed a wide product range of backing yarns, offering you the most appropriate yarn solution for each specific application:

• Environmental sustainable yarns for eco-friendly carpet designs
• Flame Retardant Yarns for the aircraft, cruise and train flooring market.
• UV Stabilised Yarns for outdoor carpet and rug applications. The UV inhibitor will stop the PP yarn degrading when exposed to Ultra Violet rays.

We attach great importance to high quality and continually strive for innovative product performance. Examples of initiatives pursued in the scope of environmental sustainability include the Bonar Yarns' recycling program. This program has an important impact on the way in which polypropylene carpet backing yarns are produced in the near future. Using a dynamic process, Bonar Yarns are developing PP warp and weft yarns made from 100% recycled material that technically meet all tex and shrinkage requirements consistently, so that the quality of the end product is in no way compromised.

 

Manufacture

Our production plant for carpet backing yarns is located at Dundee, Scotland.

Over the years, Scotland has seen Jute production be replaced by Polypropylene carpet yarns. Improvements in the processing and new developments in raw materials made next generations of PP backing yarns available, from warp to weft yarns and from sustainable to flame retardant yarns.

Bonar Yarns' product range is produced by new state of the art machinery. These machines have been partly developed with our preferred machine suppliers on an exclusive basis and enable Bonar Yarns to continually supply its customers with high quality products as the market develops.

Our production plant is managed by a team of production leaders, process engineers and quality managers, in order to guarantee our customers the best product possible. The link between the plant and the customer is guaranteed by our product management team, who work closely with our sales team to understand and then fulfil the customers needs.

 

Testing

All carpet yarns are tested for Dtex Shrinkage, Tensile Strength, Tenacity, Fibrillation pattern Spin oil and Twist.

Shrink

• Shrink is tested at extrusion and after heat setting
• Heat setting can be in hotbox or autoclave
• Autoclave yarn is for very low shrink applications
• This is a key parameter as the shrinkage will affect the finished width and if the carpet lays flat

Strength

• The warp yarns are under considerable tension so must have good consistent strength
• The creels are massive so any yarn breakages can cause considerable downtime and is not acceptable.
• The weft yarns mainly add stability and bulk, strength here is not key but yarn breakages will cause a lot of problems with downtime and increased knots.

Spin Oil

Spin oil is mainly for dust reduction, most looms can run with or without spin oil, some make their own looms
and spin oil is more key here for even running to reduce friction on the warp.