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Opportunities aplenty in Main Street market

May 28/June 4, 2018: Volume 33, Issue 25

By Ken Ryan


Main Street has been growing in importance as a strategic channel for flooring dealers and manufacturers for the past several years, thanks in large part to a healthy small business climate that is fostering growth. Along with that demand, observers say, comes the need for versatile flooring materials.

There are many theories as to why Main Street has risen in importance. Some executives cite the versatility of the Main Street channel in which small business owners are now exposed to a greater array of affordable flooring alternatives.

Al Boulogne, vice president, commercial resilient business, Mannington, believes Main Street is dynamic because of the vast amount of “touches” it gets in the market. “Any retail location, regardless of size, has the chance to be a hub of profitable commercial sales locally,” he explained. “Commercial spaces also have a huge variety of requirements. Offering a diverse portfolio of flooring types is critical to win.”

Getting residentially focused store owners and salespeople to see the opportunity that Main Street commercial presents takes a concentrated effort to educate, train and re-educate. At the retail level, this requires a sales team committed to guiding the customer to the right product for the application, experts say.

Brandon Kersey, hard surface and commercial brand manager for Engineered Floors, said the continued rapid movement in Main Street toward carpet tile and away from broadloom is the single largest factor in the segment’s recent growth. “As Main Street customers who have traditionally used broadloom get more exposure to carpet tile, they begin to understand the key advantages such as ease of installation, less disruption to end users’ business, ease of removal, styling options from carpet tile’s inherent modularity and high-performance backing systems,” he said.

Steven Erhlich, vice president of sales and marketing, Novalis Innovative Flooring, suggests the growth has more to do with macro trends. For example, he sees three factors driving Main Street: the home office, a stronger economy and greater design versatility.

“More people are working from home than ever before, so they are turning bedrooms, bonus rooms, garages and basements into workspaces in need of flooring solutions that are more business-oriented in performance and design. Second, there is a healthy small business climate; and third is greater design flexibility. The growing availability and promotion of business at the retail level is in turn driving the demand and sourcing for these solutions by small business with retailers.”

In just the last two years, several mills have jumped headlong into the Main Street space, in some cases offering multiple products. Phenix Flooring, which had considered the Main Street market for a few years, finally took the plunge in January. “We saw a natural fit for our brand and therefore created a full-home flooring solution through both our traditional hard and soft surface offerings,” said Jason Hair, vice president of hard surface. “We saw a successful launch of our first collection—Phenix on Main—at this past Surfaces and continue to hear good things about the products we’re offering in this space.”

The Phenix collection features olefin and nylon products in broadloom, carpet tile and carpet plank solutions as well as a complementary hard surface offering. The collection will be displayed in nine architect folders. In total, the collection includes 10 carpet options and Point of View, a luxury vinyl hard surface offering that comes in both plank and tile in 15 colors.

Stanton Carpet entered the commercial Main Street market in January with Stanton St. Decorative Commercial. The line features 17 products, including four carpet tile offerings, a first for the company.

“We always liked the idea of getting into commercial, but it had to match our identity,” said Jonathan Cohen, CEO. “This fits for us. We can be competitive with price, and as long as we stay decorative we feel like we can have a place within the market.”

Foss Flooring said it is doubling down on offering products for the home or business. Its signature carpet tiles feature a unique peel-and-stick installation with no VOCs, “which makes a quick turnaround for any small business installation possible, so they can get back to generating revenue,” Brian Warren, executive vice president of sales and marketing, explained.

Foss’ new style, Manhattan, has been the most successful new product launch in its history, Warren noted. Available in 24 x 24 tiles, as well as broadloom, the line is positioned as an ideal Main Street product.

By offering a broad portfolio of choices, observers say Main Street retailers are uniquely positioned to provide a one-stop shop for commercial products. “We offer that portfolio of products that are crafted with purpose,” Mannington’s Boulogne said. “That means those products are made with a relentless focus on design, uncompromising quality and a [range] of options for the best solution to fit the need. We aren’t pushing a single category. We have the ability to listen to customers who come to Main Street, understand their challenges and then consult with them to pick the best solution for the space.”

