The photo caption on page 8 of the ITMA Special Report (ATI June 1999) should have read: Dornier introduced two completely new weaving machines.
One of these is the A-Type air-jet loom with dobby, shown here.The sub-heading for Camstar Shines (ATI June 1999) should have read: Camstars prior success leads to InSite implementation at
Unifi.The photo caption on page 47 of the same article should have read: At Unifi, Automated Guided
Vehicles are dispatched by Camstar’s InSite MES at key points in the production cycle.”

August 1999

Carpet OverviewBy Peggy Whaley, Carpet Editor Wall-To-Wall Innovations
Consolidation, technology and versatility combine to shape the future ofthis challenging and
ever-changing market. Consolidation in the floorcoverings industry has been massive in
the last few years. There were over 250 separate corporations about five years ago now there are
60. In the last few months, $2.5 billion of an $11 billion industry have been consolidated into
mills that were already doing over $5 billion. Five to seven companies produce about 80 to 90
percent of the carpet market. Today there are fewer individual companies to make decisions that
affect the entire industry. This creates even stronger competition between the major
competitors.Fortunately, growth has been strong for the carpet industry in the past few years. This
years projections are strong again. The rug portion of the business continues to grow as well.
Carpet corporations are growing in other ways and taking advantage of its existing distribution
capabilities and expanding product offerings to include wood, ceramic tile, laminates and other
home furnishings products, such as comforters, throws and table textiles. CRI – Issue Driven

