In 1825, Erastus Bigelow formed the first carpet mill in America, giving birth to the woven carpet and rug business in the United States. In 1839, he permanently reshaped the industry with the invention of the power loom for weaving carpets. Bigelow's loom, which doubled carpet production the first year after its creation and tripled it by 1850, is now part of the Smithsonian Institution's collections. He continued to devote his life to innovation -- 35 separate patents were issued to him between 1839 and 1876. Bigelow introduced the first broadloom carpet in 1877.

The power loom with Jacquard mechanism was developed in 1849, and Brussels carpet was first manufactured by the Clinton Company of Massachusetts. The Brussels loom was slightly modified, making possible the manufacture of Wilton carpet. Later, the Hartford Carpet Company joined with Clinton Company to become Bigelow Carpet Company.

In 1878, four Shuttleworth brothers brought 14 looms from England and established their manufacturing plant in Amsterdam, New York. In 1905, the company introduced a new carpet, Karnak Wilton. Its instant success was phenomenal. Flooded with orders, a new building had to be constructed to exclusively handle Karnak production. Weavers worked four and five years without changing either the color or pattern on their looms.

Alexander Smith started his carpet manufacturing plant in 1845 in West Farms, New York. An American, Halcyon Skinner, had perfected the power loom for making Royal Axminster in 1876. He and Alexander Smith combined, forming a very successful carpet company. Alexander Smith was elected to Congress in 1878, but died on the evening of election day. Sixteen hundred people were employed at his factory at the time of his death. Alexander Smith & Sons continued. During World War I, the carpet looms were converted to make tent duck and navy blankets. In 1929 Alexander Smith & Sons was the largest manufacturer of carpets and rugs in the world.

The Carpet Industry in the United States

Of all flooring, carpet is 72% of the market. Residential market - 61.3% Contract or commercial market - 38.7%

Total industry shipments (1994) totaled 1.639 billion square yards (up 10.6% from '94) or $9.895 billion at mill level (up 6.6% from '94), estimated at $15 billion retail. (In 1950 industry shipments were 97 million square yards.)

In the past 44 years, the price of carpet has increased by only 79.5%; new car prices are up 262.9%, and all commodities combined have increased in price by 341%.

Today, there are approximately 216 corporations and 255 manufacturing plants located in 23 states.

It is estimated that 25 companies in the industry produce 89% of the nation's carpet and rugs.

Tufted carpet's share of the market was 91.4% on square yard basis, and 92.9% based on dollars.

Today there are 3.1 billion pounds of face fiber consumed each year. The largest manufacturer alone uses over two million pounds of fiber a day!

Broadloom carpet (carpet and rugs over 6' by 9' in size) accounts for 82.5% of the square yards shipped. Of the total broadloom shipments, 81.7% are tufted.

Market Share of Fibers

Nylon 64%, Olefin 28%, Polyester 7%, Wool 1%.