While the USFloors’ sales teams primarily focus on specialty retail, the Main Street jobs may — and do — happen. “We do not focus or drive marketing/ merchandising in that category,” said Jamann Stepp, director of marketing and product management. Among the COREtec collections that have Main Street applications are Pro Plus and Pro Plus Enhanced with SPC cores, he noted. Engineered Floors’ commitment to the steadily growing carpet tile market is most evident in its new state-of-the-art carpet tile plant, which will serve all commercial applications including Main Street. Meanwhile, the mill will continue to launch nylon products with styling and performance characteristics that are equivalent to products that are priced significantly higher than its commercial Pentz offerings.

Novalis has made a strong push in Main Street with a bevy of new offerings. Its NovaFloor line has a definite Main Street flair, and Abberly has tile designs and accents suitable for retail spaces. Likewise, its Davidson and Birkdale collections are designed for public spaces, offices and shops with high styling and durability. Novalis’ new rigid core products, including Serenbe HDC, Lyndon HDC and NovaCore HPC, are also finding interest from Main Street customers who have praised the offerings for their styling and ease of installation over imperfect subfloor conditions.

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Xpress Global Systems: Going the extra mile

May 28/June 4, 2018: Volume 33, Issue 25

By Reginald Tucker

In today’s hypercompetitive distribution economy, it’s no longer enough to simply move products from point A to point B. In order to gain an advantage, wholesalers must also go above and beyond by offering value-added services to manufacturers and retailers alike.

That’s precisely the edge that Xpress Global Systems, formerly Crown Transport, claims to offer its partners across the supply chain. “We’re the largest nationwide transportation hauler for the floor covering industry,” said Darrel Harris, CEO of the Chattanooga, Tenn.-based distributor. “Xpress Global is a company that’s been around for 40 years.”

According to Harris, Xpress Global Systems’ fleet entails nearly 300 trucks, and the company owns roughly 600 pieces of trailing equipment. From a logistics standpoint, about 75% of its freight originates out of Dalton, with approximately 20% coming out of the Southern California area.

“The majority of our business that we handle is LTL—less than truckload—shipments predominantly for floor covering businesses,” Harris explained. “We also have a fair amount of our business dedicated to warehousing. We store freight for our customers, and most of the time that freight then finds its way onto our trucks for local distribution.”

Xpress Global Systems also maintains a brokerage division (XTMS) that’s able to arrange transportation, truckload brokerage and LTL if it’s outside the scope of the company’s normal activities. Operating out of Xpress Global System’s Tunnel Hill, Ga., facility, XTMS is designed to provide additional services for the company’s large customer base in the region.

Harris cites additional competitive advantages. “By far it’s our expertise in handling floor covering, specifically rolled goods. Our employees are very well trained, experts in their field. It’s a type of product that requires special handling. You hear so many different stories in the industry about carpet being damaged when shipped using general commodity carriers. It’s not that we never had that problem, but it’s a very low claims percentage. Less than half of 1% of our shipments result in a claim, because we take great care of our equipment. Plus, our network is set up to make sure the carpet is handled properly.”

But it’s not just soft goods. Xpress Global is also equipped to handle pallets of hard surface products such as LVT. “We really put a big focus on the hard surface of segment of the business,” Harris said. “What’s really good about it from a transportation perspective is those goods commingle well in a transportation mode. Over the past few years we have really put a focus on exploring those opportunities with our customers.”

Creative solutions 

Xpress Global Systems also excels in what Harris refers to as “reverse logistics.” For example, if freight is delivered to a retailer but the shipment is rejected, Xpress can arrange to send it back to the originating mill. “We can assist the retailer for any reason that might create a scenario where they would need to return the product,” Harris explained.

Another competitive advantage Xpress Global Systems offers is its sheer size and scale. “There’s no one that has the broad coverage area to match our 33 facilities across the country,” Harris said. “That is something that’s very unique and special in this particular space focused on floor covering.”

