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TechTips
Laundering Instructions for Karaat™ and Classic Brush™ Mats
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Karaat™ and Classic Brush™ mats offer superior colorfastness for mats that are used in direct sunlight or laundered under high temperature, high pH washing conditions. All Solution dyed mats can be washed together. For best results Solution Dyed mats should not be washed with space dried nylon mats. For heavy solid mats, break temperatures can be raised to 160°(71°C)
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Process
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Comments
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Time
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Water Level
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Temperature
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1.
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Flush
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2-3 Min.
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Medium
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120F(49°C)
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2.
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Flush
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Optional
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2-3 Min.
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Medium
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120F(49°C)
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3.
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Break
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5 Min. |
High
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120F(49°C)
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4.
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Rinse
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2 Min.
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High
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Cold
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5.
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Rinse
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2 Min.
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High
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Cold
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6.
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Extract
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Low Speed
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1-2 Min.
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7.
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Shake Out
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Rotate wheel at wash speed with drain open
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1 Min.
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8.
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Extract
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High Speed
Max - 250 G's
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3-5 Min.
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9.
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Dry
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Optional
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5-10 Min.
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180ºF (82ºC) (Basket Temperature)
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10.
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Cool Down
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5 Min.
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*Caution: When drying mats made with solution dyed nylon yarn it is possible to melt the carpet surface. Be sure dryer temperatures do not exceed 180°F(82°C). Lay mats flat following removal from washer or dryer. Allow mats to cool before rolling. Roll mats nap out for delivery.
Laundering Instructions forPortal™ Logo Mats
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Portal™ Logo mats are most often used in light soil conditions, which minimizes the need for vigorous washing. For best results, use low water temperatures and mild detergents.
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Process
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Comments
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Time
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Water Level
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Temperature
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1.
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Flush
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2-3 Min.
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Medium
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80F(27°C)
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2.
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Flush
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Optional
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2-3 Min.
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Medium
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80F(27°C)
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3.
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Break
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See #1 Below
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5-10 Min. |
High
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100F(38°C)
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4.
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Rinse
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2 Min.
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High
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Cold
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5.
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Rinse
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2 Min.
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High
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Cold
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6.
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Extract
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Low Speed
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1-2 Min.
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7.
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Shake Out
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Rotate wheel at wash speed with drain open
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1 Min.
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8.
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Extract
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High Speed
Max - 250 G's
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3-5 Min.
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9.
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Dry
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Optional
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5-10 Min.
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180ºF (82ºC) Basket Temperature
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10.
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Cool Down
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5 Min.
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Lay mats flat following removal from washer or dryer. Allow mats to cool before rolling. Roll mats nap out for delivery.
- Do not use high pH detergents, alkali or solvents. The break should not exceed a pH of 9.5. Use a low pH non ionic detergent. 2-4 oz./100 # of mats. Consult with your chemical supplier for exact amounts.
- Do not allow mats to remain wet and in contact with each other following washing. This can cause dye transfer from one mat to another.
- Do not overdry mats
- Customer experience has shown that certain logo mat colors that are in the light blue, silver and gray shades can discolor when laundered. This problem seems to vary depending upon local water conditions. Some customers have no problems in this area while others experience significant difficulties. To help prevent this discoloring, add 1/3 - 1/2 lb. sodium per carbonate or 5-10 fluid oz. hydrogen peroxide (35% active ingredients) per 100 pounds of mats being washed, during break cycle of the regular wash formula.
Should you require additional information or if Mountville can be of further assistance, please call us at 1-800-241-5549 or 1-706-882-2961.
Laundering Instructions for Crystal™ Mats
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Comfort Flow™ and SuperScrape™ mats do not require aggressive wash procedures or drying. These mats can be washed periodically to remove oil, grease and soil. The Formula shown below does not require extensive mechanical action. Itsmain purpose is to dissolve grease residue by using hot water to emulsify oils and grease.
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Process
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Comments
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Time
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Water Level
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Temperature
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1.
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Flush
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2-3 Min.
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Medium
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120°F(49°C)
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2.
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Flush
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Optional
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2-3 Min.
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Medium
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120F(49°C)
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3.
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Break
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See Below
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5 -10 Min. |
High
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120°F(49°C)
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4.
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Rinse
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2 Min.
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High
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Cold
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5.
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Rinse
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2 Min.
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Cold
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6.
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Extract
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Low Speed
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1-2 Min.
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7.
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Shake Out
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Rotate wheel at wash speed with drain open
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1 Min.
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8.
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Extract
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High Speed
Max - 250 G's
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3-5 Min.
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9.
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Dry
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5-30 Min.
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180ºF (82ºC) Basket Temperature
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10.
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Cool Down
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5 Min.
