Carpet production is not one method but three distinct constructions: nonwoven, tufted and woven. Which one you produce with largely decides which backing solution belongs on it.
How is nonwoven carpet produced?
- A needle-punched or felt-like structure
- Fibres are bonded mechanically or chemically — there is no weaving and no stitching
- Used in: exhibitions, automotive, events
Why is tufted production the industry standard?
- It is the industry's standard production method
- Yarn is stitched through a primary backing
- It requires locking in to stop the yarn being pulled out
That last point explains why a tufted carpet almost always calls for a backing process: the yarn is only stitched into the primary backing, and what holds it there is the binder coming from the back.
What sets woven carpet apart?
- Interlaced warp and weft — Axminster and Wilton belong to this family
- High structural integrity
- Used in: luxury and rug applications
How do the three constructions compare?
| Construction | How it is bonded | Where it is used |
|---|---|---|
| Nonwoven | Mechanical or chemical fibre bonding | Exhibitions, automotive, events |
| Tufted | Stitched into a primary backing, then locked | The industry standard |
| Woven | Interlaced warp and weft | Luxury and rug applications |
Which backing solution belongs on which production?
| Customer's production | The solution it calls for |
|---|---|
| Tufted broadloom | Action Back lamination (must have a stenter) |
| Bath mats / runners | Non-slip latex embossing or TPR |
| Luxury woven rugs | Kiss-roll sizing or flat-dried anti-slip |
| Washable / green products | Rotational TPR |
| Commercial office flooring | Carpet tile lines |
We take each row of that table apart by product type in how to choose a carpet backing solution, and compare the materials themselves in latex, TPR and PVC. Our lines are on the Carpet Backing Coating page.
Frequently Asked Questions
What is the difference between tufted and woven carpet?
In a tufted carpet the yarn is stitched through a primary backing and has to be locked in so it cannot be pulled out. In a woven carpet the warp and weft are interlaced (Axminster, Wilton), which gives high structural integrity and is used in luxury and rug applications.
Where is nonwoven carpet used?
Nonwoven carpet is a needle-punched or felt-like structure whose fibres are bonded mechanically or chemically. It is used in exhibitions, automotive and event applications.
Why does a tufted carpet need a backing coating?
In tufted production the yarn is only stitched into the primary backing. It requires locking in to stop it being pulled out, and it is the backing coating or lamination applied from the rear that provides that lock.