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#Weaving

Competence since 1854

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Weaving is more than just one of the oldest crafting traditions.

It is the passion for which we have given our all from the very beginning. It is our further developed, refined core competence. And the highest quality way to produce carpeting.

Ever since.

For our textile floorings, we deliberately keep all the threads in our hands, from dyeing and spinning to processing on the looms and their backing. In this way, we ensure their unique quality. And you can tell: Our woven carpets have not only won many awards, they also easily last 20 to 25 years – without you even noticing.

Speaking of optics: Regardless of whether you decide on loop pile or velour – with their wide range of colors and designs, our textile floorings allow for a large variety of interior designs. Just as it has been for thousands of years.

ANKER has one of the largest carpet weaving mills in Europe
Facts, Figures and Data

33

weaving looms in total

22

dobby looms, including 2 m, 3 m and 4 m wide looms

11

Jacquard looms, including 2 m, 2.50 m and 4 m wide looms

Contemporary –
  For 32,000 Years

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The ancient Romans, Greeks and Egyptians, the Germanic tribes and Aztecs, and probably the late Neanderthals, as well: Humankind has been weaving for 32,000 years.

Even if the techniques have been refined during this time, the basic principle has always been the same. At least two thread systems (warp and weft) are crossed at right angles.

Nothing has changed in this respect. And it applies equally to flat and pile fabrics with loop or velour, mono-color and multi-color woven fabrics and simple to sophisticated patterns and designs. One thing must be noted, however: Weaving by hand is very laborious and time-consuming. Machines are faster and therefore more efficient. For this reason, fully automatic looms have therefore been in use since industrialization in the 19th century: Warp threads can be raised and lowered in groups, making it much easier to guide the weft thread through the shed. Weaving has never before been so fast.

Three-Dimensional
  Diversity

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Since the founding of our company, we have focused on the diversity of textile floor design.

Although a wide variety of patterns are also possible with flat weaves, our woven pile carpets offer more variety in terms of structure and texture. After all, in addition to the base weave, an additional pile layer provides a wide range of variation in textile floorings. To create these variations, we still rely on two tried-and-tested processes today: dobby and Jacquard weaving.

For the special feel of our carpets, we not only pay attention to warp and weft thread density, but we also give them volume. And how? Quite simply, really. In addition to the weft thread, we also feed steel rods into the shed: The pile yarn is wrapped around the rods, thereby creating the classic loop pile is created. The loop shape, width, and height vary depending on the diameter and shape of the rod. Incidentally, we manufacture these rods in our own metalworking shop – quality made by hand. Our velour carpets are also produced using rods and the special Wilton rod process: These rods have small knives at their ends that cut open the loops when they are pulled out.

The Jacquard process offers even more possibilities, but it is also more demanding. In contrast to dobby weaving, the individual pile threads can be raised and lowered individually, resulting in more color, more structure and more variety.

For high-quality textile floor coverings with unique designs.

Clever craftsmanship

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We wove unmistakable designs early on.

With the most state-of-the-art looms of the time. But not only that: Leopold Schoeller also patented the Whytock process. Since the pile threads are used to create sophisticated patterns in this process, the threads, which are around five times as long, have to be printed individually. But even that wasn't a problem. We dyed entire series of warp threads with suitably large drums – for a correspondingly large number of carpets.

As Leopold Schoeller was also convinced of the advantages of in-house production from the outset, he had the warp threads printed on site and adapted processes and drums for the world's largest loom at the time: ours. These looms were able to weave over a width of five meters. After all, we wanted to produce both broadlooms and cut-to-size rugs.

Thanks to the sophisticated – albeit complex – warp yarn printing process, we were able to weave the most detailed carpets and rugs in terms of color and design. To keep it that way, in-house pattern designers created the designs by hand despite all the available technical innovations.

Nowadays, the weaving process has become more modern – but it is still time-consuming.

Preparation
  Is Everything

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Before we start weaving our textile floorings, we have to make a lot of preparations.

For example, we have to prepare and insert warm and pile beams and remove old ones. The preparation process is the biggest difference between our various machines. In the dobby loom, all warp and pile threads are carded together onto the respective beam. For a two-meter-wide carpet, that's about 680 threads. The time required for this task is a good two and a half to three hours.

Jacquard weaving is different. The bobbin creel must be fitted individually for this type of weaving, as the threads can be controlled individually. As a result, hundreds of pile threads have to be attached by hand, which multiplies the working time. This is because the new yarn has to be manually knotted to the old one, and the threads have to be brought to tension and fed through the shafts and reed.

All in all, Jacquard weaving still requires a great effort, even today – but the result is worth it.

Trust Is Good –
  Control Is Better

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Even though we know how our machines work, errors and failures can always occur.

For this reason, we monitor the weft, warp, pile and raw materials, both technically and visually. Our weavers check the product quality during production and check for irregularities and smooth machine operation. Our product inspectors then keep an eye on the pattern, color and nap uniformity. They check our textile floorings before the final inspection and eliminate any defects. Because, as we all know, four eyes are better than two.