The CarpetandRug Institute (CRI), Dalton, Ga., is the national trade association for the
carpet and rug industry. CRIs membership consists of manufacturers and suppliers representing over
90 percent of all carpets and rugs produced in the United States. CRI is led by Ron VanGelderen,
president, and Dan Frierson, CEO, the Dixie Group, who is chairman of the CRI Board.According to
VanGelderen, CRI will be issue driven with an outreach attitude. The focus will be on: various
technical issues in fields of health, the environment and schools; issues addressed with
governmental agencies; and communication of all the findings on these issues.CRI has many
challenging roles. For instance, carpet in the school market is being challenged because there is a
perception that carpet is more difficult to clean. The fact is, nationwide, maintenance tends to be
lacking and budgets are diminished because of added demands for budget and other issues, such as
security. CRI and the industry will focus on communicating the facts to schools and assisting them
in knowing how to specify appropriate carpets for school, and how to care for carpet and other
floorcoverings effectively and efficiently, VanGelderen said. The Bigger Get BetterWith hard
surface flooring growing dramatically and getting stronger with many carpet manufacturers as well,
diversification appears to be the name of the game. Even Shaw Industries Inc., Dalton, Ga., is now
marketing ceramic and laminate floorings as well as carpets and rugs.If you include Armstrong World
Industries, a dominant vinyl floorcovering business, in total North American floorcovering sales,
youll see four dominant floorcovering players: Armstrong, Shaw, Mohawk and Beaulieu. They control
60 percent of the total North American floorcovering sales.Shaw Industries is considered the
largest carpet mill in the world with 1998 sales of over $3.5 billion. After trying the retail
business for a few years, its retail operations were sold to the Maxim Group. The firms addition of
Queen Carpet and its commercial divisions, Designweave and Patcraft, gave a tremendous boost in the
commercial market. Mohawk Industries, Calhoun, Ga., made even bigger in-roads after purchasing
Aladden Mills in 1994. Several others mills were acquired and then last year, it made another
significant move by acquiring World Carpets. Mohawk then acquired Image Carpets, the nations
largest producer of polyester carpet, and Durkan Patterned Carpet. Mohawk is also strong in both
residential and commercial carpets. The firms 1998 sales were over $2.6 billion.Beaulieu of
America, Dalton, Ga., had 1998 sales of about $1.5 billion. Beaulieu, a privately owned firm, has
also made several acquisitions in 1998. It acquired Marglen Industries, Columbus Mills and Peerless
Carpet of Canada. Strong in both the residential and commercial markets, Beaulieu is the only
carpet manufacturer in the United States that makes its own polypropylene polymer.Carpet mills are
now manufacturing various sizes of carpets including: modules or carpet tiles for the constantly
changing office; 6-foot goods for ease of handling; the traditional 12- and 15-foot broadloom
goods; and 4-meter carpet for export.These new systems and products are answers to end users desire
for a variety of products that meet various performance and installations needs. An example of this
is the need for a moisture-impervious carpet for health-care and educational use, or a more
sectioned surface for walking comfort and insulation and sound abating qualities in retail
installations. Fiber AdvancementsCarpet mills and fiber manufacturers are having research and
development successes in producing new fibers. There are advancements in old fibers; new backing
systems which includes advancements in soft backing, attached cushions, PVC (polyvinylchloride)
backings and hard backing that are alternatives to PVC and entirely new products, such as Sollenium
from Interface.Fiber companies are still where a large majority of the action takes place. They
definitely keep pace with whats happening and todays technologies. These companies dont just adapt
to change, they sometimes lead it.And where would the industry be without marketing Relationship
marketing abounds and has been around since we bartered with fur pelts and salt. But there is a
difference. Its now also about continually reinforcing your brand name so goods or services are
continually seen.BASF realized this and has started a marketing campaign with a new direction. The
campaign is centered around a new adaptation of its familiar slogan, We dont make the carpet, we
make the carpet better and focuses on advantages accountability, sustainability, versatility and
durability. This new campaign was launched at the recent NeoCon market in Chicago. BASF is among
the top 10 producers of chemicals and related products in the United States, Canada and Mexico,
with sales of $7.2 billion in 1998.With its reputation for innovations for solution-dyed nylon,
BASF has introduced 10 new colors for its contract nylon carpet products. Designers and specifiers
will be excited about the versatility these new colors bring to our current color pallet, said Ian
Wolstenholme, sales and marketing manager for BASFs carpet fiber products said. BASF is also
incorporating recycled content in all of its branded Zeftron® solution-dyed and natural nylon
carpet yarn products. Additionally, it is extending its 6ix Again® carpet recycling program to all
mill extruders who use BASF Ultramid® Nylon 6 polymer containing recycled content as part of BASFs
ongoing commitment to environmental responsibility and sustainable development.DuPont Flooring
Systems is a fully integrated flooring product and services distribution network. Dedicated to
delivering total customer satisfaction, it is a single source for floorcovering needs, including
products, installation, maintenance and reclamation.Most of the new technology at DuPont improves
styling capabilities of Antron® Legacy nylon and Antron Lumena® solution nylon. Dave Findlay,
director, DuPont Chemical Flooring, related that DuPont has concentrated on developing new tools to
help mill customers create carpets with deeper, richer, more vivid colors with its Antron Legacy
nylon. We have introduced nearly 20 new colors in a smaller fiber size to provide more versatility
with both color and design, Findlay said. A new innovation for Antron Lumena is the DuPont
ColorLink technology that creates a random pattern of color throughout the carpet, a styling
capability that has not previously been possible with solution-dyed nylon fiber.Continuing to lead
the industry in surface energy technology, DuPonts DuraTech® patented soil-resistance treatment is
the most durable fluorochemical/soil-release product available today. DuraTech is an integral part
of Antron Legacy nylon and Antron Lumena solution-dyed nylon. Findlay says that DuPont continually
takes steps to improve their environmental offering.More than 50 percent of the production of
Antron Lumena solution-dyed nylon contains recycle-content nylon. In addition, DuPont Flooring
Systems is committed to keeping all carpet removed out of landfills. Since Carpet Reclamations
Programs inception, approximately 44 million pounds of carpet have been reclaimed, Findlay
said. New TechnologyThe carpet industry has countless combinations of carpet patterns,
textures and fibers. New technology is making the fashion side of the industrys products very
exciting. The advancements in tufting technology allow many more patterned and textured carpet
styles. The advancements now offer fashion-oriented choices instead of the majority of products
being a commodity of beige plush.VanGelderen noted that this is happening in residential as well as
commercial business and seems to be the norm instead of the exception. The challenge on the
residential side will be to encourage traditional carpet retailers to stock the new patterns and
assist the consumer in knowing how to decorate with them.On the commercial side, the designers are
embracing the patterns easily and quickly.

