Barmag and Object Carpet Validate BICO BCF Yarn for High-Performance Carpet Applications

Field trials demonstrate yarn's processing performance, elasticity, bulk and potential for recycling-oriented carpet constructions

Barmag and Object Carpet have completed field testing of BICO BCF yarn in the carpet manufacturing process as part of a joint development project with other partners.

The trials transferred bicomponent technology into the BCF process, where it was tested across the carpet value chain. The results demonstrated the yarn's processing characteristics and its potential for carpet constructions designed with recycling considerations.

BICO Technology Creates Voluminous Yarn Structure

The yarn was produced on a Neumag S8 BCF line equipped with a BICO spinning beam.

Bicomponent yarn technology is already used in other synthetic fibre spinning processes. In the BCF application, the differing shrinkage and elongation properties of the polymers cause the yarn to self-crimp, creating its characteristic voluminous structure.

The industrial trials showed that the technology can be implemented in the BCF process for carpet production. Subsequent processing stages, including cabling, heat setting, tufting and coating, also produced good results.

Bulk and Elasticity Observed After Heat Setting

Following heat setting, the yarn demonstrated pronounced bulk combined with high elasticity.

The material also performed during tufting despite its increased titer and could be processed without problems. The yarn's elasticity enabled the production of more running metres of raw fabric than initially anticipated.

The yarn also showed good coverage of the substrate. During coating, both woven and knitted fabrics could be processed, further confirming process reliability across the production chain.

Quality Tests Demonstrate Suitability for Commercial Use

The resulting carpet constructions underwent extensive testing, including chair-castor and Vettermann tests in accordance with DIN EN 1307.

The tests found that all constructions were suitable for continuous use in commercial settings, achieving a wear class of up to Class 33, depending on the carpet construction.

Markus Reichwein, Product Manager, said:

“The tests show that a BICO BCF carpet offers more volume, high elasticity, and proven heavy-duty performance compared to standard carpet yarn. The PET-based material combination also enables recyclable carpet concepts,”

Reichwein added:

“The results impressively demonstrate that BICO BCF technology can not only be reliably integrated into existing production processes but also offers significant advantages in product performance,”

Potential Applications Across Residential and Commercial Carpets

The trials highlighted high opacity, processing properties and performance as key characteristics of BICO BCF yarn.

The industrial validation indicates that the technology can be used to develop differentiated carpet products for both residential and commercial sectors, while offering additional options for carpet constructions incorporating recycling-oriented approaches.

The successful trials also demonstrated the feasibility of integrating BICO BCF yarn into existing carpet manufacturing processes.