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April 11, 2019 - Assembly

How to Manufacture Sustainable Carpets

Each year, Americans discard about 3.9 million tons of carpet. This waste has caused new governmental regulations and organizations to form that advocate for increased awareness and proper disposal practices. As a result, it’s become imperative for carpet manufacturers to use sustainable carpet materials in an effort to address environmental concerns.

Manufacturing Materials That Impede Sustainable Carpets

Typically, polyester carpets are manufactured using water-based latex adhesives that bond the carpet fibers to the scrim backing. While water-based adhesives offer sufficient anti-ski and anti-slip properties, they are thermoset and cannot be re-melted. In addition, they increase the amount of dissimilar materials used in manufacturing processes, and the latex contaminates the polyester. This renders the carpets unable to be recycled at the end of their life.

Unfortunately, this has meant disposing carpets in landfills and increasing greenhouse gas emissions.

Manufacturing Materials That Aid Sustainable Carpets

Fortunately, there is a sustainable solution. Carpet manufacturers that replace traditional water-based latex adhesives with Bostik’s polyester adhesives are able to produce carpets that can be recycled. This is because the polyester adhesives are thermoplastic; they can be re-melted and recast. Additionally, they are compatible with the polyester carpet fibers, which further improves recyclability levels.

As a result, discarded carpets are able to become other materials, such as:

  • Decking
  • Furniture parts
  • Carpet pads

In addition to increasing carpet recyclability, Bostik’s polyester adhesives offer the following sustainable manufacturing advantages:

  • Reduced energy consumption: Unlike water-based adhesives, polyester adhesives do not require large ovens to dry. This reduces the amount of heat and energy used during manufacturing processes.
  • Reduced carbon footprint: Polyester adhesives also don’t require as much equipment or floor space for manufacturing as water-based adhesives.

Additionally, polyester adhesives improve manufacturing efficiencies. Carpets can be bonded faster; there is no need to wait for the water to evaporate, as with water-based adhesives. For more information on how Bostik’s polyester adhesives can help improve carpet manufacturing, contact a Bostik expert today.

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