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Do not use high pH detergents, alkali or solvents. The Break should not exceed a pH of 9.5. Use a Low pH non-ionic detergent. 2-6oz./100# of mats. Consult with your chemical supplier for exact amounts. Lay mats flat following removal from washer. Comfort Flow™ mats do not require extracting or drying.
Laundering Instructions for ComfortFlow™ and SuperScrape™
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Comfort Flow™ and SuperScrape™ mats do not require aggressive wash procedures or drying. These mats can be washed periodically to remove oil, grease and soil. The Formula shown below does not require extensive mechanical action. Its main purpose is to dissolve grease residue by using hot water to emulsify oils and grease.
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Process
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Comments
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Time
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Water Level
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Temperature
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1.
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Flush
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2-3 Min.
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Medium
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120°F(49°C)
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2.
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Flush
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Optional
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2-3 Min.
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Medium
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120°F(49C)
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3.
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Break
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See #2 Below
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5-10 Min. |
High
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120°F(49°C)
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4.
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Rinse
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2 Min.
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High
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Cold
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5.
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Rinse
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2 Min.
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High
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Cold
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6.
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Extract
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Low Speed
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1-2 Min.
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7.
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Shake Out
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Rotate wheel at wash speed with drain open
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1 Min.
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8.
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Extract
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High Speed
Max - 250 G's
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3-5 Min.
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9.
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Dry
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Optional
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5-30 Min.
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180ºF (82ºC)*
(Basket Temperature)
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10.
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Cool Down
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5 Min.
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Lay mats flat following removal from washer or dryer. Allow mats to cool before rolling. Roll mats nap out for delivery.
- Stained or heavily soiled mats can be washed at 140°F(60°C). Repeated laundering at this temperature can cause premature color loss.
- Do not use high pH detergents, alkali or solvents. The break should not exceed a pH of 9.5. Use a low pH non-ionic detergent. 2-4oz./100# of mats. Consult with your chemical supplier for exact amounts.
- To prevent pilling on other mats Crystal™ should not be washed with mats made of nylon or other synthetic carpet yarns
- Insure that cotton mats are thoroughly dried to prevent mildew from forming in the cotton yarn.
Instructions for Mat Drying
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Many customers are choosing to eliminate drying as part of their normal mat processing. Although there are benefits to not drying, such as reducing costs, reduced handling and labor expenses as well as freeing up needed dryer capacity, there are also disadvantages. Some of these are that some mats go out wet; sand and grit are left in the mats and at times mats can develop odors. In order to produce the best quality mats, Prestige Carpets recommends a short drying cycle. Tech Tips #1, #2 and #4, which provide recommended wash formulas for carpet topped mats, also include a 5-10 minute drying and 5 minute cool down cycle.
Instructions for Repairing Mats
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During customer use and in plant processing, mats can become ripped, cut or torn. Mats that have not been seriously damaged can be repaired. Cuts and tears are usually the result of customer abuse or may occure during processing. If cuts and tears seem excessive, contact Prestige Carpets for technical assistance or refer to the trouble shooting guide. Mat repairs can be preformed in either of two processes: Cold Patch repair or Heat Seal repair.
Cold Patch Rubber Mat Repair Process
Required Materials-
Mat Repair Kit: includes 1 oz bottle of Superbonder #420 Glue and 2 rolls of mat repair rubber.
Other required material that are not Included in the kit: Protective Gloves, Safety Glasses, Wire Brush, Heavy Weight (such as a Brick or Concrete block).
Caution: Superbonder #420 is an extremely fast drying glue. It is capable of gluing fingers together or gluing fingers to mats being repaired. Be sure to use protective rubber gloves and observe all safety precautions listed on label of the glue bottle.
Do not leave top off the bottle. Glue will harden very quickly and become unusable. Do no store glue in warm areas. Store in a refrigerator to extend shelf life.
Tips
If mats being repaired do not have Cleats, glue flat side of repair rubber to the repaired mat. Repair rubber without cleats is also available from Prestige Carpets.
Rounding cornerof repair rubber prior to gluing will help extend the life of the repair. This helps prevent the corners from catching on other mats as they are tumbling in washers and dryers.
Repair Procedure:
- Carefully sort mats to be repaired. Be sure mats to be repaired are Clean. Mats with tears longer then 12" are not recommended for repairs.
- Place mat on flat surface, rubber side up.
- Using the wire brush, buff the area around the tear.
- Cut a strip of repair rubber slightly longer than the tear to be repaired
- Carefully place the edges of the tear together so that they do not buldge or pucker. If the tear extends to the border, be sure that the edges of the border meet evenly. It may help to "spot glue" the edges together on longer tears or at the border to insure the edges remain in proper position.
- Position the repair strip on top of the tear. Keep the strip centered over the tear as much as possible. Beginning at one end, glue a small area (approx 1") of repair rubber to the mat. Apply glue sparingly. Using the handle of the wire brush, press the repair rubber down for a few seconds and then release. repeat over all areas where the glue was applied. Continue until you can feel the glue has hardened - approximately 30 seconds. Repeat until the repair is complete.
