DREF 2 is putting PP-yarn secondary carpet yarn backing out in front.

For over 20 years, DREF 2 yarns on the basis of PP fibres and a PP tape core have provided an alternative to jute backing. Due to the special characteristics of PP, such as its break strength, non-hygroscopic nature, resistance to bacteria and insects, electrical insulation and partial flame resistance, etc., this fibre material is enjoying steadily growing popularity in the carpet sector.

Textile floor coverings currently number among the most important design factors in the home and object sectors. They also represent an important element in the new and renovated building areas and like all other construction materials, are subject to strict quality regulations. The DOMOTEX fairs of recent years have clearly documented the significance of carpet and carpet flooring to hometex sales.

Apart from surface quality, which is essential to the optical appearance and durability of a textile floor covering, the underside of the carpeting also plays a major role. Up to ten years ago, the majority of tufted, woven and knitted carpets had foam backings. By contrast, high-quality carpets were given a second backing at a much earlier date and these were generally made of jute. However, in the meantime things have changed !

DREF 2 friction spinning technology for secondary carpet backing yarns has been in industrial use since its market launch in 1977. Due to the flexibility of this spinning process with regard to fibre processing and the scope of the end product range, an increasing number of niche products have been developed. In addition, the spinning costs of this coarse yarn machine are comparatively low and yarn production costs are cut considerably as a result of the raw materials that can be utilised (e.g. favourable priced PP tape is used as a yarn core for increased strength, uniform elongation, higher production speeds, etc.), high spinning speeds and a general raising of efficiency. A differentiation between other yarn manufacturing processes, which are more complicated, less flexible with regard to the use of fibres, yarn types and applications and do not provide the prerequisites for high-quality products, is clearly given and is a strong argument for the use of
DREF 2 process in this area.

During the manufacture of secondary carpet backing yarns, each DREF 2 machine spinning head is fed with two card slivers with a total weight of 20 ktex. Over the past 20 years, it has been established that 2.8 - 3.3 dtex/60 mm constitute the optimum fibre range, whereby the majority of secondary carpet backing and tufted carpet manufacturers use a PP fibre with 2.8 dtex/60 mm. Roller and clearer cards with can coilers, synthetic and flat cards are employed for the production of the card sliver, which can be directly fed in 1 m coiler cans to the DREF 2. This facilitates greater efficiency during carding, spinning and subsequent weaving with bobbins of up to 400 mm diameter and weights of 8-10 kg.

The possibility offered by the DREF 2 friction spinning principle for the integration of fibres into the open yarn end, is ideal for the feeding of continuous filaments, or a PP-filament core of 450 - 640 dtex (depending on yarn titre). This is fed in axially between the two spinning drums and then covered with a carded fibre sheath in the nip. The advantages of the core yarns produced using this method are as follows:

  - Uniform breaking strength along the entire length and excellent running properties for further
    processing (weaving and raschel knitting process).
  - Excellent yarn regularity.
  - Good adhesion of the sheath fibres to the core.
  - No rewinding required due to the direct provision of the cylindrical bobbins to the weaving
    process in a weight range of 8 - 10 kg.
  - Long, knot-free lengths.
  - High weaving effectiveness, due to the eradication of thread breaks.
  - High levels of area stability in the finished weave.
  - Retention of a textile surface character.

The leading American and European secondary carpet backing and tufted carpet companies, as well as the largest carpet producers in the Near and Middle East currently manufacture some 450 million sq.m. of carpet secondary carpet backing weave per year in the Nm 5-7.14 (200-140 tex) yarn range on the basis of 2.8 - 3.3 dtex, 60 mm PP at production speeds of 180 - 220 m/min, and spinning mill efficiency of up to 98%.

A European secondary carpet manufacturer that regularly exhibits its products at the DOMOTEX and expands its production capacity every 1-2 years with additional DREF 2 machines, provides the following product information:

Secondary backing fabric
Product information