Aquafil and OBJECT CARPET
The R2R® (Regenerated to be Regenerable) project represents a groundbreaking initiative in the carpet industry. This case study showcases the collaborative innovation between Aquafil and OBJECT CARPET and explores the creation of DUO, the first R2R® carpet, that debuted at the Berlinale 2024. By debuting at this prestigious film festival, DUO emphasizes both companies’ dedication and commitment to implementing innovations in line with circular economy principles.
The Challenge
The carpet industry traditionally relies on materials that complicate recycling processes. Conventional carpets are composed of over 30 different materials, making separation and recycling a daunting task. OBJECT CARPET and Aquafil sought to revolutionize this by creating a product that not only utilizes responsible materials but is also designed for recyclability from the outset.
The Solution: DUO Carpet
DUO is made solely from polyester and polyamide (ECONYL® regenerated yarn), two materials that can be easily separated thanks to an innovative HOTMELT adhesive. This CLICK/UNCLICK technology allows for the straightforward separation of materials after use, marking a significant advancement in carpet recycling.
Moreover, compared to conventional methods, the coating of DUO generates no harmful emissions and saves 95 % of energy and no water is used during production. Practical aspects include about 50 % less weight and easy handling during installation. [source]
The R2R® Production Cycle
The R2R® label, signifying “Born Regenerated to be Regenerable,” is crucial for ensuring the carpet’s recyclability at its life end. It helps identify carpets that are mainly made of ECONYL® yarn and designed for an easy separation process. DUO enables the polyester and ECONYL® yarn to be efficiently separated to be, then, recycled and reintegrated into the production cycle. This partnership emphasizes the practical aspects of recycling.
Impact and Future Prospects
The Berlinale 2024 was a vibrant occasion to showcase DUO’s robustness, handling thousands of visitors under various conditions. This initiative is part of OBJECT CARPET’s broader aim to exclusively offer circular carpets by 2026, demonstrating the partnership between Aquafil and OBJECT CARPET through the R2R® project and highlighting the power of collaboration in driving innovation for sustainability efforts.
DUO carpet’s development and successful deployment illustrate a significant leap towards a circular economy in the carpet industry, setting a new standard for environmental stewardship and responsible design.
