Object Carpet and Partners Test rPET BCF Yarn Production on Neumag BCF Line

Joint project evaluates carpet-to-carpet recycling using 100% recycled polyester carpet material without virgin polymer

Barmag has completed a joint research project with Object Carpet GmbH, the Institute for Textile Technology (ITA), and Next Generation Recyclingmaschinen GmbH (NGR) to assess the production of BCF yarn from recycled polyester carpet material. The project examined whether 100% recycled carpet material can be reused in carpet yarn manufacturing to support a closed-loop recycling system.

Joint project explores closed-loop carpet recycling

Barmag, together with Object Carpet GmbH, Denkendorf, the Institute for Textile Technology (ITA), Augsburg, and Next Generation Recyclingmaschinen GmbH (NGR), Feldkirchen, Austria, investigated the processing of recycled polyester for Bulked Continuous Filament (BCF) yarn production.

The objective of the project was to evaluate the suitability of 100% recycled carpet material for reuse in carpet yarn manufacturing, enabling a closed-loop production process within the carpet industry. According to the project, commercial rPET BCF production has so far relied exclusively on rPET bottle pellets.

Trials conducted on Neumag BCF line

The production trials were carried out on the Neumag BCF line at Barmag's R&D center in Neumünster.

The company stated that the system's flexible process control and adjustable parameters enable the processing of challenging materials, making it suitable for research, development and testing applications.

During the project, recycled PET sourced from 100% polyester NEOO carpet material supplied by Object Carpet was processed without adding virgin polymer. The production-scale trials demonstrated that the recycled material could be fed back into the spinning process.

Commenting on the trials, Dr. Kirsten Prehn, who is responsible for the Neumag BCF processes, said:

“During the trials, we observed that, as expected, material quality — particularly viscosity and purity — significantly influences process stability and yarn quality. Using the Neumag BCF system, we were able to adapt the process control specifically and flexibly to the particular requirements of the recycled polymer and thus produce BCF yarn.”

Carpet sample produced from recycled yarn

Part of the recycled BCF yarn was subsequently used to manufacture a carpet sample.

According to the project findings, the trials demonstrated that a mono-material carpet product can support a practical recycling loop in the BCF sector without the addition of virgin polymer.

The project also identified areas for further optimisation in material design and process control to support stable industrial implementation. Barmag stated that the flexible process control of the Neumag BCF system is an important factor in evaluating and advancing recycling processes for carpet manufacturing.