So why would a retailer prefer to have Xpress Global ship their products from a mill as opposed to just paying the mill to have the product shipped to them? Harris explains the thought process. “What we find is many retailers don’t always take the time to really understand their overall freight costs or the logistics behind it. So there could be significant cost savings with us. Also, we have capabilities in so many different areas that are all built around floor covering, which translates into other solutions we could bring to the table that they might not even be aware of. For example, we can store goods for clients in various parts of the country without them having to spend the extra funds to basically put brick-and-mortar facilities in. In essence, they can use our facilities as an opportunity to position their freight for their customers, and we can  handle shipping it out for them. So there’s just a lot of creative things we can do by opening up those discussions directly with the retailers.”

Robbie White, senior manager of distribution and logistics for Beauflor, is a believer. “Xpress Global has given us a lot of capacity that we didn’t have. But they have also worked with us on drop trailers, especially on nationwide coverage of rolled goods. With the proactive reporting they provide, we don’t have to wait on exceptions to come up. They’re really good at managing those exceptions for us.”

Other Xpress Global Systems customers attest to the distributor’s high level of service. Jared Warnack, vice president of Lowe’s division for Phenix Flooring, has been a client for more than 15 years—and for good reason. “They are a very integral part of our company. They service the majority of the nation for us, and they do a wonderful job.”

Warnack attributes that track record to the leadership at Xpress Global Systems. “When Darrel Harris [CEO] came on board, he changed some of the policies to help improve customer focus. For example, he created a customer advisory board comprising logistics personnel from most of their major manufacturer customers, and we talk about issues we face every day in the industry. Xpress Global Systems then uses that feedback to improve their service and offerings. That’s why so many specialty retailers and big box stores use them as their preferred carrier.”
















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Carpet: Fiber report—Color, cleanability and durability get the nod

May 14/21, 2018: Volume 33, Issue 24

By Ken Ryan

Today’s carpet products are developed with the consumer firmly in mind as mills gather research to ascertain what’s on their customers’ wish lists. More often than not, it is luxuriously soft carpet that combines stylish design, vibrant colors with durability.

That’s a tall order to deliver, but consumers have shown a desire to spend top dollar for these goods, and mills are working hard to accommodate them. “When we talk to consumers, soft is one of the top attributes they want, so we put our resource and development toward that,” said Jamie Welborn, vice president of residential carpet product management and development, Mohawk Industries.

Shaw Floors, meanwhile, looks at today’s residential market and sees active families with kids and pets who put great demands on carpet. “They have greater expectations of performance for their flooring,” said Teresa Tran, director of soft surface portfolio management, Shaw. “They need their carpet to be durable and spill resistant, yet soft and beautiful.”

It’s not just the carpet mills working on these innovations. Invista, maker of the Stainmaster and PetProtect brands, has spent significant R&D on its Antron fiber. It recently announced a $30-million expansion in small-lot equipment specifically for solution-dyed nylon 6,6 bulk continuous filament (BCF) fiber production to support growth of the Antron brand and the Lumena fiber portfolio that serves solution-dyed BCF nylon commercial markets. “The new technology will expand our capability to continue offering high-quality, solution-dyed nylon fiber solutions,” said Kip Kimball, vice president of Global Commercial Solutions and Home Textiles for Invista.

Phenix Flooring continues to work on new fiber systems that utilize unique cross-sections that—when combined with particular deniers and twist levels—produce textures and an outstanding tactile experience for consumers. “In addition, we constantly update our solution-dyed color bank to keep up with current color trends and styling preferences as well as supplement with leading space dye advances that give sophisticated ombrés and gradations of color,” said Chris Johnson, senior vice president of sales and marketing.

According to Mike Sanderson, vice president of marketing, Engineered Floors, consumers are becoming more receptive to the term “solution dyed,” and that is affecting their purchase decisions. “They are finding out that it’s superior to traditional piece-dyed carpets, which is exciting for our Dream Weaver retailers.”

Residential segment

The days when consumers carpeted the entire house are long gone, as residential carpet has been relegated mostly to the bedroom. However, studies have shown that when consumers are in the market for carpet, they are willing to spend extra money.

