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Shaw opens $85M carpet tile facility

New plant to bolster manufacturing capacity, recycling capabilities

December 5/12, 2016; Volume 31, Number 13         

By Ken Ryan
screen-shot-2016-12-16-at-9-11-07-amShaw Industries, the largest carpet tile producer in North America, officially unveiled its new carpet tile manufacturing facility in Adairsville, Ga., on Dec. 1. The $85 million facility, which became operational this quarter, will provide added capacity and recycling capability for the company’s Patcraft, Philadelphia Commercial and Shaw Contract modular carpet brands.

Known as Shaw Plant T1, the 600,000-square-foot facility complements the company’s existing carpet tile manufacturing, recycling and warehouse facilities in Cartersville, Ga., and in Nantong, China. The China facility opened in mid-2013 to serve the Asia Pacific market.

Vance Bell, chairman and CEO, who spoke during the ribbon-cutting event, noted that Shaw already invests hundreds of millions of dollars annually in new and expanded facilities, enhanced equipment, technology and processes, and improved distribution systems. “This is a prominent example of that commitment,” he explained, adding the new factory would allow Shaw to innovate across its broad portfolio of products for both residential and commercial applications.

Brenda Knowles, vice president, commercial marketing and product development, said there is a great deal of innovation built into this facility in terms of design features, dimensions and patterns. “The efficiencies that it has will continue to drive further innovation.”

In the commercial market, carpet tile represents an estimated 54.6% of the market in dollars and 44% in volume (FCNews, June 27) and is growing in the high single digits. It is growing robustly in the commercial arena at the expense of a declining broadloom segment. “There have been years over the past six to eight years where there has been double-digit growth in carpet tile,” Knowles said. “We see a bright future for continued growth.”

Shaw’s carpet tile facility currently employs 170 associates. The company estimates the plant will create 500 new jobs once it reaches full capacity. The carpet tile equipment takes up about one-third of the 600,000 square feet of space, which is all under one roof. There are plans to add more equipment in the building and, ultimately, more buildings to the 115-acre industrial site.

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Shaw opens $85 million carpet tile facility

Van Bell, chairman and CEO, of Shaw Industries at the grand opening.
Vance Bell, chairman and CEO, of Shaw Industries at the grand opening.

Adairsville, Ga.—Shaw Industries Group has completed construction of a new carpet tile manufacturing facility located in Adairsville, Ga. The $85 million facility, which became operational in the fourth quarter of 2016, employs 170 associates and will create a total of 500 new jobs once it reaches full capacity.

Known as Shaw Plant T1, the facility provides added production capacity and recycling capability for the company’s Patcraft, Philadelphia Commercial and Shaw Contract brands. It complements the company’s existing carpet tile manufacturing, recycling and warehouse facilities in Cartersville, Ga. and Nantong, China. The China facility opened in mid-2013 to serve the Asia Pacific market.

“The addition of this state-of-the-art carpet tile manufacturing facility allows us to continue to innovate across our broad portfolio of products,” said Vance Bell, Shaw chairman and CEO. “We invest hundreds of millions of dollars annually in new and expanded facilities, enhanced equipment, technology and processes, and improved distribution systems to create beautiful, durable, sustainable flooring to meet our customers’ diverse needs. This is a prominent example of that commitment.”

Shaw is one of Georgia’s largest manufacturing employers—with 14,000 associates in the state including 3,200 in Bartow County, where the company operates nine facilities. The company was ranked among Forbes’ America’s Best Large Employers for 2015 and 2016 and has been recognized by Training magazine as a “Training Top 125” company for the 13th consecutive year (2017).