- When the repair is completed, check edges to be sure all edges are securely glued down.
- Place weight on top of repaired area. Allow to sit for 10-15 Minutes.
- Inspect the mat to be sure the mat lies flat and does not create a tripping hazard.
Heat Seal Mat Repair Process
Materials Required:
- Electric grinder with coarse disc or electric drill with wire brush
- Non-stick teflon coated fabric
- Uncured repair rubber
- Heat seal unit with minimum 5 minute cycle timer
- Scissors
- Gloves
- Face Shield
- Dust Mask
Repair Procedure:
- Inspect mats to insures suitability for repair. Discard mats with numerous tears, excessively large tears, ect.
- Use grinder or drill to buff rubber surfaces. If mats are cleated, remove all cleats in the area to be covered with repair rubber.
- Set heat seal timer to 5 minutes. Temperature should be 400°F(200°C). Air pressure should be at the maximum (app. 80 psi) setting.
- Cut rubber to proper size. Remove plastic backing.
- Apply rubber to repair area.
- Place mat in heat seal unit. Cover repair with teflon fabric to protect heat seal heads. Be sure rubber side of mat faces heated platen.
- Cook for 5 minutes.
- Allow repaired mat to cool.
- Trim Excess Rubber from edge of mat.
Keep uncured rubber in refigerator to prevent pre-curing of rubber.
Instructions for Adding Labels to Mats
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There are two procedures to add labels to mats. These are: Heat Seal-with Uncured Rubber and Heat Seal-without Uncured Rubber. Both processes allow laundries to add labels to their existing mat inventory. However, labels applied with the Heat Seal Process with uncured rubber produce a more permanent result. Below are instructions for both procedures.
Required Materials:
- Labels - Available for purchase from Mountville Europe.
- Uncured Rubber - Available for purchase from Mountville Europe.
- Indelible ink marking pen.
Required Equipment:
- Heat Seal Machine*
- Grinder with wire brush attached.
- Teflon coated fabric.
*Labeling was done using a NatMar Mat Master mat repair process. However any type heat seal machine capable of meeting the time and temperature requirements should work.
Heat Seal Process-with uncured rubber
- Buff off the area where the labels are to be applied so you have a smooth surface. If the mat is cleated, be sure to remove all cleats. With smoothed backed mats it is also necessary to buff the rubber to improve the bond between the label and the rubber. Use care not to be too aggressive in grinding as you may grind through the rubber backing, damaging the mat.
- Set your heat seal machine to full air pressure (80 psi is desirable) and 350 degree temperature
- Remove the white label from its paper backing.
- Using the black permanent ink-marking pen, mark the white label as needed. Doing this before the label is vulcanized to the rubber backing makes the ink of the marking pen more permanent.
- Place the mat in the heat seal machine with the buffed rubber area in the middle
- Cut and place in the middle of the buffed area a piece of black uncured rubber that is slightly larger than the lable being applied. Remove the plastic backing from the rubber.
- Place the label on the uncured rubber.
- Cover the label and the entire repair area with a piece of Teflon coated fabric.
- Close the heat seal machine and allow the label and the rubber to cook for 8 minutes.
- When the cook cycle is completed, allow the mat to cool before handling.
Heat Seal Process-without uncured rubber
The Heat Seal Process-without uncured rubber is very similar to the Heat Seal Process-with uncured rubber. The only difference is that you omit the use of the uncured rubber (see step 6 above) And you reduce the cooking cycle time (see step 10 above) from 8 minutes to 2 minutes.
Our Experience has shown the Heat Seal Process-with uncured rubber to be more permanent than the Heat Seal Process-without uncured rubber. In our testing of the Heat Seal Process using uncured rubber, lables have lasted over 100 wash cycles. Normally heat-sealed labels without uncured rubber begin to fail after 40-50 wash cycles
The setup and effectiveness of heat seal equipment can vary widely depending on the available air pressure and the head produced by the individual machine. Because of this, we recommend that laundries thoroughly wash test several samples before undertaking a large relabeling program.
Instructions for Date Codes
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For quality control purposes all mats are date coded at time of manufature. Date codes are located on the back of each mat. These codes include the Month and year of creations, the press and shift the mat was backed on and the name of the employee on duty.
Example:
For a 3x10 created in March of 2006 the date code would read: MAR 06 A1 BP
Each part of the date code represents the following:
- MAR 06 - The month and year in which the mat is manufactured.
- A1 - This is the press and shift in which the mat was made.
- BP - These are the initials of the employee that made this mat.
There is a size label placed in opposite corners of each mat to aid in size identification. The above date code is placed next to one of these size labels.
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