We think the mills are setting the carpet industry up for some challenging times.
And they know it. I went to Surfaces specifically to get more information about polyester carpet. The nice thing about face-to-face conversations is that some people, sometimes, will be honest with you. I asked a mill exec if they were seeing any problems with the "new" poly. He said they were seeing much the same problems as when they last pushed it, He figured that in two to three years they would have to address the problems, but right now the most critical thing for them was to sell something or they'd be out of business. Poly is selling really well and at a higher profit margin than nylon, so the mills have accepted the higher dissatisfaction with their product as the cost of staying alive.
I got a round table discussion going with retailers in the WFCA reception area. They all said that poly was selling well, and at a higher profit margin for them as well as the mill. They all said they warned about potential concerns and tried to get customers to buy nylon. One said he made all poly buyers write out a statement saying they had been informed and understood the limitations of polyester carpet. One retailer said he liked the idea of having the "frugal" customer learn their lesson and have to come back and buy better carpet in a few years.
The mills know what they're doing, and the retailers know what they're selling, so if poor performing poly is the only issue you probably aren't going to hurt anyone's feelings by letting the customer know they got what they paid for.
Designers, unfortunately, often know color and texture and not much else, and often have no margin for eating their mistakes. They also can often be swayed by marketing hooey just as easily as anyone else, so you have to be more careful with them.