UltraBond The green way to bond Theres so much more to gain when - - PowerPoint PPT Presentation
UltraBond The green way to bond Theres so much more to gain when bonding goes green B.I.G. at a glance Global industrial group > 2.0 billion Euro Turnover 2018 Key player in Polymers, Engineered Products & Flooring Solutions
There’s so much more to gain when bonding goes green
The green way to bond
▪ Global industrial group ▪ > 2.0 billion Euro Turnover 2018 ▪ Key player in Polymers, Engineered Products & Flooring Solutions ▪ Headquartered in Belgium ▪ > 5000 employees in 27 plants, 16 sales offices and distribution centers spread across 16 countries ▪ Family owned, financially solid
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Fibres Technical Textiles Yarns
FLOORING SOLUTIONS
ENGINEERED PRODUCTS
POLYMERS
2018 EST. CONSOLIDATED TURNOVER
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
Geotextiles Geotextiles Floor coverings Floor coverings Filtration Filtration Automotive Automotive Hygiene Hygiene Upholstery Upholstery
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BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
◼ 100% recyclable fabrics
made possible
◼ Highest value recycled
products by having a 100% PP solution
◼ Retain mechanical
properties of chemical bonded fabrics
◼ Decrease environmental
impact by clean processes
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Proprietary 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
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Wear Deformation & Creases Pile Binder
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
Proprietary and Confidential to Beaulieu Fibres International
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%
(-93% during consolidation)
(-93% during consolidation) Maintenance Cost Reduction 0%
Consolidation equipment Hot air Furnace (110°C) Hot air Furnace (145°C) Hot air Furnace (145°C)
Proprietary and Confidential to Beaulieu Fibres International
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
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Location, date Proprietary and Confidential to Beaulieu Fibres International
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
5 ◼ Option 1: Blending of PP fibres + UltraBond MC ◼ Option 2: Bicomponent fibre – UltraBond BC
Oven Oven
High strength core Low melt sheath
10-20 % UltraBond MC 100 % UltraBond BC
UltraBond MC PP Fibre
blending of the UltraBond MC
fibers are contributing
◼ 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 resistance
as Latex bonded materials
◼ VOC Reduction
◼
Low VOC fibers
◼
No Latex
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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
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
Proprietary and Confidential to Beaulieu Fibres International
Taber: Rubber wheels – 2 kg - 200 cycli
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Location, date
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
Proprietary and Confidential to Beaulieu Fibres International
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Location, date
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
Proprietary and Confidential to Beaulieu Fibres International
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
Proprietary and Confidential to Beaulieu Fibres International
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UltraBond Latex
BEAULIEU FIBRES INTERNATIONAL
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
Location, date
UltraBond MC UltraBond BC UltraBond 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
Proprietary and Confidential to Beaulieu Fibres International
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
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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
Maintenance intensity (no latex)
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
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
Proprietary and Confidential to Beaulieu Fibres International 6
◼ 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 16
BEAULIEU FIBRES INTERNATIONAL
BEAULIEU FIBRES INTERNATIONAL
Proprietary and Confidential to Beaulieu Fibres International
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