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Title / Demonstrate advanced knowledge of carpet manufacturing technologies
Level / 5 / Credits / 35
Purpose / People credited with this unit standard are able to explain the principles of tufted carpet manufacturing and demonstrate knowledge of: quality management in tufted carpet manufacture; patterning systems used in tufted carpet manufacture; manufacturing and structures of woven carpet; yarn engineering for wool carpets; and techniques for insect-resist treatment of wool carpets.
Classification / Textiles Manufacture > Carpet Manufacture
Available grade / Achieved
Explanatory notes
None.
Outcomes and evidence requirements
Outcome 1
Explain the principles of tufted carpet manufacturing.
Evidence requirements
1.1Tufted carpet manufacturing process is explained in relation to the essential components of the process.
Rangestitching pile yarn into a pre-woven or spunbonded backing fabric, fixing the tufts (or loops) into place using an adhesive, pile down.
1.2Tufting mechanisms are explained in terms of the materials and the process for inserting tufts of yarn into the primary backing fabric.
Rangeessential materials of the process – needles, loopers and knives, reed plate fingers, backing fabric, adhesive.
1.3Tufting needles, loopers, and hooks are described in terms of their features and purpose.
1.4Tufting needles, loopers, and hooks are described in terms of their maintenance requirements.
1.5Modular gauge parts in tufting machinery are explained in terms of their features and purpose.
Rangeneedles, loopers, knives, reed fingers.
1.6Ancillary equipment is described in terms of their features and purpose.
Rangeyarn creels and beams, cloth feed, mending gun, inspection frame.
Outcome 2
Demonstrate knowledge of quality management in tufted carpet manufacture.
Evidence requirements
2.1The general rules for achieving carpet manufacture reliably and without faults are explained in accordance with a carpet specification.
Rangeavoiding stoppages, machinery and settings, machine control devices, machine maintenance, housekeeping methods.
2.2Inspection of tufted carpets is explained in terms of the fault identification processes and equipment used.
Rangecarpet type – unbacked, finished;
equipment – inspection frame, visual inspection, sophisticated fault detectors.
2.3Faults in tufted carpet are explained in terms of their effect on the carpet quality and durability.
Rangevisible – gaps created by yarn breakage, stripes, streaks, bands;
non visible – stitch rate, gauge, pile height.
2.4Causes of faults, and methods for rectifying faults in tufted carpet, are described in accordance with the fault type.
Rangeloop-pile faults – chainstitching, rough pile, rough backstitch, split looping, stop marks, uneven spacing of stripes;
cut-pile faults – pull-down (drag), ‘J’ tufting, split looping, rough backstitch, isolated stripes, uneven spacing of stripes, excessive damage to backing fabric, tufts protruding from back of fabric, stop marks.
2.5The significance of high-speed machinery is explained in terms of product quality and production processes.
Outcome 3
Demonstrate knowledge of patterning systems used in tufted carpet manufacture.
Evidence requirements
3.1Patterning systems on tufting machines are identified in terms of the patterning techniques for tufted carpets.
Rangesystems – yarn tensioning, crossover, colour interchange.
3.2Yarn tensioning system is explained in terms of patterning techniques and pattern type for tufted carpets.
Rangedisc cam, servo yarn variator, universal type patterning attachment systems (utpa), slat patterning, scroll patterning, full repeat scroll system.
3.3Crossover system is explained in terms of patterning techniques and pattern type for tufted carpets.
Rangesingle straight needle bar, single staggered needlebar, double sliding needlebar, shifting mechanisms, combinations of patterning mechanisms.
3.4Colour interchange system is explained in terms of patterning techniques and pattern type for tufted carpets.
Rangeindividually controlled needles, colortec, computer yarn placement.
3.5Faults in patterned tufted carpet are explained in terms of their effect on the carpet quality and durability.
Rangeincorrect yarn colour, incorrect colour sequence on creel, incorrect sequence on sliding needle bar, incorrect scroll pattern, damaged scroll pattern, incorrect pattern disc, crossover shift marks.
Outcome 4
Demonstrate knowledge of manufacturing and structures of woven carpet.
RangeAxminster, Wilton.
Evidence requirements
4.1Axminster woven carpet is explained in terms of advantages for manufacturing of pattern carpets.
4.2The Axminster weaving process is explained in terms of the types of carpets produced through this process.
4.3The principal types of machinery used in the manufacture of Axminster woven carpet are explained in terms of their advantages, features, and production techniques.
Rangelooms – gripper-jacquard, spool-gripper.
4.4Wilton woven carpet is explained in terms of manufacturing woven carpets.
4.5The Wilton weaving process is explained in terms of the types of carpets produced through this process.
Rangecut-pile, cut-loop, loop-pile.
4.6The principal types of machinery used in the manufacture of Wilton woven carpet are explained in terms of their advantages, features, and production techniques.
Rangelooms – single-rapier weaving, double-rapier weaving, triple-rapier weaving;
jacquard mechanisms.
Outcome 5
Demonstrate knowledge of yarn engineering for wool carpets.
Evidence requirements
5.1Key factors to be considered when selecting a yarn for a particular type of carpet are described in terms of the main categories of carpet.
Rangecategories – woollen spun velour, woollen spun velour, woollen spun frisé, semi-worsted loop pile, woollen heavy gauge, woollen spun saxony loop pile, Axminster, Wilton;
selection factors may include but are not limited to – bulk and cover, cost, count, colour, abrasion resistance, regularity, strength.
5.2Tufting gauges and yarn counts are explained in terms of the carpet type it is produced for.
5.3Twist stability in carpet yarns is described in relation to production of a balanced yarn.
Rangetwist factor, yarn settability.
5.4The benefits and limitations of melt-bonding are described in terms of woollen carpet yarns.
Outcome 6
Demonstrate knowledge of techniques for insect-resist treatment of wool carpets.
Evidence requirements
6.1The species of moths and beetles that deposit their lavae in carpets are identified and the conditions in which they flourish in carpets explained.
6.2Insect-resist treatments are identified in terms of their ability to protect wool carpets.
6.3The techniques used to apply insect-resist treatments are explained in accordance with manufacturers’ instructions and health and safety requirements.
Rangedyebath application, application during scouring, powder application.
This unit standard is expiring. Assessment against the standard must take place by the last date for assessment set out below.
Status information and last date for assessment for superseded versions
Process / Version / Date / Last Date for AssessmentRegistration / 1 / 19 May 2006 / 31 December 2019
Rollover / 2 / 16 July 2010 / 31 December 2019
Review / 3 / 19 May 2016 / 31 December 2019
Consent and Moderation Requirements (CMR) reference / 0030
This AMAP can be accessed at
Please note
Providers must be granted consent to assess against standards (accredited) by NZQA, or an inter-institutional body with delegated authority for quality assurance, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment.
Industry Training Organisations must be granted consent to assess against standards by NZQA before they can register credits from assessment against unit standards.
Providers and Industry Training Organisations, which have been granted consent and which are assessing against unit standards must engage with the moderation system that applies to those standards.
Consent requirements and an outline of the moderation system that applies to this standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The AMAP also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.
Comments on this unit standard
Please contact the Apparel and Textile Industry Training Organisation if you wish to suggest changes to the content of this unit standard.
CompetenzSSB Code 101571 / New Zealand Qualifications Authority 2019 / / New Zealand Qualifications Aut