Continuing the quest of Roger De Clerck, founder of Beaulieu Belgium, Mieke and Carl Bouckaert established Beaulieu of America in 1978 as the first producer of polypropylene oriental rugs. As sales grew Carl and Mieke invested in yarn extrusion in 1981 becoming the first manufacturer in the carpet and rug industry to produce their own yarn. Sparked by continued growth, the Bouckaerts diversified into tufting carpet in 1984, establishing a factory known today as Beaulieu Commercial in Chatsworth, Georgia.
In 1987, Beaulieu of America's extrusion capacity was greatly increased with the addition of the Bridgeport, Alabama facility. This modern facility gives Beaulieu the ability to produce nylon polymers and nylon yarns. In 1990, Beaulieu continued its vertical integration with the addition of yet another new facility in Bridgeport, Alabama for the extrusion of polypropylene staple fiber, polypropylene slit film, and weaving of primary and secondary backing.