The amount of carpet that is reaching the end of its useful life and entering the waste stream is ever-increasing. Estimated total discards for 2005 are 5 billion pounds. Land disposal, or landfilling, is by far the most common disposal method (90%). While most components that make up carpet are recyclable or reusable, only about 10% of waste carpet currently gets handled in these ways. Increasing recycling and reuse would reduce waste and recover valuable resources.
Carpet is generally a four component system, with nylon as the face fiber, polypropylene as the primary and secondary backing, styrene-butadiene-rubber (SBR) latex as the adhesive that binds the primary backing to the secondary backing, and calcium carbonate as filler in the latex.
Current carpet manufacturing practice involves tufting the face fiber into a primary backing and then binding the primary backing to the secondary backing using SBR latex. The latex binder holds the face fiber in place. Calcium carbonate is used as economic filler in the latex, and does not contribute to the properties of the carpet. On curing, the SBR latex is cross linked and hence becomes a thermoset. Nylon and polypropylene are the current common face fiber and the backing materials respectively.
To prevent unnecessary land filling of used carpets and other waste generated in the carpet industry, Carpet Recycling LLC has developed a proven process for recycling used carpets. Although numerous companies have tried to develop processes to recycle post-consumer and industrial carpet, only Carpet Recovery Inc. has developed a process that is commercially viable.
A significant characteristic of Carpet Recycling’s process is that we accept ALL post consumer and industrial carpet – regardless of manufacturer, fiber type or construction. Carpet Recycling’s patented recycling process can keep millions of pounds of used carpet out of our landfills every year.