Beaulieu Fibres International launches UltraBond, the cost-effective solution for fully recyclable, latex-free, sustainable carpets

• Latex-free: UltraBond allows 100% recyclable thermal bonded nonwovens
• Sustainability & cost-efficiency: significant reductions in CO₂ emissions and energy and water consumption for manufacturers of needlepunched exhibition & contract flooring
• UltraBond debuts at Domotex 2019 Stand B56 Hall 11

Wielsbeke, Belgium – January 10, 2019 – Beaulieu Fibres International (BFI) unveils a unique opportunity for carpet manufacturers to create fully recyclable needlepunch carpets, and benefit from production and resource savings, without influencing performance.

Launched at Domotex 2019, new UltraBond is a patented polyolefin bonding staple fibre that eliminates the need for latex or other chemical binders to bind nonwovens. It opens up a new path for creating 100% polypropylene (PP) needlepunch carpets which meet the same performance requirements as traditional latex-bonded carpets while reducing the end-of-life environmental impact. Functional properties such as pilling resistance, resistance to wear and abrasion, and also UV resistance are guaranteed.

Using UltraBond manufacturers finally gain the potential to cost-efficiently produce 100% recyclable carpets. In addition to the general benefits of making recycled PP available for the plastics production chain and reduced waste generation, environmental advantages and financial savings arise from a total lack of water and less energy use. As a 100% dry process, thermal bonding uses no water and results in a total absence of waste water. There is also a reduction in the VOC level of the carpet. This all leads to a significant reduction in a needlepunch carpet’s ecological footprint.

The sustainability benefits are quantified through lifecycle analysis (LCA) of an exhibition carpet application – among the primary applications for needlepunch carpets. Evaluations show that the absence of water consumption directly translates into a large energy saving of 93% when using UltraBond compared to a latex bonding solution, and also a potential annual water saving of over 20 million litres for 100 million m² of exhibition applications in the EU. Without the addition of any other bonding agent, CO₂ emissions are reduced by 35% over the full production process.

Karena Cancilleri, Vice President Beaulieu Engineered Products, Beaulieu International Group, commented, “Recyclability and achieving a greener, more cost-effective production process without compromising on current performance levels are significant unsolved topics within today’s carpet industry. By eliminating the need for latex and chemical binders through UltraBond, we offer needlepunch manufacturers a breakthrough they have been looking for that boosts environmental and economic sustainability. We see textile flooring as just the beginning. Together with our customers, we look forward to exploring the potential of this unique thermal bonding fibre in other applications such as laminated nonwovens or as an alternative to dry powders.”

Discover more about UltraBond from the Beaulieu Fibres International team at Stand B56 Hall 11, Domotex 2019 in Hannover, Germany from January 11-14, 2019.

Beaulieu Fibres International

As largest European producer of PP fibres, our company is part of the Engineered Products Business Unit of Beaulieu International Group, with headquarters in Belgium.

With three production sites in Europe – two in Belgium and one in Italy, we supply PP and PE/PP BICO fibres with linear densities of 0.9 den to 450 den to customers in industries such as Automotive, Hygiene, Geotextiles, Flooring, Filtration and Upholstery. Our broad portfolio includes colored fibres, high elongation fibres, high tenacity fibres, ultrasoft fibres with different cross-sections, including trilobal, suitable for a wide range of processing technologies. Beaulieu Fibres International has 235 employees and reported a turnover of 188 million euros in 2017.

Member of Beaulieu International Group

Beaulieu International Group is a well-respected industrial group with headquarters in Belgium. It holds an important market position both in the production of raw materials and intermediate goods, and the supply of perfectly finished floorcoverings.

Beaulieu International Group is composed of three business units. ‘Flooring Solutions’, is a worldwide leader in wall-to-wall floorcoverings (carpet, needle felt, artificial grass, cushion vinyl, vinyl planks, laminate, parquet, wall panels and mats). A second business Unit, 'Polymers', produces polypropylene granules for numerous applications. The third business unit ‘Engineered Products’, houses the activities related to ‘Fibres’, ‘Yarns’, ‘Technical Textiles’ and ‘Technical Sheets’.

Another division of Beaulieu International Group is specialized in the development and production of quality upholstery fabrics for the sofa industry.

Beaulieu International Group has more than 5,000 employees in 27 plants, 16 representative offices and distribution centres spread across 16 countries. In 2017, the combined turnover was close to €2 billion.

The Beaulieu International Group's entrepreneurial spirit and innovative ambitions make it the model of diversity and evolution within the sector. They allow it to create added value sustainably for customers, employees, suppliers, shareholders and for the society in which it operates.