Dongsheng Customizes 12,000 m² of Carpet for Crowne Plaza Kunshan
Project location
Kunshan, Jiangsu, China
Cooperation period
2023
Main Products
Axminster Carpet , Nylon Printed Carpet
Total carpet area
12,000 m²
Production lead time
48 days
Main Application Areas
Guest rooms, guest room corridors, ballroom, meeting rooms, lobby, lobby bar, VIP lounge, etc.
I. Client Background
Crowne Plaza Kunshan is part of InterContinental Hotels Group (IHG). This project involves multiple areas, including guest rooms, guest room corridors, the ballroom, meeting rooms, the lobby, the lobby bar, and the VIP lounge.
Because different areas differ in foot traffic, frequency of use, furniture load, pattern expression, and maintenance requirements, the hotel did not use a single uniform product for this carpet purchase. Instead, it required carpet type, material, and specifications to be matched separately to each space.
Based on the actual usage needs of each hotel area, Dongsheng Carpet supplied approximately 12,000 m² of custom carpet for the project, including 80% Wool 20% Nylon Axminster Carpet and Nylon Printed Carpet (Nylon Printed Carpet), and coordinated project delivery from design confirmation, sampling, and mass production through on-site installation.
II. What Carpets Did Dongsheng Specify for the Project?
This project did not use a single product to cover all areas. Instead, carpets were specified according to the actual needs of different hotel spaces.
Guest Rooms and Banquet Areas
The 80/20 wool-nylon construction combines wool's surface texture, resilience, and pattern performance, while the addition of nylon enhances durability in commercial environments.
Axminster products are mainly used in areas with high requirements for spatial effect, pattern performance, and long-term use.
Guest Room Corridors
Used Nylon Printed Carpet
Hotel Corridor Carpet: Corridors constantly bear guest traffic and the rolling of luggage and service carts, so this part of the project focused on wear resistance, resilience, anti-crushing performance, and later cleaning and maintenance.a
The printing process also meets the requirements of long corridors for consistency in pattern, color, and spatial design.
III. How Did Dongsheng Turn the Hotel Design into Production-Ready Carpet?
The hotel's overall spaces incorporate design elements such as Jiangnan culture and Kunqu Opera, and the carpets needed to remain consistent with the interior design.
Dongsheng's design team carried out production-level development of the patterns based on the project design scheme, including:
Pattern scale, color relationships, line weights, Repeat, actual installation dimensions, and visual transitions between different areas.
For Axminster Carpet, the design needed to be further converted into yarn colors and pattern data suitable for weaving; for Nylon Printed Carpet, color samples and trial printing were required to confirm the actual color and pattern effect.
In other words, Dongsheng's role in this project was not just "producing to drawing," but truly converting the design artwork into a carpet solution that could be mass-produced and installed on site.
IV. Complex Corridors: How Did Dongsheng Solve Pattern Alignment?
Some corridors in the project had curved walls, corners, and irregular areas.
If production and cutting were done directly according to standard straight areas, on-site installation could easily lead to pattern misalignment, broken patterns at corners, or increased material waste.
For these locations, the Dongsheng team measured on-site dimensions and used computer layout, confirming before production:
Pattern direction, Repeat position, curved-area dimensions, corner transitions, and cutting positions.
During installation, cutting and joining were then carried out according to actual site conditions, so that the pattern remained as naturally continuous as possible in complex areas.
V. 12,000 m² Bulk Production: How Did Dongsheng Control Batch Consistency?
The real challenge in a 12,000 m² hotel carpet project is not producing one beautiful sample, but whether the design and specifications can be consistently replicated across the entire project after the sample is approved.
In this project, Dongsheng used the final approved sample and technical specifications as the baseline for bulk production and focused on controlling the following:
Color Batch Control
Axminster yarns and printed products were produced according to approved color standards, controlling color variation between batches.
Pattern and Repeat Control
During Axminster weaving and printing production, pattern scale, Repeat, and pattern position were continuously checked to reduce visual deviation after large-area installation.
Product Specification Control
Check pile height, pile weight, face structure, backing, and other key technical parameters according to approved specifications.
In-Process Inspection and Finished Product Inspection
During production, check the carpet surface, pattern, color, and process stability; at the finished product stage, re-check appearance, specifications, and packaging information.
Area Numbering and Zoned Packaging
Roll numbers and area identification were assigned according to floor, area, and installation needs, reducing sorting and communication costs after the 12,000 m² of carpet arrived on site.
VI. 48-Day Production: How Did Dongsheng Coordinate with the Hotel's Construction Schedule?
For this project, the production cycle for approximately 12,000 m² of carpet was 48 days, and the on-site installation period was 20 days.
To match the project schedule, Dongsheng worked backward from the sample approval date to set the production plan and organized production according to the actual installation sequence of different areas:
Raw material preparation → bulk production → QC → zoned packaging → shipping → on-site installation.
Guest rooms, corridors, the ballroom, and public areas were coordinated separately according to site progress, avoiding delays caused by area identification or installation sequence issues once large quantities of carpet arrived on site.
For hotel projects, what buyers really need is not just a standalone "production cycle number," but whether the supplier can organize production and delivery according to project milestones
VII. Project Quality and Testing Coordination
In response to the actual usage requirements of the hotel project, Dongsheng confirmed and controlled the carpet's color, appearance, specifications, and related performance according to the product structure and project technical requirements.
For project requirements such as flame retardancy, Dongsheng can provide corresponding test documentation based on the actual product structure.
Dongsheng commercial carpet products can meet flame-retardant standards such as ASTM E648 Class I and EN 13501-1 Cfl-s1 according to project and target-market requirements, subject to the actual project product and corresponding test reports.
VIII. Project Delivery Results
Dongsheng ultimately completed the production and project coordination for approximately 12,000 m² of custom carpet for Crowne Plaza Kunshan.
The project covered:
80% Wool / 20% Nylon Axminster Carpet
Nylon Printed Carpet
Guest rooms, corridors, ballroom, meeting rooms, and public areas
48-day production cycle
20-day on-site installation period
From design development and sample approval to 12,000 m² bulk production, complex corridor layout, area numbering, and on-site installation, Dongsheng executed the project around one set of approved standards.
IX. If You Are Purchasing Carpet for a Hotel Project
If your hotel, resort, or commercial project is selecting carpets or evaluating suppliers, you can provide Dongsheng with:
Artwork / CAD / floor plans, application areas, estimated purchase area, target materials and specifications, flame-retardant or testing requirements, and planned delivery time.
Dongsheng can evaluate suitable options according to project requirements:
- Axminster Carpet
- Printed Carpet
- Machine-Tufted Carpet
- Hand-Tufted Carpet
- Carpet Tiles
- Wilton Carpet
And, based on confirmed specifications, proceed to design, sampling, quotation, and mass production.
Dongsheng Carpet was founded in 1998 and specializes in bulk custom carpet supply. Its clients include hotel groups, property owners and operations managers, FF&E procurement companies, general contractors, interior design firms, construction contractors, importers, and regional distributors. It can undertake custom carpet projects for hotels, office and commercial spaces, transportation hubs, ships and yachts, clubs, high-end private residences, exhibition venues, and other diversified projects.
