How we convert plastic bottles into our beautifully soft hard wearing rugs.
To make our beautifully soft yet hard wearing rugs our factory takes plastic bottles through a process of washing, shredding and spinning to turn them into an end product which can be used again and again.
Plastic bottles are collected & sorted.
The plastic bottles are collected and taken to recycling cycles where it is sorted.
Polyethylene terephthalate plastic (PET) bottles are sorted from the other plastic bottles.
This is done by a machine that uses infrared beams that detect the PET plastic by the different reflection of the plastics.
Precision jets of air separate the bottles.
Shredded, washed & dried.
The plastic is shredded by a machine and washed to remove any impurities such as remnants of original contents and labels.
The flakes are then dried ready for the next process.
Melted into pellets and made into fibre.
The flakes are heated, further screened and cleaned, dried and placed in a vented extruder.
The extruded plastic is cooled and then thoroughly chopped to make plastic pellets.
The pellets are then melted and put into a spinneret to produce fibres.
Spun into yarn and dyed.
The fibres are doube spun to produce yarn.
The yarn is dyed to produce coloured yarn to create the design of the rug.
Rug is handwoven and packaged.
The yarn placed on a loom and handwoven to produce a rug.
Once made the rug is quality inspected and packaged ready for despatch.
Diamond is available in 5 colours and 5 sizes.
Diamond is woven with a tighter yarn count meaning that the rugs are particularly suitable for use in hallways where extra foot traffic may be expected.
Multi is available in 6 colours and 5 sizes.
To achieve the extremely soft feel of Multi, we bring together many strands of yarn and hand spin these together to double the yarn count which gives an extra texture and softness.
Stria is available in 4 colours and 5 sizes.
Interwoven strands of two colours are bought together to give our Stria rug a contemporary look for your hallway or room.