Have you always wondered how carpet brushes & brooms are made?  If not, then you are lucky. The article you are reading now discusses how carpet brushes are made; it also provides pictures of each step in order to easily understand what exactly happens during this process. So without further ado, here are the five main steps in making carpet brushes.

Step 1 – Drilling:

Drilling is an extremely vital step of the household brush making process, as it allows you to decide how many holes your brush is going to have and what size/diameter each hole will be. It also determines the depth of the holes.

a) No. of holes

Density of the brush depends on the number of holes we make on the handle. The number of filaments can vary depending on this. In addition, the number of holes is directly correlated with the quality of your brush.

b) Diameter of holes

Diameter of holes varies depending on the diameter of your filaments. If you want a tighter, denser brush, it is advised to make fewer holes with larger diameters as it will hold more filaments. For wider, softer brushes, more holes with smaller diameters are best.

c) Depth of the holes

This decides how soft or stiff our broom will be. For stiffer brushes it is ideal to make deeper holes on the handle. This will help your brush last longer and keep its shape. Shallow ​holes on the other hand produce a softer brush, which is not suitable for heavy duty cleaning tasks.

Step 2 – Tufting:

Tufting is a process in which filaments are inserted in the hole. Each filament has embedded a certain color combination at predetermined lengths which makes it special for cleaning purposes.  Before moving to this step, you need to consider some important points as it makes our carpet brush unique as compared to brushes available in the market. At the tufting stage, it is necessary to ensure that all filaments are inserted and there is not a single free end left.

a) Number of filaments per hole

This determines the density and softness of our brush. More filaments results in a denser, softer brush; it also increases the lifespan of your carpet brush as more filaments means more cleaning. Fewer number of filaments makes way for stiff carpet brush which is ideal for heavy duty cleaning purposes.

b) Color combination for filaments

If you want to add unique color combinations to your filament, this is the right place to do that. You can blend colors however you want to. For example, white filaments can be blended with different shades of blue or with the desired shade of pink. The possibilities are endless!

c) Length of the filaments

This is an important consideration when adding color combinations to your filament. Depending on whether you want a long carpet brush which is ideal for deep cleaning and a small one which is ideal for quick touch-ups, you can decide the length of your filaments. Length of the filaments also contributes to strength and weight of the carpet brush,

Types of filaments

Types of filaments in tufting process

• PP monofilament: Best for all-purpose cleaning of carpets and rugs
• Nylon monofilament: Ideal for deep cleaning, this filament also picks up pet hair effectively.
• PET monofilament: Good at both general purpose carpet brushing and picking up pet hair.
• Natural fibers : Ideal for deep cleaning, these are eco-friendly and excellent for pet owners.
• Nylon 66 filaments are slightly stiffer than the PP monofilament. It lasts longer and provides better results when used to clean high traffic areas like stairs, halls or heavily soiled carpets.

As you can see, after this step; we will have a carpet brush with unique color combinations that is both strong and soft at the same time.

Step 3 – Trimming:

The main idea behind brush trimming is to give each filament a perfect cut to ensure you get the cleanest lines possible on your carpet brush. Trimming process makes a big difference in how a brush will look. Having a proper trimmer will also give a uniformity of the filament and a symmetric looking brush.

Step 4 – Flagging:

Flagging facilitates to split the ends of the filament, as a result making the brush look like one that is already used for some time. This step helps in distributing trapped dust and dirt evenly on our carpet brush. Flagging helps in better cleaning and distributing trapped dust and dirt evenly on our carpet brush. It also helps in proper beating to get closer to the area we want to clean.

Step 5 – Beating:

Being the last step of the process, beating facilitates split ends and spread like a blanket on the brush. This is what helps us in cleaning as this step opens up the split ends and spreads like a carpet on our brush.

Pretty much every carpet brush available out there goes through these five main steps so you’ll have an idea about how it is made. It will also help you produce an even better product on your own.

All of the five main steps mentioned above are crucial to making carpet brushes. If any step is ignored or done improperly, it will lead to a inferior quality brush which may cheaper but not be able to deliver good results.

It is very important that each step has high quality machinery and tools in order to get the best quality product. Otherwise, one may end up with a very poor quality carpet brush which has no place on the market.

That is why it is important to use the right equipment for each of these five main steps in making carpet brushes; if done correctly, you will end up with an excellent product that also looks good which will create your brand image.

If you are looking for Automatic Brush Making Machines, BORGHI should be your preferred choice. BORGHI has over 70 years of experience in designing and manufacturing innovative solutions for the Clean and Hygiene industry.

We offer a wide variety of industrial brush making machines to meet all needs- from small scale operations to large enterprises. Our focus on quality coupled with our support has helped Borghi India maintain our position as the popular brush machine manufacturer and supplier in this space.