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Burtco Enterprises

Carpet manufacturer blends technology and style.

Burtco Enterprises Inc. Dalton carpet manufacturer blends pattern technology and style to create premium products. Burtco Enterprises Inc. was founded in 1978 and originally functioned as a custom carpet manufacturer featuring printed and specialty carpets. With the development of graphics tufting, the Dalton, Ga.-based firm was one of the first in the industry to use computer chips to make graphics patterns. Burtco soon became a featured supplier of graphics-patterned products.  Quality is supreme at Burtco and evidence of this is in the construction of our products, along with our cost-effectiveness and performance, said Bob Kokoszka, president. Also evident at the company is attention to detail. Many of the highly stylized, intricate, carpet designs admired in leading resorts, hotels, convention centers and gaming facilities were custom-designed by Burtcos professional design team. The carpet is manufactured at Burtco Tufting, Chickamauga, Ga.

Tapistron carpet manufactured by Burtco is installed at the Mission Viejo Country Club, Mission Viejo, Calif. The firm also is a premier supplier of golf spike carpeting to the golf and country-club markets. A variety of designs and colorways in spike-proof patterned carpets are running product lines and available for prompt shipment. Custom orders can easily be accommodated. In-house professional designers work in conjunction with clients, designing for companies around the world and creating one-of-a-kind art for the floor. Industry InvolvementKokoszka also involves himself in areas of leadership for the industry. He is president of the American Floorcovering Alliance Inc. (AFA), formerly the Dalton Floor Covering Market (DFCMA) (See Fiber World News, TW, this issue). A lot of exciting things have been happening with the organization since Kokoszkas presidency, including the name change. The board took a look at current activities and profile and determined the association needs to keep pace with the changes within our industry and to expand our scope to be able to anticipate any future changes. We also wanted to do so with greater professionalism and involvement, Kokoszka explained. AFA, he said, will operate in a niche mode, not in conflict, but harmoniously with other industry groups. Also, AFA will represent all segments of floor-covering manufacturing and related services, and serve the collective needs of the industry. CYP TechnologyBurtco has been working with Tapistron Internationals Computerized Yarn Placement (CYP) technology for several years. This collaboration began when principals of Burtco recognized the potential, took a risk and purchased machinery in early 1995. State-of-the-art CYP technology gave Burtco a competitive edge in design and production flexibility. CYP allowed for the creation of a virtually limitless array of pattern and color options in carpeting.Improved performance and reliability of the process paid off and gave unsurpassed quality levels and construction densities. From a small-scale geometric to a 25-foot floral design pattern repeat, CYP allows ideas to be transformed into beautiful carpets that lend enduring strength and elegance to any commercial interior, according to Burtco. 
Bob Kokoszka, president, Burtco, inspects carpet as it is tufted on the Tapistron machine.When it became apparent that Tapistron International was having financial problems and was headed for a bankruptcy filing, principals of Burtco and DavisandDavis (a specialty rug manufacturer in Chattanooga, Tenn.) decided to put together a plan to purchase all of the assets of Tapistron. They formed a new corporation CYP Technologies, which is owned 50/50 by the principals in Burtco (Burton Brown and Bob Kokoszka) and in DavisandDavis (Wendall Davis and Dick Miller).  CYP Technologies did not purchase the corporation. However, they did purchase the machinery, spare parts, trademarks, patents, all intellectual properties, furnishings and any other materials that were in Tapistrons inventory.We did this to ensure that we could continue to run and repair and service our equipment to protect our investment, our jobs, and our future, Kokoszka explained.Kokoszka noted that CYP Technologies will service all CYP machines worldwide. He continued, We will also be doing research and development work to make improvements on the existing technology, and we will be building machines for other carpet manufacturers. According to Kokoszka, the CYP machine allows the advantage of making various tuft densities. The machine can be adjusted easily to run from 50 up to 200 tufts per square inch. While weaving machines tuft from about 50 up to about 80 to 100 tufts per square inch, they cannot effectively and economically run the solution-dyed nylon yarns and make a product that approaches the quality level that can be achieved using the CYP machine. All of this technology, he continued, allows Burtco to offer beautiful patterns with multi-textures cut pile, loop pile, random sheared, and cut and loop custom-designed and custom-colored for a project using wool or solution-dyed nylon. The initial cost, the maintenance cost and the performance are better than other patterned alternatives, according to Kokoszka. Burtcos flagship fiber is Zeftron 2000, a solution-dyed nylon yarn system from BASF.Kokoszka said that products made on the CYP machine compete very well with woven carpets, such as Wilton and Axminster. Although we use only six different yarns in the patterns, we have proven that we can do beautiful styling and coloring using six yarns. For projects of 1,000 yards or more, pricing is less than woven products and may be a little higher than printed carpet, but the quality and performance of the finished CYP product is unequaled.Changing the pattern on the CYP machine takes about five minutes. The operator simply slides a floppy disk into the computer, types in the construction specifications and its ready to go. Patterns can be chosen from a catalog, or patterns or logos can be custom-designed.When we combine the flexibility to make cut pile and loop pile and random sheared all in the same pattern, we can achieve some very interesting and appealing looks for the floor, Kokoszka said. CYP technology sets Burtco apart from many other manufacturers. We are limited only by the imagination and creativity of both the customer and Burtcos designers. It just doesnt get any better than this.

May 2002