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 constructions. 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.
Sample Cycle Times
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
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.
- Full Repeat Scroll (FRS)
- Single, double and unequal Sliding Needle Bar
- Fine Line
- Cut Pile
- Cut & Loop Pile
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.
Saving you money
Reducing Total Sample Making Labour by up to 90%
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
Mtuft uses a single package of yarn per colour - up to 8 colours
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 $
||Direct cost allowance
|Yarn and materials
||Direct cost allowance
||Saving you over 80%
Freeing the Production Facility from Sample Making
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
The Mtuft can produce samples that accurately replicate all tufted production lines and designs from your production plant.
Cost of a traditional sampling machine
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.