Dalton—According to Mohawk Industries, its new SmartStrand fiber made with DuPont’s Sorona Polymer is the “biggest fiber innovation in 20 years.” That’s how strongly Mohawk feels about this technology, first being introduced into the Horizon Collection by Mohawk, Floorscapes and ColorCenter lines. SmartStrand fiber with DuPont Sorona polymer is a Mohawk exclusive, and promises benefits in performance, stain resistance and comfort. Ed Williams, Mohawk’s senior vice president of marketing, said, “SmartStrand fiber has the resilience of nylon, coupled with remarkable stain resistance and a very soft hand. Unlike many stain treatments that are added to the fiber after manufacture, Smart-Strand’s stain resistance is engineered into the fiber, so it will never wear off, no matter how many times it is cleaned.”

And this built-in stain resistance reaches new levels of protection, allowing tough stains such as mustard and red wine to be removed with warm water and a mild detergent or Mohawk Floorcare Essentials, he noted. “Tests show that it even resists damage from bleach and acne medications. In fact, its stain resistance is so good that Mohawk is offering its first-ever Limited Lifetime Warranty for stain resistance. You’re looking at a product that will do things other fibers just can’t.” SmartStrand has been in development at Mohawk for more than two years. It has an all-new chemical makeup, from a family of polymers based on 1,3-propanediol (PDO). The chemical shorthand for the polymer name is 3GT. Like nylon, Smart-Strand is readily dyeable, giving capet designers an infinite range of colors. 

In fact, as many as three different dyeing processes can be used with the fiber, so there are new options for multi-color effects, Williams noted. “Research also indicated that wearability and durability performance is equal to or better than equivalent constructions of premium nylon. The product is also inherently soft. While not technically considered to be a soft yarn, Smart-Strand has a good hand with a very good tactile, full feeling, and it provides this comfort without having to reduce the fiber’s denier and compromise performance characteristics.” SmartStrand lends itself to a wide range of carpet constructions, as well—standard textures, friezes, berber flecks, high-twist styles—providing the ability to use the fiber readily through all price points. Williams noted that Mohawk had considered looking at a new line of solution-dyed nylon products that was directed to residential use, but shelved the idea with the advent of SmartStrand fiber.

“According to what our chemists tell me,” said Mike Zoellner, Mohawk’s vice president of marketing services, “SmartStrand is not nylon, it’s not polyester and it’s not olefin. It’s a new derivative of petroleum. In essence, it’s a new fiber. It has chemical properties similar to nylon and similar to polyester. We are positioning it as a new class of fiber.” Easy To See Benefits Demonstrations are being set up at Mohawk’s regional shows to showcase the cleanability and other benefits of products made with the SmartStrand fiber. “The demonstrations clearly show superior cleanability using problem stains such as mustard dried for days, red wine, benzoil peroxide and other materials,” Williams said.

“Retailers will be able to see first-hand the difference between products with SmartStrand and those with other fibers. A DVD of the demonstration will be available at retail to show customers the value of the product’s engineeredin stain resistance, and actual samples will also show cleanability. We think this is critical. “Consumers have come to expect stain resistant treatments,” he explained, “but we want them to understand why the engineeredin stain performance of SmartStrand is a giant step forward.” SmartStrand is being introduced by Mohawk in three ways: through a collection called New Generation in the Horizon Collection by Mohawk, as well as exclusive lines in Floorscapes and ColorCenter stores. Products featuring SmartStrand will be available in the second quarter of 2005.

“We have product to show, but because it is a new fiber technology, before we can actually start selling it to dealers, we want to make sure that we have enough inventory to back it, and it’s new to us. we are going to show it at all the regional shows and at Floorscapes, so retailers will be able to touch it and feel it.” “Right now, we’re only looking at SmartStrand for the residential side,” explained Zoellner. “Some of the properties lend themselves to perhaps going into the Main Street commercial arena, but right now we don’t have any plans to take it there or to the specified commercial market. “Anything is possible,” he added, “we have to learn what the fiber can and cannot do. We’ve tested it, using the Hexapod test where simulated walking is performed, and so, from a residential perspective, we know exactly how it performs. We haven’t even begun to think about any commercial applications.”

Zoellner noted, there are 10 products that are in development with the new fiber. Power Of Smart Technology DuPont Sorona polymers have already made a dramatic impact in other textile businesses. They are used in apparel because of their stain resistance and dyeability. They help activewear and swimwear manufacturers produce vivid colors, and their comfort characteristics are also very popular for intimate wear. Upholstery fabrics are being made from Sorona polymers because of their stain resistance, and more uses are on the way, he noted. What’s more,

DuPont has initiatives in place so that Sorona polymers may ultimately be bio-based, rather than made from petroleum. A plant is under construction now that will convert corn sugars into 1,3-propanediol, with the first production available in 2006. Sorona polymers are readily recyclable. “This is something we think is important as well,” Williams concluded. “Mohawk is already the world’s largest recycler of PET, and we are very encouraged by the prospect of offering this superior technology with an environmental story behind it. We think Mohawk’s SmartStrand fiber is the next chapter in this great story.” For more on SmartStrand, call 877/275-6642.

In other news, Mohawk has announced plans to significantly expand its presence at its Bennettsville, S.C., location next year. The mill plans to build a new yarn manufacturing facility near Bennettsville to complement its existing Oak River plant. The facility currently provides jobs for more than 600 employees and the expansion is expected to initially create approximately 300 new jobs. Steve Powers, vice president of yarn manufacturing, commented, “Our Oak River plant is one of our largest yarn operations and the history of success that the company has enjoyed here in Bennettsville makes us eager to grow this operation.” Powers added that Mohawk expects the facility to be operational by the end of 2005. The new facility will be built on property adjacent to the Oak River plant. Oak River presently produces over 50 million pounds of spun and filament fiber annually.

Jerry Hendrix, director of human resources for Mohawk’s yarn division, said, “We’re very excited about the opportunity to expand our operations in Bennettsville. This is a tremendous community of hard working, conscientious people, and we look forward to welcoming more of them into the Mohawk family.” According to Zoellner, the expansion at the Bennettsville plant has nothing to do with SmartStrand, rather “it has more to do with modernizing our facilities and doing a little consolidation here and there.” Depending on how SmartStrand does in the marketplace however, he did express a hope that the two might become connected. —Louis Iannaco