It opens up a new path for creating 100% polypropylene (PP) needlepunch carpets, which meet the same performance requirements as traditional latex-bonded carpets while reducing the end-of-life environmental impact, the company reports. Functional properties, such as pilling resistance, resistance to wear and abrasion, and also UV resistance, are guaranteed.

Using UltraBond manufacturers gain the potential to cost-efficiently produce 100% recyclable carpets. In addition to the general benefits of making recycled PP available for the plastics production chain and reduced waste generation, environmental advantages and financial savings arise from a total lack of water and less energy use. As a 100% dry process, thermal bonding uses no water and results in a total absence of waste water, according to the manufacturer. There is also a reduction in the VOC level of the carpet.

“Recyclability and achieving a greener, more cost-effective production process without compromising on current performance levels are significant unsolved topics within today’s carpet industry. By eliminating the need for latex and chemical binders through UltraBond, we offer needlepunch manufacturers a breakthrough they have been looking for that boosts environmental and economic sustainability,” commented Karena Cancilleri, Vice President Beaulieu Engineered Products, Beaulieu International Group.

“We see textile flooring as just the beginning. Together with our customers, we look forward to exploring the potential of this unique thermal bonding fibre in other applications such as laminated nonwovens or as an alternative to dry powders.”

The sustainability benefits are quantified through lifecycle analysis (LCA) of an exhibition carpet application – among the primary applications for needlepunch carpets. Evaluations show that the absence of water consumption directly translates into a large energy saving of 93% when using UltraBond compared to a latex bonding solution, and also a potential annual water saving of over 20 million litres for 100 million m2 of exhibition applications in the EU. Without the addition of any other bonding agent, CO2 emissions are reduced by 35% over the full production process.

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