Barmag and Object Carpet, working with other partners in a joint development project, have tested BICO BCF yarn in the carpet manufacturing process. According to the companies, the trials show that the yarn technology offers performance advantages and opens new possibilities for recycling-oriented carpet constructions.
The trials marked a developmental milestone for the carpet industry. For the first time, bicomponent technology – already established in other synthetic fiber applications – was transferred to the BCF process and tested across the entire carpet value chain. The trials point to a new class of yarn that combines improved performance characteristics with new possibilities for modern carpet constructions.
“The tests show that a BICO BCF carpet offers more volume, high elasticity, and proven heavy-duty performance compared to standard carpet yarn. The PET-based material combination also enables recyclable carpet concepts,” said Markus Reichwein, product manager, summarizing the test results.
The yarn was manufactured on a Neumag S8 BCF line equipped with a BICO spinning beam. While the principle of bicomponent yarn is established in other synthetic fiber spinning processes, its integration into the BCF process is new. Due to the differing shrinkage and elongation properties of the polymers used, the material combination causes the yarn to self-crimp, creating its voluminous structure.
The trials on the Neumag S8 BCF system demonstrate that the approach can also be implemented on an industrial scale for the carpet industry. Subsequent process steps – including cabling, heat setting, tufting, and coating – also yielded consistent results.
Results across the process chain
After heat setting, the yarn showed pronounced bulk combined with high elasticity. It also performed well in the tufting process: despite an increased titer, the yarn could be processed without issue. Due to the yarn’s elasticity, more running meters of raw fabric were produced than initially anticipated.
The yarn is also characterized by good coverage of the substrate. Process reliability was further confirmed during the coating process, with both woven and knitted fabrics processed successfully.
Quality testing for continuous use
The carpet constructions were tested for continuous use, including chair-castor and Vettermann tests in accordance with DIN EN 1307. According to the companies, all constructions are suitable for continuous use in commercial settings and achieved a wear class of up to Class 33, depending on the carpet construction. “The results demonstrate that BICO BCF technology can be reliably integrated into existing production processes while offering advantages in product performance,” said Reichwein.
The companies said the tests show that BICO BCF yarn offers high opacity, strong processing properties, and consistent performance.
