Barmag and Object Carpet, together with other partners, have successfully tested BICO BCF yarn in carpet production. The trials demonstrated that the bicomponent yarn can deliver improved performance while also creating new opportunities for developing recycling-oriented carpet constructions.

The trials represent an important step for the carpet industry, as bicomponent technology, which is already used in other synthetic fibre applications, has now been successfully adapted to the bulk continuous filament (BCF) process. The technology was tested across the carpet production chain, demonstrating its potential to combine enhanced performance with new construction possibilities.

The yarn was produced on a Neumag S8 BCF system equipped with a BICO spinning beam. While bicomponent yarn production is already established in other synthetic fibre spinning processes, its successful integration into BCF carpet production represents a new development. The two polymers used in the yarn have different shrinkage and elongation properties, causing the yarn to self-crimp and develop a distinctive, voluminous structure.

After heat setting, the yarn developed a high level of bulk while retaining strong elasticity. It also performed well during tufting. Despite having a higher titer, the yarn could be processed without significant difficulties. Its elasticity also enabled the production of more metres of unfinished carpet fabric than initially expected. The yarn also provided good coverage of the carpet substrate. Its processing reliability was further demonstrated during coating, with both woven and knitted fabrics successfully processed.