Biodegradable Carpet

European Bioplastics

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2006

DS Textile Platform

A joint R&D project from

DS Fibres

&

Sommer Needlepunch

The Company

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2006

DS Textile Platform

The Company

DS Group, a niche player

♦ DS Fibres is market leader in dope

dyed polyester fibre

♦ Sommer Needlepunch is market

leader in event carpets

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♦ DAM De Saedeleir or DS Technical

textiles is specialised in

technical nonwovens.

♦ Work force of 350 people

♦ Turnover of 80+ million euros

♦ Located in Dendermonde (B) and Baisieux (F)

The Idea

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The Idea

Where did the idea come from?

� August 2004 : Alken-Maes introduced a biodegradable cup for the folkfestival in Dranouter. (Belgium) The article catched our attention.

Sept 1 2004 : Cargill DOW (at the time)

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� Sept 1 2004 : Cargill DOW (at the time) responded to our request and saw it as an excellent ‘strategic fit’.

� Oct 26 2004 : Aquisition by DS of Sommer Needlepunch.Sommer having the Biocolor technology in the house.(100% recyclable carpet)

Biodegradable Carpet ???

� ‘event’ carpet is a carpet with a short life

cycle.

� After the event, the carpet is mostly

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� After the event, the carpet is mostly

disposed off.

� Recyclability is one solution,

Compostability is another, perhaps even

better.

Mile stones

� 14th september ‘04: Meeting with NatureworksPLA in Brussels, Belgium.

� 1st february ’05 : First resin-trials for the production of PLA-staple fibres in Dendermonde.

� 21st april ’05 : Project approval by IwT, Flanders, Belgium.

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� 21st april ’05 : Project approval by IwT, Flanders, Belgium.

� 1st october ’05 : Collaboration on coloration started with Ciba Specialty Chemicals, Basel, Switserland.

� 16th february ’06 : Presentation of the BIOCOLOR PLUS carpet at Centexbel Symposium Gent.World Primeur!

� 23rd february ’06 : presentation to NatureworksPLA of the first fully biodegradable carpet in Paris, France.

� 21st september ’06 : Lecture at the Internationale Chemiefasertagung in Dornbirn, Austria.

The Product

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2006

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The Product

BIOCOLOR PLUS Carpet

Main structures

� Flat

(printable)

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2006

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(printable)

� Velours

� Ribs

BIOCOLOR is a patented product (recyclable)

BIOCOLOR PLUS patent is pending (compostable)

The Important Carpet Characteristics

� Total thicknes

� Weight

� Lisson-abrasion test

High performance in a

limited time-frame.

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� Lisson-abrasion test

� Fire-retardency

� Dimentional Stability

� Tenacity and Elongation

louis.cauffman@louiscauffman.comlouis.cauffman@louiscauffman.com

European Bioplastics

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2006

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louis.cauffman@louiscauffman.comlouis.cauffman@louiscauffman.com

The Future

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The Future

Next steps

�Supply-chain (resin, colorants,…)

�Cost (Market acceptance)

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�Cost (Market acceptance)

�Waste Management

Substitution potential for

bioplastics is high

� (EU-)regulations on the Non-food uses of

crops.� feed-stock

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crops.� feed-stock

� Capacity runs short for the moment.�more

polymer capacity.

� From early adaptors situation � Main

stream market.

Choice of (fibre)colorants?

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BLACK WHITE

DS Fibres uses a

Dope-dyed technique.

No water is envolved.

With project partner

colorants are selected

carefully.

End of life scenario’s

Available carpet allows :� Incineration

� Recycling

– Remelting and re-use (as currently for PP etc)

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– Remelting and re-use (as currently for PP etc)

– Depolymerisation – (assuming proper disposal of waste products)

� Approved landfill(note that EU legislation is moving away from landfill)

� Accidental disposal - to land or water

- Bacterial and weather-induced polymer breakdown

(UV+Oxygen+moisture)

� Re-Use

Waste Management Solutions

Carpet

Grinding 2nd lifeGrinding Grinding

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Injection molding

RegranulationNeedlepunching

Airlaying

Chemical

Recycling

PP/SBR

PP/PE

PLA/PLA

PP/SBR

PP/PE

PLA/PLA

PLA/PLA

PP/PE

! Value !

M u tu a l lo n g te rm g o a l

w aste

1 9 5 0

O il

Mutual long term Goal

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w aste

O il

N o o il

N o w aste

N o w a ste2 0 0 7

2 0 0 0

B io co lo r P L A

O il

B io co lo r

D S O F F E R S S O L U T IO N S

Which way to choose?

PP/SBR PP/PE PLA/PLA

Composting NP NP R

Incineration R R NR

Landfill NR NR NR

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Recycling RD R RRecycling is not possible in iternaty

NP Not Possible

NR Not Recommanded

R Recommanded

RD Recommanded but difficult

Which way to choose?

Pollution Cost Value + -

Composting ++ - + + 4 1 3

Incineration -- + (?) + 2 2 0

Landfill -- + + (?) -- 2 4 -2

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Landfill -- + + (?) -- 2 4 -2

==> Can, or will it be influenced by

policies & measures?

Regulatory situation on compostability

� EN 13432

– Non-compostable components must

• Each be under 1% in final article

• In sum be under 5% in final article

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� Other regulations

– Seem less strict

– Partner is drawing up comparison

The BIOCOLOR PLUS carpet reaches this

regulation comfortably.Certification still needs to be organised.

100% Compostable?

BIOCOLOR PLUS REACHES 99% BIODEGRADABILITY

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PLA is

Compostable

Some colorants and

certain additifs

need re-styling

3 different approaches,

3 different speeds

Referential Carpet

PP pile material

SBR-Latex Backing material

Recyclable Carpet

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Recyclable Carpet

PP pile material

PE Backing material

Compostable Carpet

PLA pile material

PLA Backing material

2006 2008 2010

Development progress

� Organisation of trial-placements &

Marketing

� Optimalisation of technical performances

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2006

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� Optimalisation of technical performances

� Certification by DIN-Certco or AIB-

Vinçotte, …others.

� Choice of colorants & colors

� Further (financial) support

O v e rv ie w o f b io p o ly m e rs

♦ S ta r c h P o ly m e r s

♦♦♦♦ P o ly la c tic a c id (P L A )

Further developments!

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♦♦♦♦ P o ly tr im e th y le n e te r e p h ta la te

(P T T )

♦♦♦♦ P o ly b u ty le n e te r e p h ta la te

(P B T )

♦♦♦♦ P o ly b u ty le n e su c c in a te (P B S )

♦♦♦♦ P o ly h y d r o x y a lk a n o a te s

(P H A ’s)

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2006

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Soon …under your feet!