The nitty gritty on commercial carpet

April 11th, 2011 7:38 am

I have been recently invited on a carpet mill tour with four other interior designers from four different Milwaukee-based architecture and design firms. We have spent two days in Dalton, GA and Chattanooga, TN learning and seeing first hand how carpet, one of the most critical finishes in any commercial space, is made.

J&J/Invision is called a boutique carpet mill by some. I would agree with that statement. Their smaller scale, customization flexibility, and client-oriented business operation confirms that smaller companies have actually something good going for them. Being a small business owner myself, I know how much more emotional and attached I get to projects and clients I work with. Any issues or concerned with a project are received and handled personally. Processes are modified to the need of a specific situation, because they can be in a smaller setting. Don’t we all know too well, that the more hands there are in a pot, the more impossible it is to get anything done…not to mention done fast.

That is probably why J&J/Invision was able to implement new pattern collections, expend into new markets, implement hugely successful sustainable manufacturing processes without a big battle, or delay.

(images downloaded from

It was very cool to see how fiber is extruded, steamed and set; how it’s then put on smaller size rollers and transported to the finishing plant for tufting; how some fibers are magnetically charged to received a certain type of dye; how the 6′ wide carpet rolls are laid out and cut into tiles with extreme precision, and finished with all four beveled edges; how 12′ wide goods are made into broadloom product for wall to wall installation; how antimicrobial finish is being applied, and backing being heat set. All these steps being closely monitors by workers who are totally committed to making quality product and meeting client expectations. Many quality control points along the process ensure that any flaws in the product get pulled before it ever sees the end of production line, or the job site, for that matter.

The majority of their carpet manufacturing process is not any different from other mills. Though, it sure seems as though J&J/Invision is taking their sustainable stands very seriously. From gaining access to previously landfill committed old carpet to recycle the 6.0 Nylon from the face of the carpet, to reusing all the scraps from the production line to make more carpet, to recycling of all water used in the plant, to an on-site recycling collection for employees of J&J/Invision mill, they are quite progressive in their thinking, and acting.



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