There’s even more encouraging news down the road, according to Shaw’s Brad Christensen, vice president, builder strategy, who observed that while Shaw is certainly seeing growth in its residential segments, single-family homebuilding is also trending.

“The average age of the first-time homebuyer is 32. With that statistic in mind, by 2025 there will be 24 million Americans between the ages of 30 and 34. Previous studies showed the millennial market preferred densely populated, walkable, urban neighborhoods that offer multifamily living spaces to the suburbs of their childhood. Yet, new surveys demonstrate that while millennials might be content urban, multifamily dwellers right now, they see themselves as single family homeowners in the future.”

Residential represents the largest growth segment for Southwind, according to Richard Abramowicz, executive vice president. As such, the company is putting the necessary resources behind it. “I think residential is the biggest growth opportunity for all of us and why we are trying to be innovative with our products. It’s a very big market.”

What’s new

Mohawk has championed the push of luxurious soft and that continues to be a major thrust with SmartStrand. As Mohawk’s Welborn noted, “SmartStrand fiber is softer than nylon and polyester, performs extremely well and has nice hand/bulk, and you will see us continue to expand in that area.”

As the movement toward cleaner homes grows, Mohawk, among others, is responding by adding Forever Clean to SmartStrand as well as ActivFresh technology to its Silk Colorwall line, which features new products in 2018. “Some of the products are tighter, denser, cleaner than the old Silk,” Welborn said. “From a technology standpoint, we added ActivFresh, an anti-microbial additive to the carpet, which is a new feature. You will see us expand in that growing segment.”

In Bellera High Performance Carpet, Shaw is giving consumers a wide variety of patterns, solids and textures from which to choose, albeit without sacrificing resiliency. “Our designers were extremely intentional with their choices, giving consumers numerous styles to match current trends,” Tran said. “We offer glamorous styles as seen in Outside the Lines, classic patterns in Diamonds Forever and Lead the Way, as well as visuals with a more organic look to complement modern farmhouse or coastal design trends. Each of these styles includes the attributes that make Bellera one of a kind.”

The fiber in Bellera has been treated with R2X soil and stain resistance technology and now features crush resistance to keep carpets lasting longer. To showcase the durability of its re-engineered fiber, Shaw simulated five years’ worth of activity with real people on Bellera carpet. When new Bellera samples and those with five years’ worth of wear were placed side by side, customers and RSAs alike were unable to tell the difference, Christensen said.

Phenix, which began showing carpet styles tufted from one of its new fiber systems during the winter markets, has identified a new yarn that provides great bulk and apparent value. “It has become one of our most anticipated launches, which we expect will lead to additional product opportunities,” Phenix’s Johnson said, referring to Opulence HD. “It’s a softer yarn that provides a look of luxury.”

Engineered Floors uses PureColor, a proprietary solution-dyed fiber, as its go-to market strategy at residential retail. “We try to educate the RSA and consumer on PureColor as often as possible,” Sanderson said. “Both groups are learning that since the color goes all the way through the fiber, stains that are detrimental to other carpets aren’t an issue with PureColor.”

Southwind’s Classic Traditions collection, a soft PET line, is being marketed as “eclectic patterns for everyday elegance.” It was shown at Surfaces 2018 and will feature eight stylish Color Point and LCL patterns that the company said are fashion-forward fabrics for the floor. “We had such a great response at Surfaces,” Abramowicz said.

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Mills find a niche with custom rug programs

March 19/26, 2018: Volume 33, Issue 20

By Ken Ryan


As hard surface products continue to take market share residentially, carpet mills are facing some choices: hope the pendulum swings back to broadloom, or get in on the action. Many of them chose the latter, offering custom area rug programs as an add-on sale to hardwood and other types of hard surfaces. In fact, for some mills, business has been flourishing in this era of hard surface growth.

“I tell people we are no longer in the carpet business,” said Don Karlin, director of broadloom sales for Nourison, which is strictly a soft surface supplier. “I tell people we are in the hard surface business and rugs are the complementary piece. The world is all about fabricated rugs.”

