Mc Three News

M CT H R E E N E W S B I R T H D AY A B O U T O U R H I S T O R Y

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service and a global range are our driving force.

In response to an ever-changing textiles landscape, McThree is poised to take on the global competition with innovation backed by outstanding service. We are vertically integrated in Belgium and Turkey to absorb costs and provide the

or southern hemisphere. Moving forward,

highest quality rugs at the most affordable price.

we aspire to create even more sustainable selections with an eye to creating a fully recyclable end product. McThree aspires to contribute to a greener world in the years to come.”

And, as rug buyers demand, and deserve,

With an eye for trends, McThree creates

more functionality in rugs that translates

rugs that let customers turn inspiration

into comfort and worry-free care, they

into reality. CEO Stefaan Duchi describes

start looking for diverse shopping

the company’s exciting new direction:

destinations. Sales and Marketing

"Today’s buyers want products that

Director Chris Schoonjans says of the

match their personal tastes and evolving

evolution, “Our customers want to be

lifestyle. For example, a new homeowner

inspired on Instagram, Facebook and

may want an oversized selection to

Twitter. And, when they set their mind on

fill a large home while a world traveler

a rug, they want to order online and get it

may desire a tribal pattern inspired

immediately. For this reason, the service

by their holiday adventures. That’s

we provide to our customers is more

why we constantly create and deliver

crucial than ever before. McThree must

new patterns, styles and seasonally

adapt and respond to the everchanging

appropriate selections regardless of

demand for the latest in home

whether the customer is in the northern

accessories and décor.”

“Today’s buyers want products that match their personal and evolving style.”

— Stefaan Duchi

40 years of history

1979

Since our inception in 1979 as a woven rug factory in Anderson, South Carolina, US, we've grown into a global production operation in Waregem, Belgium and Bursa, Turkey. Operating with 59 looms, a 25 million kg extrusion capacity and a consolidated turnover of 155 million US dollars.

Orian Rugs establishes itself in Anderson, SC as the first woven rug manufacturer in the USA as a reaction to the low dollar rate and market for Belgian textiles.

1993

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the importance of the American

Orian Rugs assumes responsibility for McThree to strengthen its growth path. McThree expands new production

1989

ranges to Europe and America.

Three entrepreneurs start a weaving company with the time’s newest weaving technology using heatset polypropylene yarns.

Imitation wool carpets are born and McThree enjoys an international presence.

1995 McThree expands their weaving operation and pulls more activities in-house. The design department is founded, and the addition of an in-production finishing and shearing line offer more flexibility and control.

2013 Expansion continues and McThree adds production in Europe and Asia as the demand for offshore products increases. Sofiteks, owned by the Vanwynsberghe family, from Bursa in Turkey becomes the company’s newest member.

1998

2019 Orian Rugs in Anderson, SC celebrates their 40th Anniversary of operation, accounting for 30% of all rugs woven in America.

McThree makes the company vertical, offering a full-service construction effort. From yarn extrusion and weaving to stocking and shipping, all efforts are contained and managed by the company. R&D begins on yarn and construction improvements.

Fthis U TisUour R Evision It is an honor to be celebrating 30 years of McThree. During our time in the spotlight, though, we don’t just want to share where

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we’ve been . . . we also want to highlight where we’re going.

We can’t ignore the ecological pressure

practice they’re flawed because the

caused by our modern lives any more.

finished product doesn’t close the

By 2050, we intend to contribute to a

recycling loop.

different way of being. rPES (recycled PES) and rPA promise an

Today, our production process is clean and non-polluting.

Tomorrow, we will add full recyclability with the intention of further reducing our carbon footprint to create a healthier planet.

A product's carbon footprint is becoming

alternative for now virgin polymers. Global

exponentially more important than its

investments reinforce the idea with a

cost. And, as transport demand grows, so

focus on recycled PP (polypropylene). It’s

will the need to alter production locations

essential to our carpets and the packaging

to reduce emissions and greatly reduce

industry, especially in its transparent form,

dependence on natural resources, like oil.

hence the current complexity.

As a result, the petrochemical industry,

Today, we have recycled PP made from

which is thriving thanks to derivatives

post-consumer packaging. However, this

such as PES and PP, will adjust by

rPP is not white or transparent, which

increasing the cost of virgin chips.

means it's unsuitable for yarn extrusion.

This creates a reversion to closed-loop

This is where extraordinary opportunity

economies for quality base materials,

lies. We’re partnering with innovators on

as replacement with natural fibers is

both sides of the Atlantic who dedicate

not an option. Reduced water reserves

themselves to fine-tuning rPP. The

leave the world in a cotton shortage and

improvements create allowances for

volume production cannot be sustained by

rich color and depth for improved yarn

chemistry alone.

extrusion. rChips will be produced nearby to support ongoing efforts to reduce

We’re all aware of recycled yarns made

transportation costs, build a closed-loop

of PET chips from recycled water bottles.

economy and drastically cut our carbon

Although it's a wonderful concept, in

footprint.

