ulster

ULSTER

A custom design by Ulster Carpets for Ritz-Carlton Berlin. Image courtesy of Ritz-Carlton Berlin and G.A Group.

Ulster Carpets was founded in 1938 in Portadown, Northern Ireland, by George Walter Wilson and remains privately owned by the same family. The company is the premier supplier of Axminster and Wilton carpets to the residential, hospitality, marine and casino sectors across the world. Sustainability and Product Engineer Carol Howson told Hannah Barnett some of the secrets of the company’s success.

The story of Ulster Carpets is one defined by innovation. The company has combined its family-owned values with a pioneering, global approach to business. The result is a technologically advanced, service-driven company with flair, flexibility and a dedication to quality.

“Looking back through our history,” said Carol Howson, Sustainability and Product Engineer, “it is clear that forward-thinking is at the heart of everything we do. We continue to pioneer innovative, marketleading technology that focuses on manufacturing the highest quality carpets in the most efficient way.”

Innovation woven in Ulster Carpets has continuously led in its sector. The company introduced the first 15-foot Axminster loom in 1962, installed electronic Jacquard looms in 1987 and later became the first carpet manufacturer to offer 5-metre-wide woven Wilton carpets.

In 1999, Ulster Carpets launched a patented weaving technology and in 2022, this was taken a step further with

the introduction of the new generation of PSYLO TM looms. This technology has revolutionised the colour and designs the company offers, while also significantly increasing efficiencies.

The company is now well established with offices around the world, including London, Berlin, Paris. In the US, the company operates a main office in Marietta, Georgia, and has sales and design teams across North America working with the leading hotel brands and all the major casinos.

“Having expert teams working directly with our customers helps to turn interior

design visions into reality,” said Ms Howson. “We take a collaborative approach to every project and work closely with customers to develop design ideas. It is this partnership approach that makes all the difference to our customers and why we have such high levels of repeat business.”

Every week, Ulster Carpets weaves the equivalent of four football pitches of Axminster carpet and the company buys around 2.5 million kilos of wool a year – the equivalent to 1.47 million fleeces.

The holistic approach

As an innovative operation, Ulster Carpets has been actively looking at its environmental impact and carbon footprint for at least 20 years. In 2008, it was the first company in Northern Ireland, and the first textile manufacturer in the UK, to be awarded the Carbon Trust Standard after cutting carbon emissions by over half.

The company has now taken a holistic approach to its sustainability strategy,

which means looking at all areas of business to drive improvement.

“As the world’s largest Axminster weaving site, efficiency in production is one of our top priorities,” Ms Howson explained.

“In 2021, we conducted a robust review to assess our environmental standards.

The findings showed that we have made a great start, with strong foundations in place which have been used as a springboard to grow our sustainability strategy.”

In April 2023, the company published its first sustainability report. The report outlines how Ulster Carpets has made changes over the last few years to reduce its impact and sets out sustainability targets to achieve by 2025. These include a 50% reduction in carbon emissions, reduction of water consumption by 5% and a 20% reduction of waste.

On the crest of a wave

Ulster Carpets recently completed its largest ever cruise ship project and the illustrious Icon of the Seas set sail for the first time in January 2024.

The stunning grand ballroom at The Drake Chicago. Image by Todd Kaminski, Kaminski Studio.

The game-changing cruise ship from Royal Caribbean International is 365 metres long, weighs 250,800 gross tonnes and has a capacity for 5,610 guests and 2,500 crew. It also features over 55,000 square metres of bespoke carpet designed and manufactured by Ulster Carpets.

“Projects like this demonstrate that there is still an appetite for wool-rich carpets in the hospitality sector, particularly the envi -

ronmentally conscious cruise industry,” Ms Howson reflected. “It was certainly a project that put us to the test. We created over 75 different designs for Icon – a huge increase on the 20 different designs for an average project.”

The Icon of the Seas project also allowed the company to showcase its ability to create unique designs, with the team in Portadown and the design studio

The game-changing cruise ship, Icon of the Seas, is the largest-ever marine project completed by Ulster Carpets. Image courtesy of Royal Caribbean International.

Custom carpet at The Overlook in the AquaDome within Icon of the Seas. Image courtesy of Royal Caribbean International.

in London producing flooring works of art to match the distinctive design and style of each area on the ship.

“Like every project we work on, we had to make sure we met strict deadlines to keep the project on track – which put our weaving and finishing teams under pressure,” Ms Howson said. “However, while Icon of the Seas was a larger project than most, we have vast experience of working on hospitality projects that have high demands in terms of design and quality.”

Together for the future

An Ulster Carpets product contains a high percentage of wool, a rapidly renewable raw material, sourced primarily from the British Isles. As a fully integrated manufacturer, the company enjoys full control over its processes. Wool is sourced and spun at its own mill and all Axminster and Wilton products are designed and manufactured in the UK. Additionally, all process waste is used to produce a luxury triple layer underlay called Axfelt.

Ulster Carpets matched the Art Deco style of the Ritz-Carlton Berlin with a custom carpet. Image courtesy of Ritz-Carlton Berlin and G.A Group.

“From sourcing the highest quality wool, spinning and dyeing the yarn, through to the bespoke design, weaving and delivery of luxury carpets and rugs, we control every aspect of the manufacturing process,” Ms Howson explained. “This is different to most carpet manufacturers, who will outsource different elements to other companies.”

As a result of this fully integrated status, the company also enjoys control over a large part of its supply chain. The materials that are sourced externally, are largely done so as locally as possible. “We choose suppliers who can deliver goods and services that align with our sustainability ethos and support us in achieving our own targets,” said Ms Howson.

Looking ahead, Ulster Carpets plans to continue to innovate and lead in every aspect of its business. Like many manufacturers in the UK, the company faces cost pressures compared to the competition based in lower cost economies, so intends to find innovative solutions to offset that disadvantage.

“Our focus is on reinforcing our position as a premium quality producer by adding as much value as possible to our product offering,” said Ms Howson. “That will be achieved through skilled people, use of technology, R&D and investment in machinery. We are always looking for ways to improve and will continue to provide excellent products and service to our customers.”

Ms Howson’s position of Sustainability and Product Engineer was created just

last year, demonstrating Ulster Carpets’ ongoing commitment to becoming a more sustainable brand.

“I feel very privileged to be given the opportunity to make positive changes for the future of the company, as well as on the overarching path to Net Zero,” she concluded. We all have a role to play as individuals, but it is very rewarding being able to make a positive contribution on a larger scale.”

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