Following is a sampling of some custom rug programs and offerings available today.

Anderson Tuftex

A/T, a Shaw Industries brand, will continue to utilize the custom area rug program Tuftex has had for the past several years. “We can cut any of our A/T carpets into a custom area rug up to 24 x 36 feet,” said Katie Ford, director of brand strategy. She said shapes for area rugs include rectangles, squares, rounds and ovals, as well as floor and stair runners. “We also offer a full assortment of edge treatments such as binding, serging, fabric and leather.”


Couristan has built on the success of a custom area rug program it started in 2014. Its program allows dealers to fabricate a Couristan product into a custom area rug that addresses their customers’ decorating needs. Today, Couristan’s broadloom business is heavily fabricated, with more than 50% of its business in fabricated rugs. “The hard surface [category] has actually helped our business,” said Len Andolino, executive vice president–residential division, Couristan. “We are pushing the envelope with fabricated rugs.”


Lexmark Residential recently launched its Unite Custom Rug Program that lets retailers select their choice from any of Lexmark Living’s three broadloom pattern collections. “What is great about this program is it is built on the same construction as our hospitality line, which is our bread and butter,” said John Madden, general manager, Western region.


Masland’s program, Custom Area Carpets and Rugs, expands design options for the floor and offers custom capabilities. Options range from wall-to-wall to inset area carpets and rugs to loose-laid rugs on top of flooring surfaces. This Dixie Group brand has a custom program that can make any size or shape rug from its broadloom offerings. The program has been well-received, according to Jared Coffin, vice president–rugs and wool products, who noted, “Rugs gives us an insight into trends; therefore, it’s an important part of our business.”


Karastan, Mohawk’s high-end rug supplier, lets users create their own looks with its Inspired Luxury program. Customers are able to choose looks from a select group of styles, 100 color options and custom rug bindings. In addition, at Surfaces 2018, Mohawk Home showed Vintage Tapis, a hand-knotted collection available in four sizes including 10 x 14. The line is designed with soft, natural cotton rather than jute. According to Mohawk executives, the most sought-after line at the show was Spike Market with Everstrand fiber. This premium polyester is produced with up to 100% post-consumer content from plastic bottles. The rugs are stain resistant.

Nance Industries

For Nance Industries, rugs have always been its bread and butter. “That is really our niche, and you are seeing a lot better growth in rugs,” said Mike Nance, principal. The company showed new custom-made rugs at the show. In fact, Nance employs two custom-rug artists who can create almost any design pattern or theme a customer can imagine at any size they choose.


Fifty to Infinity is a custom-rug program by Nourison that utilizes the very best in woven broadloom rugs. Each rug is made to order from premium woven broadloom carpeting and serged on the edges for a quality, finished look. Production time takes seven to 10 business days. Available sizes range from

5 x 7 to 10 x 10 and everything in between.

Phenix Flooring

Phenix is no stranger to trying new things—or markets, for that matter. At Surfaces, it announced its entry into the area rug business under the Cleaner Home Rugs banner.

Mark Clayton, president and CEO, said the move into rugs is a nod to the explosive growth of hard surfaces. “With so many beautiful patterns in our line, this is just a natural addition to what we are doing for hard surfaces.”

Prestige Mills

Add Prestige to the list of carpet mills looking to leverage the growth of hard surfaces. According to Peter Feldman, president, a high percentage of the company’s broadloom business ends up as rugs, in some cases cut by their dealers after shipping. “While cutting broadloom carpet into rugs is good for the rug business, you are only using part of the room with rugs, so more carpet is required if you are going to go that way,” Feldman said. “It is a challenge, but we are up for it.”

Prestige Mills also sells rugs under the Stark Studio Rugs label. Stark, the wholesale rug division of Stark Carpet, is a to-the-trade carpet, fabric, rugs and wallcovering specialist with a significant presence in the custom-rug space.

Stanton Carpet

Stanton is well known for the style and design of its broadloom selections. But the fact is many of the company’s inspirations come from high-end area rugs, according to Jonathan Cohen, CEO. Stanton has been selling custom rugs for years. The company even has a “Create A Rug” page on its website that allows customers to choose carpet style and color, select the finish (i.e., hand serging, binding options) and then use the custom rug visualizer to choose their rug.

