In 1839, Erastus Bigelow invented the power loom for weaving carpets, forever changing the carpet industry. Through use of the loom, carpet production was doubled in its first year of use and tripled by 1850. Bigelow’s loom can now be seen at the Smithsonian Institute. Building on this innovation, a power loom with Jacquard mechanism was developed in 1849.

Others continued their attempts to perfect this innovation as well. In 1876, Halcyon Skinner developed a power loom for making Royal Axminster. He formed a carpet company with Alexander Smith and in 1929 Alexander Smith & Sons was the largest manufacturer of carpets and rugs in the world. Such a company boosted the economy by employing over 1,600 people by the time of Skinner’s death.

In 1928, the first Karastan rugs were introduced to the public by industrialist/retailer Marshall Field. Field created this machine-made rug woven through the back featuring various designs and virtually limitless color capabilities by modifying a traditional Axminster weaving loom.

THE TUFTED CARPET INDUSTRY:
The tufted carpet industry was essentially born in Dalton, Georgia as a result of the demand for bedspreads. The first mechanized tufting machine was developed to accommodate such a demand. Machines were developed into four, eight, 24, and more needles to make parallel rows of tufting known as chenille. Mats and rugs were created using cotton yarns and fabrics. In 1946, the carpet industry used 30,000 bales of cotton and the volume increased greatly after World War II. By 1950, almost 500,000 bales were being used. The industry was the third largest consumer of Georgian cotton in 1952.

Dalton’s economy expanded as the industry continued to grow. Yarn, sheeting, duck mills, and agents were established in Dalton working strictly for the carpet industry. Machine shops were formed to manufacture the single and multi-needle machines needed, and dye plants for yarn were built. Printing shops supplied the tags and labels needed for the carpeting, while box factories supplied shipping cartons. Getting items to the consumers and market was big business for rail and motor freight lines as well.

As demand increased, the need for more technology increased. Machinery was developed so that chenille rugs could be made wider and larger and broadloom carpets could be created. Furthermore, development of new fibers increased the growth of broadloom carpeting.

In 1954, wool and synthetic fibers such as polyester, nylon, rayon, and acrylics were introduced into the industry, replacing cotton as the only fiber used in crafting tufted products. The introduction of synthetic fibers and bulk continuous filament nylon yarns boosted the industry by providing a durable, more economical – compared to wool – quality to offer to the marketplace. The American carpet industry was transformed from low-volume production of woven luxury products to mass production of high-quality and well-priced goods.