Posted on

Shaw to invest $184 million in fiber manufacturing facility

Andalusia, Ala.—Shaw Industries will invest $184 million in its Andalusia, Ala., manufacturing facility, which creates fiber used to manufacture carpet. The project will include construction of new and expanded building assets, and installation of substantial amounts of new manufacturing equipment.

“These investments will ensure the long-term viability of this critical operation within Shaw’s portfolio of manufacturing facilities,” said Vance Bell, Shaw chairman and CEO. “They are designed to improve the plant’s ability to compete successfully in the marketplace for the short and long term. This facility upgrade will utilize state of the art technology and innovative processes that will be industry leading in cost and quality.”

The changes will improve efficiency and production as well as ergonomics and safety for the more than 1,000 associates who work at the plant. Additionally, improvements to chillers and the use of new equipment stand to improve energy efficiency. Demolition work is underway at the facility, and new equipment is set to be in place and operational by mid-2018; the facility will remain operational throughout the transition.

“Shaw’s commitment to safety and product quality are the cornerstone of business,” said Ron Fantroy, Shaw plant manager for Plant 65/Andalusia. “This tremendous investment illustrates our continual effort to improve our operations and employ advanced manufacturing techniques to meet the needs of our associates and customers.

Shaw’s operations are more complex than ever. As a result, almost every job at Shaw—from designers and data scientists to machinists and managers—requires a higher skill level than in the past. Shaw benefits from a talented, well-trained associate base in Covington County, where it is the county’s largest employer.

“Andalusia and Shaw Industries have worked together in the past to make sure that Shaw’s Andalusia operation is poised for success,” said Andalusia Mayor Earl Johnson. “The Andalusia Council, Utilities Board and myself together with Southeast Gas and PowerSouth Energy Cooperative were glad to do our part to help Shaw decide to make this major investment in the Andalusia plant. Shaw had other options, and in making this decision, we are pleased that they will be part of our community for years to come.”

Posted on

Ardex Americas to expand Aliquippa facility

Screen Shot 2017-07-12 at 10.12.21 AMAliquippa, Pa.—Ardex Americas recently announced a major expansion of its Aliquippa, Pa., manufacturing facility, effectively doubling its size. This is the third such expansion for the company this year. In February Ardex released news of an extension for the Dallas, Ga., plant and is also currently working to expand the manufacturing footprint in Stockton, Calif. The Aliquippa addition, which is the site of the Americas headquarters, includes significant increases in warehouse and production capabilities to better facilitate Ardex’s growth strategy.

“This expansion is a direct result of our growth and allows Ardex to continue to provide innovative products to our existing customer base as well as meet the future needs of an expanding market,” Jesse David, Ardex Americas president, explained. “We are committed to investing capital into our plants and infrastructure to provide the very highest levels of service and support that our customers demand.”

The expansion includes the addition of a new production operation and additional capacity to support future growth. “We wanted to enhance the capabilities of our operation group and increase efficiencies in the long term,” Jim Masterson, Ardex director of operations, added. “This will help both production and storage and position us well for the future.”

The Aliquippa expansion project will continue in phases for the rest of 2017 and into 2018 but will have no effect on how customers are serviced.

Posted on

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.