Lees Carpet manufacturing
facility, located in Glasgow, VA, is a fully integrated commercial
carpet manufacturer with over 33 acres (1,462,459 square feet) under
one roof, employing more than 1,200 people. Glasgow produces 20 million
square yards of carpet and 30 million pounds of yarn annually.
Raw man made
nylon filament (fiber) is received into the Yarn facility from DuPont™.
Color is added to the nylon filament by one of two continuous dye
lines. Next, two or more (up to six) individual dyed ends are plied
together by any one of fifty-three twisting machines resulting in
a finished yarn product. In a typical year finished SKU’s at
the Glasgow yarn facility total 450 units.
Finished, colored yarn, goes from the yarn warehouse into the first
carpet mill process known as tufting. Depending on the carpet specified,
between 1,152 and 2,000 individual finished yarn packages are then
placed into a series of predetermined creel positions, located behind
any one of the mill’s forty-five tufting machines, and subsequently
“threaded” into the tufting machine needles. The tufter
places the yarn (via computer control) into a substrate known as primary
backing at a rate of 25 square yards per hour up to 350 square yards
per hour depending on the complexity and design of the product.
Carpet can also be produced from white yarn , and “piece”
dyed in unbacked carpet form.
There are basically
3 categories of carpet manufactured at the Lees’ Glasgow facility:
Broadloom (primarily 12’ wide), Modular (primarily 18”
& 24” tiles), and 6 Ft. Thermobond™. Finished carpet
SKU’s at Glasgow total 1,100 products during a typical year.
Broadloom carpet is finished in either 12 foot or 13.5 foot widths
and is processed on one of two existing laminator lines. The laminator
coats the underside of the carpet with either a resin based (Unibond®)
backing or a latex backing (Actionbac). This backing application process
serves to protect the otherwise exposed yarn on the reverse side of
the carpet and to provide “tuft bind” (this keeps the
tufted yarn from being pulled from the carpet primary backing). The
finished carpet is then inspected, rolled, wrapped, and located to
the warehouse for shipping.
Modular carpet is finished in a similar manner to Broadloom. Modular
carpet, however, receives a PVC (polyvinyl-chloride) compound, a much
heavier and thicker coating than is applied to Broadloom. Modular
carpet then goes to a process known as die cutting, where the finished
carpet is cut into either 18 inch or 24 inch squares, boxed, wrapped,
and located to the warehouse for shipping.
Six (6) foot wide Thermobond™ carpet is finished in the exact
manner as Modular, without the die cutting process. The 6 foot wide
carpet is inspected, rolled, wrapped, and located to the warehouse
for subsequent shipping.