wool dyeing
& synthetic extrusion
Clean, loose wool is dyed in batch lots; then dried and blended to ensure consistency of shade prior to spinning.

Synthetic fibres are produced at our Fibremakers’ plant in Bayswater, Victoria. These include solution-dyed or white continuous filament Nylon 6, Nylon 6,6 and polypropylene.

spinning
Individual woollen fibres are aligned and processed for consistent thickness and weight before being spun together into yarn.

Synthetic processed yarn is made by twisting or air entangling extruded fibres together. Different textures are produced by adjusting the shape and thickness of the extruded filament as well as varying the system for setting the twisted yarn.

Yarns can be combined into single or multi-ply thickness, depending on the strength or colour combination required.

tufting
All yarn is converted into carpet using broadloom tufting machines, which can be configured to produce many different carpet styles and constructions (including loop, cut, twist and cut-loop).

Our ability to produce customised carpet is unsurpassed. Directly involved in the design and development of new pattern attachments, we offer a large range of finishes exclusive to Godfrey Hirst.

dyeing and printing
Godfrey Hirst operates two dyeing systems. Titan is the name of a computerised jet printing and fixing system developed by Godfrey Hirst for use on fully-tufted carpet. This award-winning system allows intricate designs and multiple colours to be applied in a single pass.

The Kuster line is used for dyeing solid-shade woollen and nylon carpets. The dye solution is flooded over the moving carpet allowing even penetration of colour through the pile fibre.

finishing
Tufted carpet is fed through a laminating machine, applying latex and a secondary backing to secure the tufts and give the carpet more strength. It is then passed through a dryer to cure the latex.

With cut and cut-loop products, the carpet passes through a cropping process (off-line shearing) to ensure uniform height and finish before the laminating stage. Following final inspection, the finished carpet is rolled, packed and transported to Melbourne Logistics for distribution.