Four Walls Process

Bob’s vision for the future of flooring was to create products that were not just beautiful but also environmentally responsible. He realized that traditional carpet manufacturing methods were not only outdated but also harmful to the environment. That’s why he introduced the Four Walls Process, which allows Engineered Flooring to produce all of their carpets under one roof, maximizing sustainability and efficiency. This also allowed them to be nimble in their approach to innovation and design. Their proprietary PureColor® fiber manufacturing process is a prime example of this, using 87% less water, 30% less energy, and emitting 42% fewer greenhouse gasses than traditional carpet manufacturing. This not only helps our partnership to minimize our carbon footprint, but it also allows us to sell carpets that are kinder to the environment.

Solution-Dyed Fiber

One of the key components of Engineered Flooring’s manufacturing process is its solution-dyed fiber, PureColor®. This process dyes the fibers at the polymer source, resulting in a color that goes all the way through the fiber, meaning it won’t fade, wear off, or stain. This not only adds to the durability and longevity of our carpets but also provides a level of stain resistance that sets our products apart in the industry. This makes it ideal for high-traffic areas such as hallways, living rooms, and dining rooms where spills and stains are more likely to occur.

In addition to its stain resistance, the PureColor® solution-dyed fiber also offers excellent lightfastness. This means that the colors in our carpets will not fade or change over time, even when exposed to direct sunlight or other sources of UV light. This makes Engineered Flooring carpets ideal for use in areas with large windows or skylights. The lightfastness of our carpets also ensures that they will maintain their beauty and vibrant colors for years to come, even in high-traffic areas with heavy foot traffic.

Another benefit of Engineered Flooring’s PureColor® solution-dyed fiber is that it makes maintenance a breeze for cleaning crews. Since the color goes all the way through the fiber, there is no need to worry about color loss or fading when using cleaning solutions or heavy-duty equipment. This not only saves time and effort for the cleaning crew but also ensures that the carpets will look as good as new after each cleaning. Additionally, since the carpets are highly resistant to stains, they will require less frequent deep cleaning, further reducing maintenance costs.

For pet owners, PureColor® solution-dyed fibers are the perfect solution for their concerns about stains. The carpets are highly resistant to stains, including those caused by pet accidents, making them ideal for homes with pets. Furthermore, the carpets are easy to clean and maintain, so any accidents can be quickly and easily cleaned up, making it a perfect option for pet owners who want to keep their home looking and smelling fresh.

Strong & Durable Twisting

Another aspect that sets our carpets apart is the strength and durability of Engineered Flooring’s fibers. This is achieved through their twisting process, where two cones of single-ply fibers are twisted together to create a two-ply fiber. This both increases the strength of the fiber and also allows for the opportunity to add flex or tonal looks by twisting various fiber colors together. This process is then reinforced through their heat setting process, where they apply heat to lock in the twist, increasing its durability and preventing the fibers from unraveling.

The Tufting Process

Finally, carpets from Engineered Flooring are designed with both form and function in mind. The tufting process allows for the adjustment of pile height, density, weight, and the creation of unique patterns and loops. This process is followed by the coding department, where a secondary backing system is attached to the tufted primary using a thin smooth layer of adhesive between the two backing systems. This final step ensures a high-quality finished product that is both beautiful and functional. This ensures that Engineered Flooring’s carpets can withstand heavy foot traffic, regular vacuuming, and professional cleaning without showing signs of wear and tear. No carpet is satisfactory if it is not comfortable to walk on. The texture of the carpets we sell provides a comfortable and inviting feel underfoot, making them a perfect addition to any home. Their plush and soft fibers are gentle on bare feet, providing a warm and welcoming atmosphere to any room.

People want carpets that match their personal style and complement the design of their space. The carpets sold at Floor Country are available in a wide range of styles, colors, and designs, making it easy to find the perfect match for your home or office. At Engineered Floors, their mission has always been to support their customers and to serve their community every step of the way. Engineered Flooring is proud to offer its products through its family of brands, including the residential brand, Dreamweaver by Engineered Floors. At Floor Country, we also offer a wide range of other flooring options such as LVT, hardwood, and laminate that are made with disruptive technology like solution-dyed PET or digital print LVT. This allows you to create a cohesive look throughout your home or office, regardless of the room or area.