ADNC | Quality with a Difference

Carpet manufacture at ADNC is a complex process involving people, sophisticated equipment and high quality raw materials. Starting with chips and fibres from our suppliers, we extrude, tuft, dye, weave and cut carpet for every type of installation, including palaces, hotels, offices and residences. On this page you can find out about our plants and processes.

The BCF plant produces an annual output of 6,000 tons of polypropylene yarn. We produce yarn in our BCF plant from locally-sourced raw material and using state-of-the art Neumag equipment. The BCF plant takes raw polypropylene and blends it, then pulls, straightens and spins it into yarn. To make polypropylene frieze, two yarns are twisted into thick, two-ply yarns. These yarns are steamed and heated to fix their shape. The final step is winding the yarns onto tubes prior to tufting.

Axminster was recently introduced to the ADNC product line. The first of its kind in the Middle East with a quality blend of 80% British wool and 20% nylon. It has the capability of producing the finest carpets in the world to suit the customers' needs.

ADNC has five tufting machines. Together they produce 9.5 million m2 of carpet per year, at widths of 3.66 or 4m. In the tufting plant the yarn is fed into antistatic nylon tubes leading to the tufting needle, which push the yarn into loops. Automatic controls ensure that all the loops are of specific height. To make cut pile, knives snip the loops. This process is carried out with several hundred needles, producing several thousand square metres of carpet a day.

Polyester carpet is dyed in the dyeing plant. Greige carpet is prepared for dyeing by stitching several rolls together to make one continuous roll. We then feed this roll into a vat of water. The carpet is brought under pressure in the vat in a mixture of chemicals and dyes for several hours and then steamed, fixing the colours. The process is completed by washing off the excess colour and drying the carpet.

Where printed designs are required, we have a chromo jet printer. Like an ink jet printer, this printer uses automated colour jets, for precise dyeing deep into the carpet pile face. Up to 8 colours are used.

We stitch the ends of the carpet rolls together to make one, continuous belt. Then we roll this belt under a dispenser, which spreads latex onto the back side of the carpet. A secondary backing is coated with latex and then these are rolled together, sealing them in a sandwich-like process. Then we cure the latex in an oven.
We also offer needlefelt as a secondary carpet backing, on request.

Finishing the carpet requires steaming, brushing, vacuuming and final shearing to ensure that all the cut pile tufts are of the same length. Then the carpet is rolled into 20 to 40 meter lengths and packaged for shipping.

Quality control
For information on our quality management processes, inspection and checking, Click here.



	FACTORY TOUR
			Carpet manufacture at ADNC is a complex process involving people, sophisticated equipment and high quality raw materials. Starting with chips and fibres from our suppliers, we extrude, tuft, dye, weave and cut carpet for every type of installation, including palaces, hotels, offices and residences. On this page you can find out about our plants and processes. The BCF plant produces an annual output of 6,000 tons of polypropylene yarn. We produce yarn in our BCF plant from locally-sourced raw material and using state-of-the art Neumag equipment. The BCF plant takes raw polypropylene and blends it, then pulls, straightens and spins it into yarn. To make polypropylene frieze, two yarns are twisted into thick, two-ply yarns. These yarns are steamed and heated to fix their shape. The final step is winding the yarns onto tubes prior to tufting. Axminster was recently introduced to the ADNC product line. The first of its kind in the Middle East with a quality blend of 80% British wool and 20% nylon. It has the capability of producing the finest carpets in the world to suit the customers' needs. ADNC has five tufting machines. Together they produce 9.5 million m2 of carpet per year, at widths of 3.66 or 4m. In the tufting plant the yarn is fed into antistatic nylon tubes leading to the tufting needle, which push the yarn into loops. Automatic controls ensure that all the loops are of specific height. To make cut pile, knives snip the loops. This process is carried out with several hundred needles, producing several thousand square metres of carpet a day. Polyester carpet is dyed in the dyeing plant. Greige carpet is prepared for dyeing by stitching several rolls together to make one continuous roll. We then feed this roll into a vat of water. The carpet is brought under pressure in the vat in a mixture of chemicals and dyes for several hours and then steamed, fixing the colours. The process is completed by washing off the excess colour and drying the carpet. Where printed designs are required, we have a chromo jet printer. Like an ink jet printer, this printer uses automated colour jets, for precise dyeing deep into the carpet pile face. Up to 8 colours are used. We stitch the ends of the carpet rolls together to make one, continuous belt. Then we roll this belt under a dispenser, which spreads latex onto the back side of the carpet. A secondary backing is coated with latex and then these are rolled together, sealing them in a sandwich-like process. Then we cure the latex in an oven. We also offer needlefelt as a secondary carpet backing, on request. Finishing the carpet requires steaming, brushing, vacuuming and final shearing to ensure that all the cut pile tufts are of the same length. Then the carpet is rolled into 20 to 40 meter lengths and packaged for shipping. Quality control For information on our quality management processes, inspection and checking, Click here.