Inside Theodore Alexander’s upholstery operations

THOMASVILLE, N.C. – Recently Theodore Alexander invited Home News Now to visit its upholstery plant just outside High Point in Thomasville. Employing about 32 production workers with more soon to follow, the 50,000-square-foot operation produces a wide mix of product – from sofas and settees to loveseats, sectionals and ottomans.

The tour showed the depth and breadth of the luxury furniture producer’s processes, from eight-way hand tied seating to the tufting of leather seats and backs. In each situation, the product is touched by the hands of many people before it goes out the door. This bench- made type of production helps create a quality level that customers – retailers and designers alike – have come to expect from the line.

Below is a glimpse of the people at work, who are dedicated to not only producing to the company’s – and customers high construction quality and tailoring standards. They also will help grow the line to become a more important part of the overall mix as the company has plans to double upholstery sales over the next two to three years. With their many decades of experience, the company is depending on them to pull off this ambitious goal in the weeks, months and years ahead.

Scroll down to see the plant, the people and the processes all at work.

Daniel Connor, director of manufacturing, shows large templates used for fabric patterns.
A worker is seen tracing the patterns from the templates on rolls of fabric.
A worker marks the areas on a cushion where buttons will be placed.
Thousands of yards of fabric and leathers are in stock at any given time in order to process orders as quickly as possible.
Frames are just about ready to be upholstered.
Sewers cut fabric to be used on a variety of upholstery pieces produced at the plant.
Tim Luther affixes foam to the arms of a side chair.
Darrel Walker affixes fabric to the sides of a settee.
A closer look at the application of fabric to the frame.
Daniel Connor, director of manufacturing, shows how the fabric is lined up on a cushion.
A closer look at the level of detail and expertise that goes into the application of fabrics to a cushion.
Chuck Schidham is at work putting nailhead trim on a tufted sofa.

Thomas Russell

Home News Now Editor-in-Chief Thomas Russell has covered the furniture industry for 25 years at various daily and weekly consumer and trade publications. He can be reached at tom@homenewsnow.com and at 336-508-4616.

View all posts by Thomas Russell →

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