Carpets are produced in batches and usually each batch produces between 500m2 - 3000m2 in a single width. Whilst the recipe used by the dyer remains constant, in each separate production the colour reproduction may vary from batch to batch. However, production is matched back to the original or master sample to ensure that the colour remains 'within a commercial tolerance'. To ensure perfect colour matching, it is advised that a single width is used in any installation requiring exact colour matching.
The samples held by individual retailers may not be from the same batch as current production and therefore should be used as a guide and not an exact colour match. Shedding All cut pile carpets will lose short fibre, which is created during production when spun yarn is cut for tuft formation. These fibres fall onto the surface of the pile and appear as 'fluff'. The effect varies with yarn type and may be removed by vacuum cleaning. The excess fibre is only a small fraction of the total fibre contained in the carpet.
Pulled loops occur only in looped pile carpet where one or more loops in the continuous pile is pulled through the primary backing of the carpet. Pulled loops are easily dealt with by trimming the offending end level with the rest of the pile. They should not be left as this could result in further loops being pulled and developing into a ladder. Sprouting Occasionally an odd tuft or two can work its way to the surface and stand proud of the rest of the pile. This is probably due to one end of the tuft being longer than the other. These merely need to be scissor trimmed level with the rest of the pile. They should never be pulled out.
Shading occurs because the pile of the carpet has become crushed, flattened or brushed in a different direction to the natural lie of the pile. This causes light reflection at differing angles resulting in the creation of light and dark patches on the carpet. This will occur on all pile fabrics but can be more noticeable on plainer carpets. Fading on Wool Carpets made from wool can and do fade in use. The degree of fade can depend on the colour chosen and the local conditions to which the carpet is subjected. Fading can be caused by exposure to ultra violet light which is found in daylight, but is accelerated which sunlight shines directly onto the carpet. This has the effect of lightening or "bleaching" the colour just as exposure to sunlight will lighten human hair. Pile Reversal Like shading, this occurs when the pile of the carpet changes direction and thus reflects light at different angles showing the effects of shading which can become permanent. It can occur quite quickly after installation. There is no commonly known manufacturing process which can cause or cure this phenomenon and therefore it is not a manufacturing fault. Indentations When a carpet is subjected to a heavy point load, such as under the legs of furniture, it is unreasonable to expect the carpet not to indent. Usually, the longer the load is in place, the longer it will be for the pile to recover. In the case of very heavy loads in place for a long time, the recovery time can be very considerable. It must be remembered that it is not only the pile of the carpet that becomes indented - the underlay will also indent and the backing of the carpet may also distort into the indentation in the underlay. The use of cups below furniture legs can spread the load and the net result is a larger area of less deeply indented carpet.
Flattening will occur as a result of traffic, which eventually flattens the pile particularly in the main areas of use. All pile fabrics will flatten to a greater or lesser degree dependant on the amount of traffic to which it is subjected and the construction of the product concerned.