August 1999

Culp Inc., High Point, N.C., reported sales and earnings for the fourth quarter and fiscal year
ended May 2, 1999. Net sales for the quarter totaled $132.2 million compared with $135.8 million
during 1998.Net income for the quarter was $2.9 million, or $0.23 per diluted share, compared with
$4.2 million, or $0.31 per diluted share in the fourth quarter of fiscal 1998. For the year, net
sales increased to $483.1 million compared with $476.7 million in fiscal 1998.Net income for the
year was $3.1 million, or $0.24 per diluted share, compared with $15.5 million, or $1.19 per
diluted share in fiscal 1998.JPS Textile Group Inc., Greenville, S.C., announced results for the
second quarter and six months ended May 1, 1999.For the second quarter, there was a net loss from
continuing operations of $3.5 million, or $0.35 per diluted share, compared with net income from
continuing operations of $2.3 million, or $0.23 per diluted share, for the second quarter of fiscal
1998.The reported net loss for the quarter was $26.3 million, or $2.63 per diluted share, compared
with net income of $2.9 million, or $0.29 per diluted share, for the same period in 1998.For the
first half of fiscal 1999, there was a net loss from continuing operations of $3.1 million, or
$0.31 per diluted share, compared with net income from continuing operations of $3.8 million, or
$0.38 per diluted share for the first half of fiscal 1998.Kellwood Co., St. Louis, reported record
sales and earnings before unusual items for both the fourth quarter and the year ended April
30.Sales for the year increased 3 percent to $2.15 billion, from $2.09 billion last year.Net
earnings declined to $1.95 million, or $0.07 per diluted share, due to special charges totally
$62.34 million taken in the fourth quarter. Earnings before unusual items and income taxes
increased 16 percent or $101.5 million, from $87.6 million for the same period in 1998.Diluted
earnings per share before unusual items increased the sales and earnings of Koret Inc., which was
merged into Kellwood in April 1999.Sales for the fourth quarter were a record $628.4 million, up 6
percent from $594.9 million a year ago.Texfi Industries Inc., New York, recently announced a loss
of $3.202 million, or $0.36 per basic and diluted share, for its second quarter ended April 30,
1999, compared to a loss of $2.768 million, or $0.31 per share, for the same period last year.Net
sales in the second quarter 1999 declined by 31.2 percent, to $23.438 million, from $34.084 million
for the second quarter 1998.Total costs dropped by 28.9 percent, to $24.693 million, from $34.738
million in the same period of 1998.

August 1999

Springs Industries Inc., Fort Mill, S.C., recently announced that it is expanding distribution of
its Springmaid® brand to the mass merchant channel in order to better align its value.
Historically, Springmaid has been positioned in department and specialty stores, as well as
selected national chains. The new distribution begins with shipments in spring 2000.The company
said that the decision creates the opportunity for more consumers to purchase the Springmaid brand
where they shop.Our objective is to sell Springs branded products in all channels of distribution,
said Thomas P. OConnor, Springs executive vice president. By maintaining the Wamsutta® brands
current distribution through department and specialty stores and by maximizing our private label
and valuable licensing opportunities, we are in a better position to be in front of all consumers
with products from Springs.

