Barmag, in a joint project with Object Carpet GmbH from Denkendorf, the Institute for Textile Technology, ITA, from Augsburg, and Next Generation Recyclingmaschinen GmbH, NGR, from Feldkirchen, Austria, analysed the possibilities of processing recycled polyester for the production of BCF yarn for carpets. The aim of the work was to assess the fundamental suitability of material originating from 100% recycled carpets for reuse in carpet yarn production in order to create a closed material loop in carpet manufacturing. As stated, commercial rPET BCF processes to date have been based exclusively on rPET derived from bottle-grade pellets. The trials were carried out on the Neumag BCF line at the R&D centre in Neumünster. Thanks to flexible process control and targeted parameter setting, the installation enables the processing of materials that are also more difficult to handle, which makes it suitable for development work and technology trials.
As part of the investigations, recycled PET originating from the 100% polyester NEOO carpet material supplied by Object Carpet was processed without the addition of virgin polymer. The trials, carried out on a scale close to practical production conditions, demonstrated that it is possible to feed this material back into the spinning process. Dr Kirsten Prehn, responsible for Neumag BCF processes, summarised: "During the trials, we observed that, as expected, material quality, particularly viscosity and purity, significantly affects process stability and yarn quality. Using the Neumag BCF system, we were able to adapt process control precisely and flexibly to the specific requirements of the recycled polymer and thus produce BCF yarn."
The trials confirmed the potential for a closed loop
Part of the recycled yarn obtained was then used to produce a carpet sample. The results show that a closed loop in the BCF segment is not merely a theoretical concept. A mono-material carpet product can, in practice, enable a genuine recycling loop without the addition of virgin raw material. According to the information presented, Neumag BCF systems can play an important role in the evaluation and further development of recycling processes.
At the same time, the trials identified areas where further action is possible to support stable industrial implementation and additional optimisation in material design and process control. As emphasised, the flexibility of process control in Neumag BCF systems is a key prerequisite for such work.
From carpet to carpet: flexible process control in Neumag BCF systems enables targeted processing of recycled polymers and provides the basis for closed material loops in carpet production
