When carpet inspectors arrive at a job, they often only have the slightest of clues as to what to expect. If they are asked to look at a discoloration problem, there are many different causes. One common issue includes a zigzag line running the length of the carpet.
The carpet inspector will usually notice that the zigzag line is approximately six feet long and runs the length of the carpet. Upon closer inspection, a zigzag line in the carpet is the result of a tensioning issue during manufacturing. The carpet inspector can use magnification to look at the tufts. They can also check out the backing of the carpet to know for sure.
What happens is that the tufting machine uses a staggered stitch. This means the yarn doesn’t attach to the backing in a straight line. The uneven line makes all the yarn tufts staggered. That way, it blends without obvious demarcation lines. When the yarn is not properly tensioned, it creates a look that fails to blend with the other yarn. The zigzag line appears higher or lower than the rest, and it becomes noticeable.
When the carpet inspector makes the determination that the zigzag line is a tufting issue, it is clear that it is a manufacturing issue.
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