It was here I was able to see how important health and safety is to Milliken, when they allowed me to see their general breakdown and targets, which outlined the level of production, delivery and the level of danger during operation, which was always as low as possible. I was given ear protectors and given strict instructions what to do and what not to do and I felt in extremely capable hands for such a busy factory.
We saw how the rubber was stretched, rolled and moulded, reader to be attached to matting. It was amazing to see the manufacturing process and the intricate way in which each batch was handled and labelled.
“INNOVATION ISN’T JUST A THING; IT’S EVERYTHING.” – CHRIS DESOIZA, VICE PRESIDENT OF RESEARCH & DEVELOPMENT
believing that the best ideas and innovations stem from being free to experience, experiment and learn! I found myself wondering if they would have room for me!
The factory area itself was extremely impressive. I hadn’t quite understood how large the production area would be. We were taken through carpet production, step-by-step, looking at how different finishes are created and how the carpet fibres are backed and made ready for laying. Seeing how a single strand of nylon would turn into a bright and vibrant carpet was certainly impressive and I found myself getting left behind as I gawped at the different stages and machinery.
Millitron® Technology
Once aspect of the production process that really impressed me was the Millitron® Technology – a specialised, injection dyeing technology that brings colour to the fibre after it is a finished white carpet. This technology is one of a kind as the computer-controlled micro jets inject dye with surgical precision deep into
the face of a carpet. This is why Milliken are so well-known for their personalised printed mats, for logos, patterns and solids as Millitron® adds colour to the whole fibre, rather than just the tips, as is traditionally found. This dated technique, also known as “overprinting” can fade over time as the carpet tips suffer the most wear and tear, leaving logos and branding faded and lacklustre.
With 400 micro-jets per square inch, Millitron® can create extremely detailed designs – as intricate as you can imagine. I was witness to this when I mistook beautiful printed carpets as canvas paintings in the reception at the Wigan site – it was only as I looked closer that I realised it was carpet on the walls!
Milliken Mats We moved on to the Middleton site next, which was the home of most of the matting production. It was here that I appreciated the scale at which Milliken are able to operate at with the onsite rubber production producing masses day-by-day.
Speaking of labels, we also entered the labelling room, where there were so many options to choose from to
enable customers to personalise their mats with their company name, branding, serial numbers and other information. There was also a blueprint of a mat to show the possible label placement combinations, which was both baffling and impressive.
There was even an area for testing the mats against various soils and wear and tear, using a bespoke machine that mimicked the average tread from a person, including the sole of the shoe and the impact it would have.
I hadn’t ever imagined that this much care went into the production of a single mat or carpet and it was then I realised the root to Milliken’s success. The Milliken family has a great working ethic, intelligent individuals onboard, the freedom to experiment, an interest in innovation and, overall, they really cared. Milliken don’t miss a detail; not a single thing, and that is possibly why they stay one step ahead in the matting and carpet world.
www.milliken.com
The future of our cleaning industry | TOMORROW’S CLEANING | 43 FEATURE
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