3 dreams for 2030

1

Need for creative speed The markets will continue to change and drive demand for product innovations at an accelerated rate. To fulfill future demand, we are exploring creative executions in product design and weaving.

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To allow for the creation of rPP, we must have a flow of end-of-life and redundant PP waste. In Belgium, we recycle plastic

2

Yarn and blend innovations

waste in PMD bags which are sorted, re-

With investment in the yarn division, we’re positioning

used and recycled. This means recycling

ourselves to better explore new blends and options,

redundant 100% PP carpets or 100% rPP

creating dazzling new effects and imitating natural

carpets is conceivable at the consumer

fibers even better than before to make McThree a

level. Likewise, if future laws demand that

global competitor.

businesses accept redundant carpet returns, recycling centers are available to create the rPP chips for a truly circular solution! Since PP is one of the lightest plastics, sorting dual component carpets should prove relatively easy.

We are aggressively exploring options for

3

Circular systems

synthetic and natural fiber cycling. There is great need for creative speed, and we are

We are taking the first steps in offering carpets with

dedicated to developing and using fibers

recycled content, as well as fully recyclable area rugs

that reduce our footprint and enhance

and carpets. By 2030, we aim to use redundant and

consumer comfort.

end-of-use carpets to make recycled chip material.

The result? What’s old is new again!

The future model both ensures and confirms the current, vertically-integrated production hub for developing and creating yarns and carpets using rCHIPS on the European, Asian and American continents.

Digital pen

Our creative process

All developments and designs are drawn with a digital pen, possibly the most important instrument for any designer.

Wabi Sabi The nature trend book Wabi Sabi for the 2020 collection. Wabi Sabi is a Japanese philosophy based on imperfection.

The creation process of the design team starts with trend seminars, interior fairs and market research. We take inspiring objects from

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around the globe to the studio. This is the first step in developing new products and colors. Each designer specializes in a specific

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Hand made tir les serve as co lo inspiratio n

market. This is how we create expanded collections with our team.

The following tools are necessary in our creation process.

Pompoms Heat-set pompoms

Shades Shades of nature are key for interiors and inspire us for the 2020 collection.

(twisted and heatset yarn) are made to simulate the effect in the carpet. If needed, last-minute color changes are made.

Color Once we have chosen the pantone references, the yarn lab simulates the color and we assign a masterbatch code once the color receives approval.

Hand sample A hand sample, a mini rug to sell our fabrics and a physical representation of the color and price, is created to test the color and material.

trend fairs and social media inspire the design team, who are always on the lookout for market trends.

BCF When the masterbatch receives approval, BCF (Bulk Continuous Filament) is extruded for use.

This can be 3-ply or mono color.

No mood bisoasordrs! wit hout sc

Our vision We create our own trend book through trend fairs and social media. Trend inspirations to share our vision with the customers feature 3 themes: nature, global and modern.

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Trend books,

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Trend books

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Masterb atchnechmipixs:ed po ly propyle ment wit h pig

1 Everything starts with the development of the right colors.

We have already built up a color library of approximately 2,500 colors within Mc Three. These can be mono colors or a combination of 3 colors in one extrusion wire.

Multi-colors can be made by

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twisting threads together.

FROM YARN TO RUG

2

the must know of our business

The dyes are composed of various basic pigments and fused in our lab and shredded into grains. These color grains are called the masterbatch. The coloring is therefore done in the mass (solution dyed), as a result of which the color strength and color fastness is greater in comparison with dyed yarns.

One part mystery, one part magic, the carpet manufacturing process is a carefully choreographed dance of key elements,

pass through a spinneret and are air-

production points and mechanics.

cooled before being wound onto bobbins.

Textured yarn is a generic term for filament(s) that receive a greater apparent volume or bulk than conventional yarns of a similar filament count. The term can also be used to Every McThree area rug starts with

describe yarns that are made more

polypropylene (PP), a man-made

extensible by filament distortion through,

synthetic that is lighter than both

in our case, heat/steam treatment. After

polyester and nylon. PP is beneficial in the

the PP fibers receive treatment, the yarns

area rug market as it has a low thermal

are sent on for weaving.

conductivity and doesn’t absorb water.

To create the materials necessary for

A 3-rapier weaving machine produces

weaving, PP is extruded into tiny filaments

our rugs. These machines insert 3 fillings

that are then bundled together to create

at the same time: The top, a filling for

a multi-filament yarn (a microscopic

the backing of the top carpet; The

grouping of filaments). These strands then

bottom, a filling for the backing of the

Polypropylene is much more forgiving than wool and is ideal for rigorous modern living.

4 Yarns can be put together on twisting machines and twisted or cabled.

This allows us to work creatively again with colors, yarn thicknesses and the number of revolutions.