August 1999

Carpeting Futures
A look at one of the most important shows in the carpet industry. The DFCMA (Dalton
Floor Covering Marketing Association) sponsors a Carpet Technology Show every two year. This years
event will be held September 14-16 at the NorthWest Georgia Trade and Convention Center, Dalton,
Ga. This show allows carpet industry vendors to showcase their machinery, equipment, services and
supplies to the industry. What To Expect For ’99Wanda Ellis, executive director of the DFCMA,
said the 1999 Carpet Technologies show is sold out: We actually have less exhibitors than normal
this year but only because exhibitors are taking larger spaces. They realize the importance of
being where the action is to make the right contacts to do business with carpet manufacturers. We
expect to feature some new and updated technologies that are helping to drive the growth of our
industry.Ellis conveyed that kicking off the show will be a golf tournament held at the Barnsley
InnandGolf at Barnsley Gardens in Adairsville, Ga. Exhibitors and members will be supplying players
and this will be a charity tournament for the Red Cross.Some of the other planned activities at the
show include a round table discussion, a seminar by the British Wool Bureau, and other speakers who
will be covering changes in the rug market and carpeting branding (name recognition). There will
also be a technical speaker that will address backings being introduced into the industry. There
will be something for everyone, including many featured events focusing on education, knowledge and
a realm of other opportunities for carpet mills. ExhibitorsNew exhibitors this year include
Bruno Machinery, Southern Technical Specialties, Van De Wiele, American Schonherr, Frueden Spunweb,
General Design and British Wool Marketing Board. The show is appealing to a broader range of
business as it becomes better known.It has helped that we took flyers to the Asia Floor Show and
Domotex in Germany. New contacts and other referrals are now wanting more information. Weve been
having at least one international visitor each month, Ellis said.Today, most manufacturers think in
terms of efficiencies and make use of resources to help maintain and grow profitability. The Carpet
Technologies Show allows the opportunities for diversity of products for the industry.Mahlo of
America, Germany, represented in America by Bob Harrell, Harrell Machinery Sales, has developed a
beta ray gauge which measures the precise amount of latex to go on carpet backings, proportional to
the amount of beta rays measured on the receiver end which is based on the thickness of the carpet.
Mahlo of America has another machine that electronically sees carpet patterns to make sure they go
through tufting and coating processes as straight as possible.Advanced Bio Systems, a wastewater
treatment company, has recently begun offering its services to textile companies.Representative
Harry DeLoach said the company uses the same technology that has been used to treat wastewater in
the pulp and paper business for 18 years. The reasoning behind this is because plants have
tremendous costs associated with treatment of wastewater or sludge disposal, and he noted this
technology should save money.Carpet Tech ExhibitorsAB Carter Inc.Gastonia, N.C.Booth #
250Accu-Cut/Brockie InternationalClermont, Fla.Booth # A1-33Advanced BioSystems, LLCRoebuck,
SC.Booth # 902Aircond Corp.Dalton, Ga.Booth # 148Alcon Systems Inc.Dalton, Ga.Booth # A2
26.American FiltecoMachinery Corp. (AFMC)Marietta, Ga.Booth # A 3American Line Corp.Gastonia,
