About Us - Manufacturing


The Lees Carpet facility in Glasgow, VA is a carpet manufacturing operation unlike any in the world. The plant initiated on its present site in 1934 and over seven decades has expanded to its present size.
· 1 ½ million square feet under one roof (34 acres)
· ¾ mile in length
· ¼ mile in width

A visitor to this plant will have an opportunity to see almost all the major processes involved in carpet manufacturing.
· Yarn Dyeing
· Yarn Manufacturing
· Heatsetting
· Tufting Machines (42 total)
· 12 ft. Finishing operation
· Tip-Shearing
· Inspection
· Modular manufacturing
In addition, the Glasgow plant has equipment and processing very few or no manufacturers currently possess:
· Knitting of fiber into sock
· “Space Dye” (short and long)
· Duracolor (patented Lees’ process which provides permanent resistance to acid-type
stains into the carpet fiber)
· Specialized tufting equipment 
-“Tri-Ax” Multituft (with computer controlled servos)
-“FRS” (Full Repeat Scroll)
-“Fine-Line” ( dense, low-profile product ) 
· Unibond 12’ finishing line (thermoplastic backing system)
· Encycle ( a revolutionary Non-PVC modular backing technology)
· Self-Lock (patented modular backing system incorporating mastics to the back of each module for installation).

Also located in the Glasgow facility:
· Physical and color testing labs
· Warehouse of yarn and finished goods
· Manufacturing management offices
· Design Resource Center (a complex which develops new running-line products and provides design-work / samples for custom products)

The Glasgow facility employs @ 1250 people

A typical visit to the Glasgow facility entails:
· 2 ½ hour walking tour of the manufacturing area
· Presentations on:
Fiber/yarn/dyeing
Backing systems
Maintenance
Quality Assurance
Product design
Product capabilities

In summation, a visitor can experience in one visit to the Glasgow plant:
· Almost all of the manufacturing operations involved in the production of carpet.
· An opportunity to see processes that very few manufacturers or no manufacturers can offer in the industry.
· Meet the manufacturing/technical and design personnel involved in the carpet manufacturing process.

All of this is available in the Lees Carpets facility located in Glasgow, Virginia.