Carpet recycling tufted carpets

Advantages of using PP consist of its ability to meet the color fastness and UV stability requirements, its natural resistance to staining, and its color consistency after solution dyeing. Also, there is the advantage of 100% recycling PP compounds. PP fibers with 17-33 dtex are used both for tufted and needlepunched products, as well as spun PP and BCF-PP in tufted carpets. 

Applications of Dopolymerized Nylon 6 Chemical recycling of nylon 6 carpet face fibers has been developed into a closed-loop recycling process for waste nylon carpet [25, 30-32]. The recovered nylon 6 face fibers are sent to a depolymerization reactor and teeated with superheated steam in the presence of a catalyst to produce a distillate containing caprolactam. The crude caprolactam is distilled and repolymerized to form nylon 6. The caprolactam obtained is comparable to virgin caprolactam in purity. The repolymerized nylon 6 is converted into yam and tufted into carpet. The carpets obtained from this process are very similar in physical properties to those obtained from virgin caprolactam. 

A recyclable carpet based on polypropylene fibers also has been developed [98, 99]. Unlike polyester fiber, polypropylene fiber is pigmented during the fiberforming stage. The tufted polypropylene fiber is manufactured by the use of a needle-bonding method to interlock the primary and secondary backings. The polypropylene face yams were tufted into the primary backing first. Then the... 

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