An important part of the architectural design process is planning the finishings of each build. A few of our interior design teammates recently had the opportunity to travel to Dalton, Georgia, home of the nation's leading floor-covering manufacturers, to learn more about the products they choose for their projects.
During their visit, the pair toured various Mohawk manufacturing plants where they saw how carpet, resilient, and sheet vinyl goods are made - from design, to material sourcing, manufacturing, and distribution. They received a comprehensive view of the carpet production process, along with a complete overview of the company, its history, and the types of flooring produced. The tour also included the mill's sustainability practices and use of eco-friendly materials.
The amount of design, engineering, and passion for the reduction on environmental impacts was mind-blowing to witness.
Project Designer Kimberly Keller, Assoc. AIA, stated, "We observed how recycled plastic water bottles are transformed into yarn, created into carpet, and how it is packaged and ready for delivery across the world. It entirely changed the way I view flooring."
The team learned that Mohawk reuses 58% of their total manufacturing waste and were surprised to learn that the carpet we walk on was once a water bottle! This gave them a greater perspective of the importance of reducing waste, how the design trends of carpet are generated, and the science behind different qualities and backing of the flooring.
Interior Design Director Jessica Egge, Assoc. AIA, ASID, gives an overview of the agenda and their learning experience.
Raw Materials Section:
Introduction to the materials used, such as wool, nylon, or other fibers.
Explanation of the sourcing of materials and their preparation, including cleaning, dyeing, and blending.
Weaving Process:
View machines that weave carpets, typically large industrial looms.
Explanation of various weaving techniques (e.g., tufted, woven, or needle-punched), that determine the texture and durability of the carpet.
Automated systems and hand-finishing processes
Dyeing & Design:
Learning how carpets are dyed, either before or after weaving.
Overview of design processes, from traditional patterns to modern custom designs, often using CAD technology.
Quality Control:
Demonstration of how carpets are inspected for defects, tested for durability, and treated with stain or fire-resistant coatings.
Explanation of the mill’s standards for quality and safety.
Cutting & Packaging:
How the carpets are cut to size, finished with edges, and prepared for shipment.
Insight into logistics and distribution processes.
Showroom:
Received a tour of the mill’s showroom, where finished products are displayed.
A hands-on QA session to feel and see the variety of textures, colors, and designs and ask questions about how the design is conceived.
LVT
View and experience the production and design engineering of LVT
Jessica Egge exclaimed, "The LVT process was engineering gold, it takes a whole building to produce the runs, the climate, the precision, and the process were the utmost impressive down to the packaging robots.
Mohawk utilizes AI to help with production and packaging, to become more efficient and productive.
During each visit, the pair were invited to engage with carpet mill representatives to gain a deeper understanding of specific production techniques or design innovations.
Egge continued, "From a business perspective, the marketing, distribution, and outreach strategies were particularly intriguing. It's hard to imagine how many tons of carpet are shipped worldwide, and the engineering behind it is truly impressive. It really puts the scale of the operation into perspective. The company's recycling efforts go above and beyond, reflecting a deep commitment to sustainability and the environment. As a tribe, we are responsible for providing for the future, and Mohawk embodies that philosophy. As a designer, this was fascinating and inspiring. The employees' sunny dispositions demonstrate the strong commitment Mohawk has to its workforce. I was genuinely impressed by the entire operation and the logistics of production. The experience was invaluable."