N.C.Booth # 512America SchonherrDuncan, S.C.Booth # 807, 809American Suessen Corp.Charlotte,
N.C.Booth # 301American Superba Inc.Dalton, Ga.Booth # 331/430Appalachian Electronic Inst.
Inc.Ronceverte, W.Va.Booth # 537Armstrong World IndustriesGreenville, S.C.Booth # 504BandJ
Machinery Co. Inc.Dalton, Ga.Booth # 542Babcock Textilemaschinen GmbHGermanyBooth # 507Barmag
AGGermany Booth # 710, 712, 714Belmont Textile Machinery Co.Mt. Holly, N.C.Booth # 417, 516Belt
Shop Inc.Blemont, N.C.Booth # 702BetacontrolBooth # 710, 712, 714BlakeandPendletonDalton, Ga.Booth
# 541, 543Blue Ridge PrintingKnoxville, Tenn.Both # 606Briggs-Shaffner Co.Winston-Salem, N.C.Booth
# 550British Wool Marketing BoardEnglandBooth # Lower ConcourseBruno Machinery Corp.Troy, N.Y.Booth
# B3-16Card-Monroe Corp.Chattanooga, Tenn.Booth # 205Carolina Specialty Inc.Sanford, N.C.Booth #
404Carolmac Corp. Greensville, S.C.Booth # 701Carpet and Rug InstituteDalton, Ga.Booth # Lower
ConcourseCarpet Industry Clearinghouse Inc.Dalton, Ga.Booth # 105Chattanooga Tufters
Inc.Chattanooga, Tenn.Booth # 131Chemfab Corp.Woodstock, Ga.Booth # 902Chiron Technology
Inc.Charlotte, N.C.Booth # 608CIMS Dalton, Ga.Booth # 117Cobble/Tufting Machine Co.Dalton, Ga.Booth
# 317, 416CommunicationsandElectronics Inc.Chattanooga, Tenn.Booth # 242Consolidated BalingMachine
Co. Inc.Jacksonville, Fla.Booth # 900Control Corp. of AmericaRichmond, Va.Booth # 810Cope Machinery
Co. Inc.Dalton, Ga.Booth # 245CORfine Inc.Muncie, Ind.Booth # 405Crosrol Inc./James H. Heal Co.
Ltd.Greenville, S.C.Booth # 503Daikin America Inc.Orangeburg, N.Y.Booth # 234Dawson Textile
MachineryGreensboro, N.C.Booth # A1 32Don Johns Inc.Lawrenceville, Ga.Booth # 521Dystar
L.P.Charlotte, N.C.Booth # 616Eagle PartsandMachinery Inc.Chatsworth, Ga.Booth # 150, 248Edwards
Technical Sales Co.Norcross, Ga.Booth # 600Electric System Inc.Dalton, Ga.Booth # 335, 434Eltex
U.S. Inc.Greer, S.C.Booth # 431EMS/ESIDalton, Ga.Entrelec Inc.Irving, TexasBooth # B2 8Epic
Enterprises Inc.Southern Pines, N.C.Booth # 605ErhardtandLeimer Inc.Spartanburg, S.C.Booth #
505Essex Inc.Winston-Salem, N.C.Booth # 349Etowah ChemicalChattanooga, Tenn.Booth # 249Euromac
Inc.Dalton, Ga.Booth # 305Excel MachineandSupply Kings Mountain, N.C.Booth # 348Exim Ltd./Tranoco
Inc.Greenville, S.C.Booth # A2 31FeilandDavidson Inc.Greensboro, N.C.Booth # 503Fi-Tech
Inc.Richmond, Va.Booth # 523Fiber ControlsGastonia, N.C.Booth # A2 27-30Fife Corp.Oklahoma City,
Okla.Booth # 801Fisher-RosemountRoswell, Ga.Booth # 530Fleissner GmbHandCo.Germany Booth # 613,
615Fletcher International Inc.Southern Pines, N.C.Booth # 412, 313Fortress TechnologyCanadaBooth #
443FranklandThomas Inc.Greenville, S.C.Booth # 517Freudenberg Spunweb Co.Durham, N.C.Booth #
901General Design Inc.Chattanooga, Tenn.Booth # B2 2-4Gilbos of AmericaCharlotte, N.C.Booth # 710,
712, 714GPL Plastics MachineryCharlotte, N.C.Booth # 710, 712, 714Grainger Industrial SupplyTucker,
Ga.Booth # 802Harrell Machinery Sales Dalton, Ga.Booth # 401Heatco Inc.Acworth, Ga.Booth #
610Hi-Tech ControlsandAutomationDalton, Ga.Booth # 439, 450, 548, 549Host/Racine Industries
Inc.Racine, Wis.Booth # A1 37ICBT Inc.Greensboro, N.C.Booth # 223Industrial BeltingandSupplyDalton,
Ga.Booth # 241Ingersoll-Rand Co.Chattanooga, Tenn.Booth # 140-146International Baler
Corp.Jacksonville, FlaBooth # 900International PressandShear Corp.Baxley, Ga.Booth # 900Interstate
Industrial Electronics Inc.Dalton, Ga.Booth # B2 9-11J. Zimmer Maschinenbau GmbHAustriaBooth #
804Jem PrintingRome, Ga. Booth # 135Kaeser CompressorsMarietta, Ga.Booth # 903, 904Keith
Manufacturing Co.Madras, Ore.Booth # 719, 720KustersBooth # 217/213Lawson-Hemphill Sales
