Take a deep dive into Ulster Carpets’ most colorfully challenging cruise ship project
In 1938 in Portadown, Northern Ireland, George Walter Wilson founded Ulster Carpets, a world-leading carpet manufacturing company that remains privately owned by his family. By combining the positive aspects of a family-owned business with a forward-thinking, global approach, Ulster Carpets has positioned itself as a technologically advanced, service-oriented company with flair, flexibility, and a dedication to quality. With its creative design expertise and unique weaving technology, PSYLO™, the company can provide unlimited design possibilities without the constraints of a repeating pattern, resulting in unparalleled depth and texture in design. Approximately four years after we first had the pleasure of learning more about Ulster Carpets, we catch up with Jeremy Wilson, Sales Director.
“Naturally, the past few years have been challenging due to the pandemic, which struck shortly after our last feature in Manufacturing Today. Throughout those
trying times, we devoted a year to consolidating and maintaining the continuity of our business operations. Since then, we have significantly ramped up our innovation program through numerous initiatives and investments. One of the most notable of these initiatives is multi-million-pound investment in high-speed looms at our Portadown facility spread over two years. By the end of this period, we will have an extremely productive Axminster carpet weaving facility in place,” he begins.
Poised to conclude by the end of June, Ulster Carpets’ current phase of investment will grant the company eight of the latest high-speed Axminster looms aimed at optimizing productivity. Jeremy delves deeper into the series of investments leading to this point. “Back in 2017, we acquired Griffith Textile Machinery, which had developed a high-speed loom that, when paired with our innovative yarn supply technology, gives us a unique competitive edge. These looms can weave any design we desire at speeds up to three times faster than a conventional Axminster loom. This advancement not only enables us to lower unit labor costs but also minimizes yarn wastage due to the tighter tolerances
at which it can operate.
“Four years ago, we trialed two new high-speed looms. Initially, as is often the case with new equipment, there were challenges in getting them to work properly. However, once we realized the extent of their potential, we decided to continue investing in them going forwards. Recognizing that the layouts of the original looms were not suitable for our needs, we opted to construct a bespoke shed to house them, complete with specially designed creels to hold all the necessary components at the back. By configuring them in a more efficient layout, we were able to operate them with fewer personnel. The first phase of this investment was finalized in April 2023, and since then, we have had four looms operational in our facility. At present, our focus is on completing the second phase of this expansion, which involves doubling the size of our building to accommodate an additional four looms. One of these looms is already in place, with the remaining three scheduled to be installed by the end of June,” he elaborates.
Thanks in part to such strategic investments, Ulster Carpets enjoyed exponential growth in 2023. “I believe that our growth has been driven by a number of key factors. Most of our major clients in Europe and North America are cruise ships, casinos, hotels, and domestic customers buying carpets for their properties. Following the pandemic, between 2022 and 2023, the retail sector experienced a resurgence as people working from home sought to make substantial investments 
in enhancing their houses. On the other hand, within the contract market, we have become more involved in the construction of new, large-scale cruise ships, as well as the refurbishment of existing ones, along with numerous casino renovations and similar projects. Hence, we are currently experiencing organic growth in this booming sector. Additionally, we have expanded through the acquisition of several other businesses. Shortly before the initial lockdown, we acquired Axfelt, followed by the acquisition of Solidwool in late 2022, and last year, we purchased Alternative Flooring. Combined with our existing organic growth, these acquisitions have played a pivotal role in our expansion,” Jeremy explains.
Monumental project
Last year brought about another key milestone for Ulster Carpets, with the completion of a stunning project for Royal Caribbean International on its Icon of the Seas cruise ship. “This project has arguably been one of the most uniquely complex endeavors we have been involved in. In total, we manufactured over 55,000sqm of carpet for Icon of the Seas, creating over 75 different designs. To put this in perspective, a standard project has an average of 20 different designs. The Icon of the Seas cruise ship exceeded these figures by far due to its diverse range of venues, including various restaurants, bars, nightclubs, children’s areas, dance halls, corridors, bedrooms, suites, and more. Every single one of those areas was designed with its own unique blueprint, and we planned the carpeting to optimize utilization and minimize waste for the client. Moreover, as part of the large amount of design work, we meticulously assessed the dimensions of each area to determine the most cost-effective approach for the end client. Thus, it is safe to say that this project represents a monumental process,” Jeremy emphasizes.
As it braces for the future, Ulster Carpets is considering the adoption of artificial intelligence (AI) to boost productivity. “With the amount of design content and planning complexity we have, we hope AI will empower us to simplify and improve our processes in future. Combined with our new ERP system, it could enable us to be more efficient, increase productivity, and streamline our operations,” he ends.
Fueled by strategic investments in cutting-edge technology and an eagerness to take on the most creatively challenging projects, Ulster Carpets continues to redefine the boundaries of what is possible in the realm of custom carpeting.