Beaulieu corporate presentation - Carpet Recycling UK · CML 2001 –Jan. 2016 method Environmental impact -35% Global Warming potential Cradle-to-gate Energy consumption (-700 kJ/m²)

There’s so much more to gain when bonding goes green

UltraBondThe green way to bond

▪ Global industrial group

▪ > 2.0 billion Euro Turnover 2018

▪ Key player in Polymers, EngineeredProducts & Flooring Solutions

▪ Headquartered in Belgium

▪ > 5000 employees in 27 plants, 16 sales offices and distribution centers spread across 16 countries

▪ Family owned, financially solid

B.I.G. at a glance

2

Fibres

Technical Textiles

Yarns

>1000mio EUR

FLOORINGSOLUTIONS

400mio EUR

ENGINEERED PRODUCTS

800mio EUR

POLYMERS

>2,0billion EUR

2018 EST. CONSOLIDATED TURNOVER

Turnover B.I.G. in 2018

Capabilities & Locations

BEAULIEU FIBRES INTERNATIONAL

BELGIUM - Wielsbeke

BELGIUM - Kruishoutem

ITALY - Terni

Beaulieu Fibres International Capacity of 110.000 t/y Fibres

Beaulieu Fibres International Terni

Capacity of 40.000 t/y Fibres

▪ European manufacturing leader of polyolefin mono-component and bi-component fibers

▪ Most diversified product portfolio

▪ Business model driven by innovation

GeotextilesGeotextiles

Floor coveringsFloor coverings FiltrationFiltration

AutomotiveAutomotive HygieneHygiene

UpholsteryUpholstery

5

Applications



Why UltraBond?

◼ 100% recyclable fabricsmade possible

◼ Highest value recycledproducts by having a 100% PP solution

◼ Retain mechanicalproperties of chemicalbonded fabrics

◼ Decrease environmentalimpact by clean processes

6Proprietary and Confidential to Beaulieu Fibres International Brussels, 21/11/2018

◼ Technical needs◼ Need to replace the use of SBR-Latex, a water-based

dispersion, as

◼ a pile binder to increase wear and abrasion resistance

◼ a contributor to the strength and body of the carpet

in order to recycle the material

◼ Current market solutions do not meet the performance targets

◼ Deformation and creases need to be avoided

◼ Wear performance need to be maintained

◼ Commercial needs◼ Need a cost competitive solution for all different

applications

◼ No compromise on quality for different structures

UltraBond Proof of the Need

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Wear

Deformation & Creases

Pile Binder



Proprietary and Confidential to Beaulieu Fibres International

UltraBond – Data Comparison

Location, date

Reference system

UltraBond MC system

UltraBond BC system

Total Weight (g/m²) 300 260 235

PolyPropylene Weight(g/m²)

240 260 235

Bonding Type 20 wt% SBR Latex 20 wt% UltraBond MC 100 wt% UltraBond BC

Energy Reduction(production)

0%-80%

(-93% duringconsolidation)

-80% (-93% during

consolidation)

Maintenance CostReduction

0% -40% -40%

Consolidationequipment

Hot air Furnace (110°C) Hot air Furnace (145°C) Hot air Furnace (145°C)




5

Binding a fabric without latex

Location, dateProprietary and Confidential to Beaulieu Fibres International



5

◼ Option 1: Blending of PP fibres + UltraBond MC

◼ Option 2: Bicomponent fibre – UltraBond BC

Oven

OvenHigh

strengthcore

Low meltsheath

10-20 % UltraBond MC

100 % UltraBond BC

UltraBondMC

PP Fibre

• 100% recyclable• Bonding strength dependent

on wt% and quality of blending of the UltraBondMC

• 2 SKU• Blending required

• 100% Recyclable• High bonding strength as all

fibers are contributing

• 1 SKU• No Blending required• Perfect color matching• Best TCO in the market

◼ 100% PP based solution – Fully recyclable

◼ Activation Temperature: 140 - 150 °C

◼ Residence Time in oven: 1-1,5 minutes

◼ Textile shape remains

◼ Performance drivers◼ Blending Concentration (Latex wt%)

◼ Temperature stability of furnace

◼ Mixing Quality

◼ Fibre Length (shorter = more contacts)

◼ Denier count (lower = more contacts)

◼ Equal bonding strength and wear resistanceas Latex bonded materials

◼ VOC Reduction◼ Low VOC fibers

◼ No Latex

UltraBond Performance

10 Location, date

Bonding strength(N/%elongation)

Taber test

Latex Bond 100% 4

UltraBond 95-110% 4,5

PE Fibres 50-60% 2,5

Fiber-Fiber Bond




Taber: Rubber wheels – 2 kg - 200 cycli

Value Curve Bonding technologies

11 Location, date




Value Curve Fibre Technologies

12 Location, date




0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Total PP Electricity NF Gas NF Latex Other

kg CO2 equivalent/m²

Latex

Rewind

UltraBond LCA data

Proprietary and Confidential to Beaulieu Fibres International13

-83%

-35%

-100%

UltraBond

Latex


CML 2001 – Jan. 2016 method

◼ Environmental impact◼ -35% Global Warming potential Cradle-to-gate

◼ Energy consumption (-700 kJ/m²)

◼ Water consumption (-0,2 l/m²)

◼ CO2 emission during production (-35% CO2 eq/m²)

Energy NF Energy Consol

UltraBond - Fiber data

Location, date

UltraBond MC UltraBond BCUltraBond MC

Coarse

Dtex 3,3 - 17 3,3 – 11 33 - 300

Tenacity (cN/Tex) >25

Elongation (%) >100

Cut length (mm) 60 - 100

Crimps (#/cm) 2 - 6 0,5 - 2

Outdoor UV resistance (hrs)Iso 105:B04

Up to 6.500 Up to 10.000

FR performance Up to BFL-s1 – level possible

Activation Temperature (°C)

>140




5

TCO advantage with UltraBond

Reference UltraBond MC UltraBond BC

Water Evaporation Required technology for consolidation Furnace with stable heat control

Weight reduction Depending on Latex weight

Reduction on Energy consumption -80%

Maintenance intensity (no latex) -60%

2 step process Process conditions 1 step process 80/20 Blend 1 step process No Blending need

2 SKU (fiber + latex) SKU level 2 SKU per color 1 SKU



Proprietary and Confidential to Beaulieu Fibres International6

◼ Needlepunch carpets get sustainable

◼ Fully recyclable system by 100% Polyolefin solution

◼ Improved Total Cost of Ownership

◼ Weight saving by latex removal without loss in performance

◼ Products available in different counts and colors

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UltraBond - SummaryBEAULIEU FIBRES INTERNATIONAL



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Documents

Beaulieu corporate presentation - Carpet Recycling UK · CML 2001 –Jan. 2016 method Environmental impact -35% Global Warming potential Cradle-to-gate Energy consumption (-700 kJ/m²)