Have you ever wondered how your facility’s commercial mats are made? If so, visualize the process from beginning to end and learn the necessary steps along the way. The commercial mat manufacturing cycle is one that produces high-quality mats that can effectively prevent slip and fall accidents.
3 Main Components of Commercial Mat Manufacturing Process
- High twist, heat-seat nylon yarn that traps dirt and soil and is crush resistant
- Polyester Substrate backing
- Nitrile Rubber
The Commercial Mat Manufacturing Process
- The yarn is sewn tufted, into polyester substrate, non-woven fabric.
- Tuft, nylon carpets keep constant color throughout the entire manufacturing process
- Nylon is extruded after this stage.
- Commercial mats automatically move down the assembly line.
- The mat is sprayed and washed to remove any chemicals from the dye.
- The mat is sprayed with a stain stopper to allow colors to permanently set into the surface.
- Mat is steamed, cut, and stacked.
- Vulcanization of the rubber and the carpet stage must occur last.
- Nitrile rubber is placed flat on the table, with the carpet centered on top
- Nitrile rubber backing is oil, grease, and slip resistant, and fully launderable
- Edges are reinforced with an additional 2 inch strip of rubber to strengthen the mats borders
- Any necessary labels or properties are added
- The mat is placed into the press and goes through a heat treatment.
- You now have a manufactured commercial mat.