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CarpetsPlus adds Phenix as approved vendor

Dalton, Ga.—Phenix Flooring, a Pharr family company, has joined CarpetsPlus Color Tile as an approved vendor. The manufacturer’s products, including carpet and hard surface offerings, will now be available through the CarpetsPlus network of retailers in the United States and Canada.

“We’re looking forward to working with CarpetsPlus and getting Phenix products into their showrooms and the homes of their customers,” said Chris Johnson, senior vice president of sales for Phenix Flooring. “Their family-first philosophy resonates with our values as a company and we’re confident the level of quality and service that is synonymous with Phenix will carry on through CarpetsPlus retailers across the country.”

Consumers can expect to see Phenix Flooring products in participating retail stores this spring.

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Phenix becomes approved vendor for Abbey Carpet & Floor

Dalton, Ga.—Phenix Flooring has joined Abbey Carpet & Floor and Floors To Go as an approved vendor. Phenix Flooring products, including carpet and hard surface offerings, will now be available through Abbey Carpet & Floor and Floors To Go’s network of retailers in the United States and Canada.

“This is an exciting opportunity for our company to join Abbey and Floors To Go and open additional channels to get our products in showrooms across the country,” said Chris Johnson, SVP of sales for Phenix Flooring. “They are leaders in the retail flooring space and have a history of providing their retail partners and ultimately, the end customer, with the highest quality service and the industry’s best product selection.”

Consumers can expect to see Phenix Flooring products in participating retail stores this spring.

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Phenix Flooring taps industry veteran, Jason Hair, as VP of hard surfaces

jason-hairDalton, Ga.—Phenix Flooring has hired Jason Hair as vice president of hard surfaces. Hair will be responsible for planning, developing and implementing a strategy to allow the organization to continue to expand and successfully compete within the hard surface category. Hair will be based in Dalton, Ga.

“We’re excited about our future in the ever-expanding hard surface arena and we’re thrilled to have an individual seasoned in the field to be taking on this endeavor,” said Mark C. Clayton, president of Phenix. “It provides additional opportunities for the company to grow and meet our customers’ needs and we are confident that Hair is the right person to make that happen. His insight into the industry is a huge asset on this investment in our hard surfaces department. His leadership experience makes him a perfect fit for the position and the company at large.”

Phenix entered the hard surface arena earlier this year with the successful launch of their Origins luxury vinyl tile and laminate programs.  Hair will play an integral role in expanding upon this offering with the launch of four new products at Surfaces 2017.  These products will each offer unique, industry-leading technologies which address the needs of today’s consumer.

Hair has 22 years of experience in the flooring industry. Prior to joining Phenix, Hair was the senior vice president of hard surfaces and strategic accounts for Beaulieu of America and was responsible for all aspects of the hard surfaces business.

Hair received his bachelor’s degree in business management from Georgia Southern University.

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Barnett named VP of marketing for Pharr divisions

MerrieBarnettDalton—– Pharr today announced that Merrie Barnett has been hired for the new role of vice president of marketing.

Barnett will lead the marketing functions for Pharr, including its five business units, Pharr Yarns, Phenix Flooring, Pharr HP, Belmont Land & Investment and Strand Hospitality Services. Barnett will provide strategic marketing direction for Pharr and be responsible for managing all of the traditional, digital and social marketing efforts of each of the five units.

“We’re thrilled that Merrie is joining the Pharr family and taking on the responsibility of leading our company’s marketing efforts. Her experience, not just in marketing, but with the flooring industry, is unparalleled,” said Bill Carstarphen, president and CEO of Pharr. “She brings a diverse skill set, ranging from traditional marketing executions to digital and social applications as well as a strategic thinking that will be critical to the success of all five companies.”

Prior to joining Pharr, Barnett was the director of marketing for The Mohawk Group and was responsible for the strategic direction and marketing activities of their commercial flooring division.