Modular carpets from recycled yarn

Now, old nylon fibre too is transformed into attractive carpet tiles through green methods

Updated - August 14, 2009 05:18 pm IST

Published - August 02, 2009 12:30 pm IST

Try them out: Carpets made of nylon stiff-weave and styled in tile format

Try them out: Carpets made of nylon stiff-weave and styled in tile format

‘Reincarnation’ and ‘Rags to Riches’ may just be some names that InterfacerFLOR (carpet tile manufacturer, catering to commercial and office segment worldwide) has labelled some of its new linear pattern releases in the Convert Collection of its modular carpet flooring, but the overall perspective of the mechanised approach is itself a revolutionary concept in recycling!

“Our rags-to-riches theory explains our production patterning as old nylon face fibre is recycled into a clean stream of recycled nylon. This technology helps us be a pioneer in recycling waste yarn from discarded old carpets for producing flashy tiles. InterfaceFLOR has the largest recycled content among any carpet tiles available,” boasts Raj Menon, Country Manager, InterfaceFLOR India.

Reducing waste

InterfaceFLOR’s two technologies involved here are designed to reduce manufacturing waste with a bespoke ultrasonic cutting machine installed for the purpose.

The company has also developed a pioneering ‘Cool Green’ system that allows it to recycle manufacturing and carpet waste back into its products.

“This not only reduces the material sent to landfill but also heralds a new dimension of ‘green’ manufacturing,” says Mr. Menon. “The technologies are part of InterfaceFLOR’s Mission Zero, a pledge to be the world’s first fully sustainable company by 2020.”

“The company’s ‘Cool Green’ ideology has particular significance as it enables the firm to reuse waste with sustainable solutions that last a lifetime,” said Neel Bradham, Senior Vice-President, during the launch.

Nylon stiff-weave

What makes up carpet tiles? Carpets are rolled and fixed on the floor, whereas carpet tiles from InterfaceFLOR (a modular flooring division of Interface Inc., Atlanta, U.S.) are made of nylon stiff-weave and styled in tile format. They have a structured backing made of fly ash, PVC, carbon and reinforced fibre-glass.

Carpet tile slabs can be removed individually during a spill-over or damage and can be replaced too. Both the sides – the yarn and the back — are recyclable, can be refurbished and re-used. “Our Convert Collection has 72 per cent recycled content,” contend the InterfaceFlor authorities who issue a 15-year warranty on their product.

With offices in Chennai, Delhi and Mumbai, and manufacturing facilities in the U.S., Thailand, Australia, England, Ireland and the Netherlands, InterfaceFLOR’s carpet tiles are sold in 110 countries.

For A/C rooms

Carpet tiles are suitable for a closed air-conditioned atmosphere where dust doesn’t settle from open windows. Installation is done within hours?be it on a plain concrete floor or on existing tiled floors.

They are fitted to the ground with ‘tackifier glue,’ an adhesive with low volatile organic compound (voc) which reduces the contamination level.

Facility managers love them as vacuuming is the key to daily maintenance, while dry shampooing and hot-water extraction of dirt would be yearly requirements.

“The indoor air quality doesn’t contribute to the so-called ‘sick office syndrome’,” says Mr. Menon.

Non-patterned look

Aesthetically too, the range and colours available are plenty. They are fashioned to possess a non-structured and non-patterned look. Interesting edging and laying techniques create patterns to break the monotony.

The company’s design director, David Oakey, has a vision based on bio-mimicry?emanating from natural wilderness with random patterns that are fused in soft pastels and loud bold hues. The cost is upwards of Rs. 200 per sq. ft.

“Our founder, Ray Anderson’s policies of sustainability have us moving away from traditional industrial approach of ‘take, make, waste’ to having a natural cyclical system of material and resource flows,” concurs Mr. Menon.

The Europe-based climate care organisation ‘Cool Carpet’ helps Interface in its endeavour to calculate the emission of greenhouse gases in product manufacture, from raw material acquisition to final recycle, making it support projects in renewable sources of energy and wind-farm projects helping electricity and irrigation production.

For further information, visit and; 080-30589352

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