Recycling of Polypropylene Carpet Waste into Polyester Carpet Backcoating

EPA Contract Number: 68D10058
Title: Recycling of Polypropylene Carpet Waste into Polyester Carpet Backcoating
Investigators: Hoyle, Albert G.
Small Business: Hoyle Associates
EPA Contact: Manager, SBIR Program
Phase: I
Project Period: September 1, 1991 through March 1, 1992
Project Amount: $49,600
RFA: Small Business Innovation Research (SBIR) - Phase I (1991) RFA Text |  Recipients Lists
Research Category: Hazardous Waste/Remediation , SBIR - Waste , Small Business Innovation Research (SBIR)


In the manufacture of cross-lapped, needlepunched, polypropylene, pile-surfaced carpeting, there is unavoid- able edge trim waste due to the inherent nature of the cross- lapping and needlepunching processes. This waste in its present form is useless to anyone and is presently being disposed of by dumping into a landfill site by a disposal company. Typical small businesses have to pay to have this waste removed and lose monthly at least $12,500 in fiber and backcoating as a result of this waste disposal. The disposal material decreases available landfill capacity by about 10,000 pounds per month (the amount of waste generated). In this project, Hoyle Associates propose to find the means to convert this waste into granular or fibrillar material which could be used as a heat-reactive backcoating binder for polyester needlepunched carpeting also manufac- tured by a typical small business in this market.

The waste carpeting, when converted into granular or fibrillar form, could be utilized in backcoating as follows:

(1) applying it to the back of polyester carpeting, heating to melt the polypropylene, then smoothing and resolidify' the molten material as it leaves the heat source, and

(2) melting it and applying to the back of polyester carpeting while in a molten state.

Supplemental Keywords:

Scientific Discipline, Waste, Sustainable Industry/Business, cleaner production/pollution prevention, Municipal, Technology for Sustainable Environment, Engineering, Hazardous, hazardous waste disposal, waste recycling, hazardous waste, municipal waste, recycling, reuse, disposal

Progress and Final Reports:

  • Final