LVT’s footprint expands around the globe

The luxury vinyl tile (LVT) segment has seen extreme growth since its introduction to market. Although commonly produced in Asia, the product is becoming more global as technology transforms the category. Digital printing, eco-friendly features and modernized design capabilities are among the enhanced attributes.

Expanding Footprints

HMTX Industries produces LVT in Asia, the U.S. and Europe, according to the company, explained Jeff Collum, president of HMTX Commercial, “It depends on the specifications and market sector to determine where we wish to produce the highest quality to meet market demands and best satisfy our client base.”

Similarly, Alyssa Cole, senior content marketing manager at Novalis Innovative Flooring/NovaFloor noted, “We have manufacturing facilities across the globe, giving us an advantage that many manufacturers need but don’t always have— options. Options in proximity, pricing, product specifications and the flexibility to pivot if market circumstances change. (i.e. fluctuation in the cost of containers, new regulations or tariffs, etc.).”

Global companies like Karndean Designflooring, for example, tend to choose manufacturing locations that best serve their international markets.

Said Jenne Ross, director of product at Karndean Designflooring, “All our partners share not only our commitment to manufacturing durable, beautifully designed LVT, but to environmental and social responsibility. Our LVT is manufactured in dedicated facilities in South Korea, Taiwan, Vietnam and China.”

And at Mohawk, said Adam Ward, vice president of product management, resilient, it “tries to get products from where we’re selling it. We have a domestic footprint here, but we also have our plants in Europe. We also source products from the Asia region from both areas based on demand and needs.”

With a heavy diversification of supply around the world, there is still a major appeal for Made in America products.

“The majority of our LVT is made in America at our Seretean Plant in Dalton, Ga. We’ve made a significant capital investment in our PureGrain DLVT (Digital Luxury Vinyl Tile) technology, the first domestically manufactured DLVT that uses digital emboss technology to create high-resolution designs directly on a high-density rigid core. We are bullish on domestic manufacturing because of the advantages it offers, from absolute quality control to less reliance on fluctuating freight prices,” noted Joe Young, vice president of residential product and marketing for Engineered Floors (EF).

Coming out of the Uyghur Forced Labor Protection Act (UFLPA) issue, Mannington Mills established a global, diversified supply chain to meet the needs of the market. This includes production in the U.S. as well as abroad.

“We are committed to delivering products with meaningful innovation—innovation that matters to both the retailer and the consumer. This requires capabilities from our supplier partners that deliver on that commitment,” offered David Sheehan, Mannington’s senior vice president of residential marketing and product.

Technology & Sustainability Transform

Technological advancements in LVT are constant and suppliers are now more focused than ever on sustainable initiatives.

“We have a very diverse supply chain across the world. We also partner with strategic partners to bring unique innovation to the market,” advised Roderick Macleod, director of resilient, Shaw adding, “Over the past few years, we’ve made significant technological advancements in our plants by fostering close collaboration between our quality and technical teams and our manufacturing and supply partners. This partnership has allowed us to drive continuous improvement across our entire supply base. As a result, we’ve enhanced efficiency, product quality and innovation in our manufacturing processes.”

Manufacturing its DLVT right in the company’s own backyard of Dalton, Ga. gives EF an advantage as the entirety of its manufacturing process happens under one roof.

“Since we are not moving the product from plant to plant, we significantly cut down on energy costs. By virtue of having the manufacturing line in house, we have complete quality control and can adjust on the fly to orders. With many of our raw materials close to home, we know exactly where they come from. Our Made in the U.S.A. story is another differentiating factor for consumers when they are considering their next flooring purchase,” Young added.

At Karndean, the company chooses its partners strategically to best serve its international markets while advancing its environmental and social responsibility objectives. “This includes carbon emission reduction and manufacturing products that can more easily be reused/recycled and creating work environments that prioritize the health and well-being of employees,” said Ross.

HMTX also prioritizes sustainable processes. Said Collum, “We have seen many improvements in efficiencies, but the biggest technological advances are in sustainable new materials being developed, such as HMTX’s SRP TPU flooring, and digital printing.”

Dedicated to Design

From new, diverse patterns and designs to upgraded beveled edges and glazes, LVT has undergone a style makeover thanks to new innovations in technology.

Young at EF noted, “Our state-of-the-art digital DLVT printing line is a game-changer. The advancements in digital printing technology have allowed for stunning, high-definition visuals giving our DLVT the look and feel of real wood while providing the performance features of traditional LVT. The difference is we offer 35 distinct plank designs, which is up to five times more unique designs than traditional LVT. This gives the consumer fewer plank repeats with an eye-popping, wood-like look that they’ve never seen before.”

Continued automation and efficiency in U.S. and Asian facilities continues to be the focus of today’s leading suppliers, along with enhanced aesthetics in design, which matters most to their consumers.

“We pay attention to the details that make our product look more authentic and then validate with voice of customer. While others have quickly embraced current digital printing technology, we continue to look for technologies that are meaningful to the consumer and that meet our high standards for visual consistency and quality,” said Mannington’s Sheehan.

According to Mannington, its competitive edge in producing LVT is collaboration. “Our internal resources are strongly aligned with our supplier partners to deliver visuals that win in the marketplace. We develop meaningful and exclusive technologies that allow us to provide our retailer partners with a unique selling proposition for the consumer. Our most recent examples include CraftedEdge technology featured in both our Preservation and Coventry patterns as well as TumbledEdge and NatureForm Glaze that is available in the most popular LVT tile in the market, Fresco.”

“For our domestic plants, when we first put them in, they made regular, everyday products—as you’re starting up a plant you want to do that—but we’ve added future technologies as we’ve invented them and have increased the knowledge in those plants,” said Mohawk’s Ward. A great example, he said is its Signature product launched last year that’s being made in Mohawk’s Dalton plant. “We developed the technology in our R&D centers in Europe, started making it over there and brought that technology to our domestic plants as we’ve brought on the investments and knowledge to do so.”

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