R&D Engineer * Carpet Technology

Job Title: R&D Engineer - Carpet Technology

Location: 1844 US Hwy 41 South, Calhoun, GA 30701

Job Purpose

Lead innovation in carpet technology with a focus on tufting, advanced backing systems, coating formulations, and performance-enhancing treatments. This role drives product development across fiber, backings, and surface chemistry-balancing cost, sustainability, and performance to meet evolving market needs.

Job Overview

The R&D Engineer will manage hands-on lab work, materials testing, and plant trials to develop next-generation carpet systems. Areas of focus include stain and moisture resistance, advanced backings (including recycled/recyclable content), and innovative coatings. The position works cross-functionally with production, sourcing, and marketing to commercialize scalable technologies. Occasional travel to manufacturing sites and industry events is required.

Key Responsibilities

• Develop and refine coating formulations and backing systems for improved stain resistance, moisture control, dimensional stability, and environmental performance.
• Lead formulation of topical treatments targeting soiling, pet hair release, microbial resistance, and cleanability.
• Plan and execute plant trials to scale lab innovations into full production.
• Conduct performance testing (e.g., tuft bind, delamination, LRV, VOC, dimensional stability).
• Evaluate and source raw materials such as polymers, additives, and recycled fillers for use in coatings and backings.
• Apply DOE, SPC, and root cause analysis to interpret results and drive improvements.
• Collaborate with sustainability, sourcing, and marketing teams to align product innovations with compliance and market demands.
• Monitor industry trends, emerging technologies, and competitor activity.
• Support product compliance initiatives (e.g., EPR, Red List, PFAS restrictions).
• Prepare and present detailed technical reports, cost models, and project updates to senior leadership.

Job Requirements

• Bachelor's degree in Engineering, Chemistry, Polymer Science, Materials Science, or related field.
• 7+ years of experience in the carpet or textile industry with a strong record of innovation in coatings, backings, or performance chemistry.
• Deep understanding of carpet manufacturing processes, including tufting, heat setting, lamination, and extrusion coating.
• Strong background in raw material evaluation, adhesion testing, and performance benchmarking.
• Proficient in experimental design, data analysis, and statistical process control (SPC).
• Experience developing sustainable solutions (e.g., recycled content, PVC-free systems).

Skills and Competencies

• Expertise in coating technologies including polymer dispersion, extrusion, and UV-curable systems.
• Strong knowledge of topical treatment chemistry for stain, water, odor, and microbial control.
• Demonstrated success in developing recyclable or environmentally preferred backing systems.
• Proven project leadership and cross-functional collaboration.
• Familiarity with ASTM, ISO, and CRI carpet testing standards.
• Excellent communication skills, including technical writing and presentation delivery.

Preferred Qualifications

• Experience with non-phthalate plasticizers, barrier films, or high-performance moisture backings.
• Familiarity with sustainability frameworks such as ILFI Red List, EPR, and other regulatory initiatives.
• Background in lean manufacturing, lifecycle analysis, or continuous improvement.
• Involvement in technical standards development or industry working groups.