5 The final operation before weaving is the heatset process. This is where all previous operations on the yarn are made permanent by means of heat treatment. All the coils are unwound again and pass through a conveyor through a furnace. In addition, an extra dimension may

3

or may not be added: crimping. The yarns get a curl effect, which means

During the extrusion process for the yarns, the master batches are

that the aspect on a pile carpet can

fused with the PP granules (Poly Propylene). The molten mass is

be changed considerably.

pressed through fine holes to obtain fibers. These fibers are cooled to solidify and fed into bundles (correct number of filaments per thread) during the further process. To obtain the right properties for a good carpet thread, the yarns are provided in one step (tensile strength and elongation), extruded (volume) and entangled by air (knots to bundle filaments) before being wound on bobbins. After this production step we obtain a BCF (Bulk Continuous Filament) yarn.

6 bottom carpet; The middle, a thick filling alternately woven into the top and bottom backings. Put simply, pile carpets exit the loom woven face-to-face, sandwiched by backing, and are cut into two distinct

All the yarns are eventually rewound on coils after heat setting.

Each coil is identified with a label so that we can trace everything in the event of problems.

area rugs that mirror one another for

The coils are placed in containers

increased efficiency and volume.

and are ready for shipment to the weaving mill.

Polypropylene rugs have been compared to wool and other dense textile textures, making PP an ideal raw material. However, the material is much more forgiving than wool and is ideal for rigorous modern living. Polypropylene area rugs withstand heavy foot traffic, routine cleaning and spot treatment. And they won’t fade or shed. This easily makes our area rugs the very best textile you can own.

“Colleagues call me the smiling man!”

For Rakesh Narula, Mcthree has been his second home since 1999. “Work hard and play hard people say, I enjoy preparing shipments and I also have fun with my colleagues,” he says. Rakesh started working in the confection department when he was 19 and moved on to finishing and logistics. He gets along with everyone: young or old, male or female, new or long-time colleagues. They’ll also all confirm what his hobby is: cooking! Rakesh makes the best pizza in the

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greater Waregem area.

“I am seen as Mom McThree.”

For 20 years, Nancy Secember has NANCY SECEMBER

served as our finishing expert and sampling guru. All customer and sales sample requests pass through her capable hands. Nancy helps with and advises on repairs and loves to give input on the finishing of new developments. Due to her expertise, Nancy can do any job in the stitching area. She loves to share her experience nickname Mom McThree. Nancy loves decorating her house and adapting it to the season. She has had a carpet in her home from all the collections. Carpets at work and at home!

We support the diversity of our treasured craftspeople.

ANELIEN FOURMENTRAUX

with the new colleagues, hence her

“Developing new yarn types and colors is super exciting!”

Thierry Asselineau joined McThree in 2003. Born and bred in France, now living in the Walloon area and working in Flemish speaking Flanders, Thierry loves biking, car rallies and DIY. He also stayed on after interim employment as an operator in the yarn division. With experience, Thierry worked his way up to Quality Control Manager for the Yarns division. “McThree is a dynamic company with a youthful spirit, that listens to the employees and workers. out how to create the new fashionable colors that design is looking for.

I enjoy sharing my experience with my colleagues,” this family man concludes.

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THIERRY ASSELINEAU

I love to develop new yarns and figure

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RAKESH NARULA

the knowledge of machinery and gained

“I am happy to show that a woman can do a man’s job.”

Anelien Fourmentraux, from the Walloon area, is a shining example of gender equality. A native French speaker who started working in McThree last year, Anelien came to us as an animator with a heart for animals and no textile experience. However, she stayed on after an interim role. “Working in McThree is great compared to my other jobs. I have less stress and the general work vibe is very nice. I started as a heat set operator. Luckily, McThree noticed I had potential and I was offered the Extrusion lab operator job. In principle, this is a man’s job, as it is physically demanding, but I am glad I can prove them wrong!“

600,000,000 Since the start of the yarn department in 1999, we have already made yarn three times the distance to the planet Mars, more than 600 million kilometers.

19 From yarn to transport, our product goes

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through the hands of 19 different operators.

93 We deliver to 93 countries around the world.

120,000,000 40

We have sold 120,000,000 square meters of carpet in 30 years.

Mc Three started in the Borlutstraat in Waregem, Belgium with 40 employees.

27 The yarn department makes around 27 tons of yarn a day.

Next birthday card:

Phenomenal 50!

As we celebrate 30 wonderful years, we honor the employees and workers who made McThree what it is today.

With their help, we’re working on our future. As a company, we’re excited about dramatically reducing our ecological footprint to stop climate change.

30 years to do it! We are happily anticipating, and planning for, tremendous change and explosive growth in the next 10 years. In fact,

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But we don’t have to wait another

we’re working towards a triple-size

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gazette!

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To past, present and future workers, we honor you and appreciate your ongoing support and continued efforts to make McThree stronger in the coming years. Cheers to the future – a better and brighter 10, 20, 30 years and beyond for our people and our planet!

Mc Three Carpets Mannebeekstraat 6 - Zone 2 - Vijverdam 8790 Waregem (Belgium) www.mcthree.be