The Mtuft range of machines is an innovative solution for product development of Tufted Carpet. The combination of conventional tufting machine components with a highly sophisticated control system means that one machine can sample a large range of gauges, stitch rates and onstructions. This gives a single machine the sampling capability for many production machines. Only one package of yarn is required for each color in the sample. Up to eight different yarns can be included in a sample. With over 50 units sold around the world, the Mtuft has set the benchmark for performance and flexibility, whilst saving our clients time and money.
The best practice cycle time to produce a new carpet sample, including setup time is now 20 minutes! The Mtuft innovation enables carpet manufacturers and carpet designers to get to the same end point as with traditional tufted carpet sample machinery but much quicker and with less cost.
The current response time of Carpet Designers and manufacturers to the "custom/contract" market segment is typically 2 weeks. For those who have not streamlined their creative design process "end to end" cycle times can be 3 to 4 weeks, just to produce one sample.
For the conventional tufted carpet sampling machine or running samples on a production machine, the setup time for one sample could take up to one full day with setup of up to 200 cones of yarn. This is a lot of non value added work just to setup the sampling machine. The value adding time to produce 1 carpet sample is less than 1% of the total cycle time.
The Mtuft produces a new carpet sample including the setup time, in 20 minutes. This capability enables a 2 day response time for new designs to be offered to clients. A same day service for urgent sample requests is now possible.
The Mtuft gives the designers the capability to develop new products (ie. New construction development, dye developments, etc.) and perform diagnostic work with immediate feedback.
It enables product development in miniature and the results can be seen immediately. It therefore gives the capability to perfect new product ideas before committing them to the production plant.
This exploratory stage is critical in the creative design process.
Traditional carpet sampling machines are based on production technology and can therefore only produce samples to match the gauge or type of the individual production machine.
The Mtuft has remarkable flexibility in that one machine has the capability to sample any type of tufted carpet.
All types can be produced at a wide range of gauges and stitch rates without changes to any gauge parts.
The Mtuft can produce samples of 1.0m or 2.0m by any length. It also has the capability to produce miniature samples which enables the Designer to perfect their product ideas quickly, without wasted investment in yarn and set-up time. For colour work, the designer can simply batch multiple design files of up to 8 colours and leave them to run overnight. Upon return to work next day, all 8 coloured samples will be waiting for you.
The total cost to produce a tufted carpet sample inclusive of labour and yarn is reported to be US$110. The labour cost includes the setup time and the sample producing time, with the setup time being a non-value adding cost of up to 90% of the labour time.
The Mtuft will reduce the labour costs by 90% and the designers will be able to perform other activities when the Mtuft is running as it requires no supervision. The Mtuft can even be set up to produce samples overnight.
Traditional tufted carpet sampling machines need between 30 to 50kg of yarn, which is then fed onto approximately 200 cone, just to make one carpet sample. If this quantity of yarn is not available then it has to be specially made.
A skilled operator can reduce the amount of yarn wastage, but it can be up to 0.25kg at a cost of $5 to $10 per kg. The calculated minimum yarn wastage is estimated to be $1.25 to $2.50 per sample.
The Mtuft requires only 1 package of yarn per colour so there is no wastage. The cost saving is estimated to be US $2/sample.
Cost per sample US $ |
Current |
Mtuft |
Comments |
| Labour | 100 | 10 | Direct cost allowance |
| Yarn and materials | 10 | 8 | Direct cost allowance |
| TOTAL | 110 | 18 | Saving you over 80% |
Making carpet samples on the production plant is advantageous because the samples will accurately replicate the production quality. However it comes as a great cost to the business in terms of significant production downtime.
The Mtuft can produce samples that accurately replicate all tufted production lines and designs from your production plant.
Traditional sampling machines are based on production technology and can only replicate samples with the same gauge and style of tufted carpet that the production machine can produce. These sample machines can cost up to $1.5 million. The Mtuft can produce samples for all tufted production lines and designs at a fraction of this cost.