Barmag and Object Carpet validate BICO BCF yarn

Barmag and Object Carpet, working with other partners in a joint development project, have successfully tested BICO BCF yarn in the carpet manufacturing process. According to the companies, the results show that the yarn technology offers performance advantages and opens up new possibilities for recycling-oriented carpet constructions. The trials are described as an important development step for the carpet industry. For the first time, bicomponent technology, already known from other synthetic fibre applications, was transferred to the bulked continuous filament process and validated across the carpet value chain. The work indicates the potential of a yarn class combining improved performance characteristics with options for modern carpet constructions.

More volume, elasticity and performance

“The tests show that a BICO BCF carpet offers more volume, high elasticity, and proven heavy-duty performance compared to standard carpet yarn. The PET-based material combination also enables recyclable carpet concepts,” said Product Manager Markus Reichwein, summarising the test results.

The yarn was manufactured on a Neumag S8 BCF line equipped with a BICO spinning beam. The principle of bicomponent yarn is already well established in other synthetic fibre spinning processes. The new element in this project was its successful integration into the BCF process. Due to the differing shrinkage and elongation properties of the polymers used, the material combination causes the yarn to self-crimp, creating its characteristic voluminous structure.

The trials on a Neumag S8 BCF system showed that this approach can be implemented on an industrial scale for carpet production. The subsequent process steps, from cabling and heat setting to tufting and coating, also consistently delivered good results.

Results along the process chain

After heat setting, the yarn exhibited pronounced bulk combined with high elasticity. The material also performed well in tufting. Despite the increased titer, the yarn could be processed without problems. Thanks to the yarn’s elasticity, it was also possible to produce more running metres of raw fabric than initially anticipated.

The yarn was also characterised by good coverage of the substrate. Process reliability was further confirmed during coating, where both woven and knitted fabrics could be processed.

Filament cross-section of BICO BCF 70% PET / 30% PBT

Quality testing for commercial use

The developed carpet constructions were tested extensively, including chair-castor and Vettermann tests in accordance with DIN EN 1307. All constructions were found suitable for continuous use in commercial settings and achieved a wear class of up to Class 33, depending on the carpet construction.

“The results impressively demonstrate that BICO BCF technology can not only be reliably integrated into existing production processes but also offers significant advantages in product performance,” said Markus Reichwein.

The overall conclusion of the tests is that BICO BCF yarn provides high opacity, good processing properties and strong performance. The technology offers carpet manufacturers new options for developing high-performance and differentiated products for both residential and commercial applications. The industrial validation indicates that BICO BCF is technically feasible and may contribute to future carpet constructions with a focus on sustainability.