Workers gather discarded plastics from diverse sources, including dumps and beaches.
Before the rug manufacturing begins, the design, color, and pattern of each rug are chosen.
Specific colors are incorporated into the melted polypropylene pellets, based on the pattern.
The workers use the thick liquid obtained from the coloring and re-melting process to form yarns.
After quality control assessment, workers cut the yarn strands into various sizes needed for rug design.
Our Mat’s recycled outdoor mats are designed in the USA. Once the design specs are approved, we have a sample mat created in one of our approved factories in Asia to ensure colors, design, and product specs are exactly as envisioned. Once the sample mat is approved, the manufacturing process begins!
Used polypropylene plastics are collected from various sources and include items such as water bottles, medicine containers, food containers, and single-use shopping bags. These used plastic products are chopped up in a grinder and then melted down to a thick liquid. That liquid is cooled into little pellets which are then sold to companies who manufacture their products from recycled polypropylene.
Our Mat is dedicated to contributing to the reduction of plastic waste in our environment by producing plastic mats using 100% recycled polypropylene. Explore the production process of our outdoor mats made from recycled polypropylene plastic.
Conclusion
The process of creating plastic rugs is both laborious and time-consuming, from collecting polypropylene plastics to cleaning, melting, and coloring. Despite the challenges, the resulting finished product, beautiful, elegant, and sturdy, justifies the effort.
Turning plastic waste into rugs addresses the issue of plastic pollution, making the process worthwhile.
Rugs by Roo stands out as a premier collection of recycled plastic rugs from global brands. They provide customers with top-notch options in luxury recycled rugs. Explore their extensive selection to find the perfect plastic rug for your needs.
Initially, workers gather discarded plastics from diverse sources, including dumps and beaches. Following the collection, the plastics undergo a washing process to eliminate dirt and foreign substances.
After cleaning, the workers pack the plastic into a grinder and cut it into pieces.
Following the chopping process, the pieces are melted into a thick liquid. The liquid is then cooled into small pellets for convenient use by manufacturing companies.
The workers use the thick liquid obtained from the coloring and re-melting process to form yarns necessary for weaving the rug.The liquid is channeled through a pipe and then expelled into a water pool. As the fluid passes through the water, it solidifies, forming long strands with a straw-like structure.The machine operator can adjust the pipes to different sizes, resulting in strands of varying thickness based on the rug’s design.
Quality control checks are conducted to ensure that all strands possess the exact color and weight required for the specific rug design. This assessment occurs after the collection of the tube strands.Any strands falling below the required standards are recycled along with the next batch of plastics.
After quality control assessment, workers cut the yarn strands into various sizes needed for rug design. The strands are also sorted by color.These yarn strands are then loaded onto a loom for the rug-weaving process. An overseer ensures the entire weaving process is error-free and adheres to the required design.
Once the rug weaving is complete, the rugs are removed from the loom and transferred to the next machine for edge cutting and sealing. A thorough quality control check and inspection are conducted on each rug.
Each unique mat design has its specific “mold” that dictates the design and the number of colors to be used in the weaving process.Once the mold is loaded into the machine, manual rug weaving commences. Throughout the process, factory staff members monitor every machine, ensuring that each loop is threaded into the loom at the right time and place.
