Barmag, in collaboration with Object Carpet GmbH, the Institute for Textile Technology (ITA), and Next Generation Recyclingmaschinen GmbH (NGR), has successfully evaluated the use of recycled polyester in bulked continuous filament (BCF) yarn production. The project aimed to assess whether 100% recycled carpet material could be reused to manufacture new carpet yarn, supporting a closed-loop recycling system for the carpet industry.

During the study, recycled PET obtained from Object Carpet’s 100% polyester NEOO carpet material was processed without adding any virgin polyester. The production-scale trials confirmed that the recycled material could be successfully fed back into the spinning process.

According to Dr. Kirsten Prehn, who is responsible for Neumag BCF processes, the tests showed that the quality of the recycled material, particularly its viscosity and purity, plays an important role in process stability and yarn quality. She added that the Neumag BCF system allowed the process settings to be adjusted according to the specific properties of the recycled polymer, enabling the successful production of BCF yarn.

Part of the recycled yarn produced during the trials was later used to manufacture a carpet sample. The results demonstrate that a closed-loop recycling system for mono-material polyester carpets is achievable in practice, allowing new carpet yarn and carpets to be produced entirely from recycled carpet material without the need for virgin polymer.