The broadloom carpet industry in the United States began in 1791 when William Sprague started the first woven carpet mill in Philadelphia. Others opened during the early 1800s in New England. 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.

Industrialist/retailer Marshall Field had a traditional Axminster weaving loom modified to create what no one else had ever created -- a machine-made rug woven through the back, just like a handmade Oriental, featuring intricate designs and virtually unlimited color variety. Karastan's rug mill was established in 1926, and introduced the first Karastan rugs to the public in 1928.

Alexander Smith, Bigelow, and Karastan are companies continuing today as divisions of Mohawk Industries, headquartered in Georgia.

There are many manufacturers today producing both simulations of antique designs and updated "oriental" type rugs by both weaving and tufting processes. Through the late 1800s, Dalton, Georgia, struggled with cotton mills and steel manufacturing works to forge a small town in the north Georgia hills. Northwest Georgia, with its hard-packed clay, poor farmland, and rolling hills was among the last areas of Georgia settled. Rich in a heritage of Cherokee Indians and Civil War battles, that northern corner of the state was rugged and spawned people who were independent and self-sufficient. Those were the people who brought forth and nurtured the tufted textile industry. The industry's infancy was in Dalton; it has gone through intense growth in Dalton; and it has now matured in and around Dalton. The carpet industry's impact is great on this region, this state, and the nation, and the story of its growth is unique.

Machines quickly developed into four, then eight, twenty-four, and more needles to make the parallel rows of tufting known as "chenille." By 1941, all but about one percent of tufted bedspreads were machine made. Mats and rugs were created with the same process, using cotton yarns and fabric. Volume increased rapidly after World War II, because people were hungry for color and beauty. To show the extent of growth, 30,000 bales of cotton were consumed in 1946 by the industry. By 1950, approximately 500,000 bales were used, and the industry was the third largest consumer of cotton grown in Georgia in 1952.

Until about 1954, cotton was virtually the only fiber used in tufted products. Wool and manmade fibers -- polyester, nylon, rayon, and acrylics -- were gradually introduced by textile men in Dalton. Nylon was first introduced in 1947 and grew steadily to dominate the market. Polyester was first used in 1965 and was followed soon by polypropylene (olefin). Most manufacturers will agree that the single most important development in the industry was the introduction of bulk continuous filament nylon yarns. These yarns provided a luxurious quality, durable carpet, similar to wool, which was more economical to produce. Therefore, a durable, luxury product was offered to the consumer for less money.