Carpet & Rug Manufacturing
Description
Companies in this industry manufacture woven, tufted, and other types of rugs and carpet using natural and synthetic fibers. Major companies include Engineered Floors, Interface, Mohawk Industries, and Shaw Industries (all based in the US), along with Balta (Belgium), Oriental Weavers (Egypt), and Suminoe Textile (Japan).
The global carpets and rugs market is forecast to reach about $150 billion by 2034, at a compound annual growth rate (CAGR) of 6.9% between 2025 and 2034, according to Custom Market Insights. Apart from US and China, other noteworthy geographic markets in the market are Germany and the UK, according to Statista.
The US carpet and rug manufacturing industry includes about 250 establishments (single-location companies and units of multi-location companies) with annual revenue of about $10 billion.
COMPETITIVE LANDSCAPE
Demand for carpeting depends on residential and commercial real estate construction and home sales, which can be cyclical. With many costs fixed, profitability of individual companies depends on their volume of business. Large companies enjoy significant economies of scale in manufacturing and distribution. The US industry is highly concentrated: the 50 largest companies account for over 95% of revenue.
Competition comes from providers of other types of floor coverings, including hardwood and ceramic tile. Many carpet manufacturers have expanded into noncarpet flooring products.
PRODUCTS, OPERATIONS & TECHNOLOGY
Most carpeting is made on large tufting machines that use rows of needles to sew loops of nylon thread into a latex backing. The loops are cut to produce tufts and additional backing is glued on to the bottom to hold the tufts in place; polypropylene and polyester thread are also used. Rugs and woven carpeting are made on looms using wool, cotton, silk, or synthetic thread. Most carpeting is made as 100-foot rolls ("roll goods") of various widths - mainly 12 or 15 feet ("broadloom") - but modular carpet tiles also are made. Major products include roll carpet and rug goods (about 55%), automobile and aircraft carpet (about 10%), finishing for tufted carpet and rugs (about 5%). Other products account for about 30%.
Nylon thread, the major raw material for carpet manufacturing, is made from crude oil and is therefore subject to cost changes that can be volatile. Carpet manufacturers may produce their own filament and thread or buy from third-party suppliers.
The global carpets and rugs market is forecast to reach about $150 billion by 2034, at a compound annual growth rate (CAGR) of 6.9% between 2025 and 2034, according to Custom Market Insights. Apart from US and China, other noteworthy geographic markets in the market are Germany and the UK, according to Statista.
The US carpet and rug manufacturing industry includes about 250 establishments (single-location companies and units of multi-location companies) with annual revenue of about $10 billion.
COMPETITIVE LANDSCAPE
Demand for carpeting depends on residential and commercial real estate construction and home sales, which can be cyclical. With many costs fixed, profitability of individual companies depends on their volume of business. Large companies enjoy significant economies of scale in manufacturing and distribution. The US industry is highly concentrated: the 50 largest companies account for over 95% of revenue.
Competition comes from providers of other types of floor coverings, including hardwood and ceramic tile. Many carpet manufacturers have expanded into noncarpet flooring products.
PRODUCTS, OPERATIONS & TECHNOLOGY
Most carpeting is made on large tufting machines that use rows of needles to sew loops of nylon thread into a latex backing. The loops are cut to produce tufts and additional backing is glued on to the bottom to hold the tufts in place; polypropylene and polyester thread are also used. Rugs and woven carpeting are made on looms using wool, cotton, silk, or synthetic thread. Most carpeting is made as 100-foot rolls ("roll goods") of various widths - mainly 12 or 15 feet ("broadloom") - but modular carpet tiles also are made. Major products include roll carpet and rug goods (about 55%), automobile and aircraft carpet (about 10%), finishing for tufted carpet and rugs (about 5%). Other products account for about 30%.
Nylon thread, the major raw material for carpet manufacturing, is made from crude oil and is therefore subject to cost changes that can be volatile. Carpet manufacturers may produce their own filament and thread or buy from third-party suppliers.
Table of Contents
- Industry Overview
- Quarterly Industry Update
- Business Challenges
- Business Trends
- Industry Opportunities
- Call Preparation Questions
- Financial Information
- Industry Forecast
- Web Links and Acronyms
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