Kalogridis International Ltd. has been producing custom carpets since 1976. During this time, we have developed a unique carpet making process that ensures customers the highest quality.
“Custom” carpet provides customer specific design, coloration, pile heights, etc. All are designed for each individual customer. Our carpet is made for your vessel and to your exact specifications. Even a solid carpet absent of design may be “custom”, as yarns are dyed in house to meet your exact requirements.
For solid color machine quality carpets, times can be as short as one week but average around ten working days. Custom projects generally take 8 plus weeks for small to mid-sized aircrafts. BBJs and complex larger aircrafts can take 12 plus weeks depending on complexity of design, number of colors, and types of yarn.
The first step in creating a custom carpet is the design process. After the carpet has been designed and colors have been selected, yarn is dyed, dried, and put on to cones for tufting. Design patterns are traced onto backing, which is stretched on specially engineered frames for the tufting process. All tufting is done by hand and a special latex coat is applied to the back of the carpet for extra durability. The carpet then goes to the finishing floor where all necessary shearing and carving is done. Each stage of the process is mandatorily inspected by our Quality Control staff to ensure perfection. After the carpet has been completed, before being packed and shipped, it goes through its last visual and measurement inspection.
Handmade quality carpets are made, one stitch at a time, using a hand tufting shuttle. A machine made quality carpet is made by a machine which uses numerous needles to expedite the manufacturing process. This is a timely and cost effective method of producing predominately solid color loop, cut pile, and multi-colored textured carpets.
The design staff consists of specially trained and talented designers. Unique designs and techniques can be developed by our staff to make your carpet truly one of a kind. It is also possible to work with an independent designer or design firm. If you are purchasing a new aircraft, it is likely that the manufacturer will have a design team you can work with. This applies to select refurbishing centers as well.
In choosing a design for your carpet you can either choose from one of the many preexisting Kalogridis designs, work with a designer to create something personal and unique, or supply your own. Samples are then manufactured and expedited for your approval. The standard samples are a twelve inch by twelve inch completed portion of a carpet that represents the colors and designs that will be used. Larger samples can be made upon request.
Most of our carpets are made entirely of wool. We also have silk available, which creates luxurious highlights when used in the carpet body, or as an accent. Lurex can be incorporated into the design, which creates a metallic look. Other materials such as fiber optics, linen and mohair can also be incorporated into your specific designs.
Wool is a natural fiber and as such it wears extremely well, resists stain and soil, and is easy to maintain. Wool is also considered naturally flame retardant.
Kalogridis uses exclusively blended New Zealand wool. Made with long, durable fibers, this wool provides for superior quality and long lasting carpet, and is considered the best wool in the world.
By dyeing in house, we are able to ensure the correct desired coloration for your carpet. Unlike production dye houses, after our yarn is dyed it is hung to air dry instead of being sent through an oven to speed up the drying process, which causes alterations to colors.
Formulas are developed for each individual colors requested. When yarn is placed into dye tanks, the color formula is inserted into the dying solution which colors the yarn. The yarn color is checked under various lighting sources to ensure a color match, and a sample is made from the newly dyed yarn. This sample will be sent to you for final approval before the production process begins.
Loop pile is the natural result of tufting. When yarn is pushed through carpet backing, a loop is formed. Cut pile is created using a small blade within the tufting gun which clips off the tip of the loop resulting in a flat, cut surface. Loop pile is lighter in value than cut pile; when viewing loop pile, you see the outermost layers of the yarn. In contrast, cut pile is much darker than loop pile. When viewing cut pile, you see the innermost layers of the yarn.
There is no concrete rule, with loop and cut piles, that one will outlast the other. The wear and tear of your carpet depends on several factors. How a carpet wears is, for the most part, dependent upon its fiber content and stitch rate; the denser the fiber and stitch rate, the longer the wear. Ultimately, the overall wear depends on usage and proper maintenance.
Pile height refers to the measurement from the backing of the carpet to the top of the carpet surface. There are several things to consider when choosing the best pile height for your aircraft or yacht. Most importantly is weight. Typically, by having a higher pile height, a carpet may be heavier. Chair base clearance should be kept in mind as well as lower side wall and air duct clearance.
Carving is a way of sculpting carpet. It is used to define certain design areas of the carpet which gives these portions definition and depth. All carving is hand done by our in-house artisians.
Tip-shearing is a process that clips portions of loops in loop pile carpets. This creates visual interest by introducing a darker cut pile shade to a loop carpet.
All of our aircraft carpets not only meet, but exceed FAA requirements pertaining to burn testing. A DER burn certification is supplied with each Kalogridis carpet upon request.
Because natural fibers are used to make our carpets, maintenance is fairly simple. A schedule of regular vacuuming will greatly aid in lengthening the life of your carpet. Spills are easy to remove. A cleaning kit with complete instructions can be requested at any time. Professional cleaning is also suggested depending on aircraft use.
The life expectancy of your carpet will depend greatly upon the amount of use, and how well it is maintained. When cared for properly, you should be able to enjoy your carpet for many years to come. Most Kalogridis carpets have a service length in excess of five years. Recently, Kalogridis retrofitted a Challenger 601 which had been with its original carpet made by Kalogridis over twenty years ago.
Benefits of a Kalogridis carpet include accuracy of design and color, proper functionality, longevity of carpet service life, and attentive and rapid support response.
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