Spartanburg, S.C.Booth # 703Lessco Inc.Dalton, Ga.Booth # 123M-tecBooth # 213, 217Mahlo America
Inc.Spartanburg, S.C.Booth # 401Marsh Micro SystemsChattanooga, Tenn.Booth # 612Mart Corp.Sanford,
N.C.Booth # 800MitterBooth # 213, 217Moisture Register ProductsTyron, Ga.Booth # 602MSS
ServicesDalton, Ga.Booth # 201Multi State Sewing SupplyandEquipment Corp.Haleyville, Ala.Booth #
815N. Schlumberger (USA) Fort Mill, S.C.Booth # 815N.C. Carpet Equipment Newark, N.J.Booth #
300National Carpet Equipment Inc.Brooklyn Park, Minn.Booth # 300Nedgraphics Inc.Chattanooga,
Tenn.Booth # 143NITTA Corp. of AmericaSwanee, Ga.Booth # 811Norville IndustriesDalton, Ga.Booth #
340PAF Sales, LLCGreensboro, N.C.Booth # 413Panda ProductsCartersville, Ga.Booth # 812Paragon
Plastics Inc.Union, S.C.Booth # B3 14, 15Perpetual Machine Co.Dalton, Ga.Booth # 323Pierret North
AmericaSpartanburg, S.C.Booth # 132Plantex Amchinery Inc.Dalton, Ga.Booth # 141Pleva USACharlotte,
N.C.Booth # 519Polyfil N.V.BelgiumBooth # A1 35, 36Praxair Surface TechnologiesCharlotte, N.C.Booth
# 715Precision LoopersDalton, Ga.Booth # A1 34Pruetts Supply Inc.LaFayette, Ga.Booth # 309Roden
Electrical Supply Inc.Dalton, Ga.Booth # 613, 615Saurer Textile SystemsCharlotte, N.C.Booth #
423Schoen Machinery Inc.Beverly, Mass.Booth # 403Sellers of AmericaDalton, Ga.Booth # 109Shell
ChemicalsVarnell, Ga.Booth # 441SMLAustriaBooth # 713SmythandCompanyMontgomery, Ala.Booth #
700Southeast Industrial Dev. Assoc.Chattanooga, Tenn.Booth # 611Southern Technical Specialties
Inc.Eastman, Ga.Booth # 817Stangdridge Color Corp.Social Circle, Ga.Booth # 400Scientific
Technologies Inc.Fremont, Calif.Booth # 701.SunbrandAtlanta, Ga.Booth # 435, 534Sybron Chemical
Inc.Wellford, S.C.Booth # 601Talladega MachineandSupply Co.Talladega, Ala.Booth # B1 1Tapistron
Internationals Inc.Ringgold, Ga.Booth # 231, 237Tex AmericaCharlotte, N.C.Booth # 713 Textile
Management Systems Inc.New Orleans, La.Booth # 803, 805TextileWeb Inc.Greensboro, N.C.Booth #
345Textube Corp.Greer, S.C.Booth # B2 7Trumeter Co. Inc.Deerfield Beach, Fla.Booth # 539Tuftco
Corp.Chattanooga, Tenn.Booth # 341, 440Universal Textile Sales Inc.Dalton, Ga.Booth # 618, 619Van
De Wiele of AmericaGreer, S.C.Booth # 818, 819W.T. Hollis Co./Bowman Dunn Mfg.LaGrange, Ga.Booth #
705Waring Products Inc.Dalton, Ga.Booth # 705Waste Technology Corp.Jacksonville, Fla.Booth #
900Baling presses.Whitfield Oil Company Inc.Chickamauga, Ga.Booth # 350, 438Whitin Roberts
Co.Sanford, N.C.Booth # 814Yesco Industrial SupplyChattanooga, Tenn.Booth # 800Zenith PumpsSanford,
N.C.Booth # 609Zima Corp.Spartanburg, S.C.Booth # 213, 217

 
August 1999

HarrietandHenderson Yarns Inc., Henderson, N.C., recently held a ceremony to celebrate its new
spinning facility in Cedartown, Ga.Approximately 240 people attended the open house. Guests
received a tour of the facility after opening comments from local and state politicians and several
members of HarrietandHendersons management team. Georgia State Sen. Nathan Dean (D), a native of
Cedartown, presented a Georgia state flag to Marshall Cooper, HarrietandHendersons chairman and
CEO.The new facility is the companys eighth yarn manufacturing facility and has the capability to
manufacture 40 million pounds of open-end cotton annually.The 200,000-square-foot facility opened
in October 1998 and has been running at full capacity since December. It was built in a
straight-line design with a layout designed for maximum efficiency. All of the manufacturing
equipment was supplied by Rieter Corp.All data is monitored through the SpiderWeb® system.

August 1999