In Q4 2019, CARE reports another record quarter for the recycling rate and continues a dramatic increase in performance.

Unfortunately, two major recycled output projects, both CARE grant recipients, were unable to start up during 2019 due to factors beyond their control, including permit delays and failure of PG&E to deliver power. This impacted the Recycling Rate for Q4, which reached 22.5 percent, a Q4 high, but short of the 24% goal. Nevertheless, this rate represents a 44% increase over Q4 2018.

While the normal Q4 seasonal slowdown was observed and considering sales of new carpet set another new low, recycled output remained strong. In terms of collection, Q4 ended with 73 public drop-off sites, an increase of 20 sites over the end of 2018. CARE 2019 collections were up 28% over 2018, and the number of counties serviced rose by three to fifty.

Overall 2019 was a very good year in terms of growth in the recycling rate. See presentation below for details.

2019 was a significant year for the CARE California Carpet Stewardship Grants Program, which is designed to help boost the state’s  carpet recycling rate, provide additional infrastructure for the carpet recycling industry and support the creation of new products that will grow demand for carpet recycling for years to come.

The Program awarded 14 capital grants to 10 companies for recycling, manufacturing/finished product capacity and collection expansion; six testing grants to six companies for recycled product testing; and 12 micro grants to 12 post-consumer carpet (PCC) collection sites across California between 2018 and 2019 to help facilitate collection site efficiencies and convenient collection. These Cycle 2 and Cycle 3 awards totaled more than $6 million, with more than 90 percent of funds distributed to California-based companies. Four new processors or manufacturers using California PCC (post-consumer carpet) and five new California PCC collectors came online through the grants program.

The 2018-19 capital grants program resulted in nearly 20 million new pounds of California-sourced PCC recycled output in 2019 as well as more than 2.5 million new pounds of California-sourced PCC used in finished products in 2019. Three new products made with California PCC resulted from the capital grants program as well as one new significant market opportunity. This new market uses PCC in Eastman’s carbon renewal technology to make new materials through chemical recycling. The new products include Green Hive Group’s AbsorbsWell spill absorbent and SaN Pallets’ end caps and pallets. The Cycle 2 product testing program also explored eight new products made with California PCC. After successful trials, Swisstrax flooring tiles and 3B Protection ballistic barriers are now listed in the CARE Recycled Carpet-Derived Product Catalog.

It is essential to keep carpet clean and dry in order for it to be recycled, and CARE’s micro grants help retailers and collection sites do just that. The Cycle 2 micro grants program resulted in seven additional weather-protected structures at CARE drop-off sites across California and 10 new covered containers to be used for convenient PCC collection at California carpet retailers. The projects resulted in approximately 1.1 million new pounds collected in 2019.

CARE anticipates launching new cycles of its capital, testing and micro grants programs in March 2020. CARE also anticipates announcing a new pilot program designed specifically to increase California PCC collection in the spring.

For questions about the CARE grants program, please email Abbie Beane, CARE grants administrator, at ABeane@CarpetRecovery.org

CARE has published a report compiled by GHD, Inc. that documents testing and use of recycled PET carpet (RPC) material for civil engineering uses.  Based on previous feasibility studies, the report covers two pilot studies of applications of Recycled PET Carpet: (RPC) on filtration applications and erosion control. While there were promising initial results, there were also elements of concern identified that warrant further investigation. Through ongoing research and development, CARE continues its efforts to identify potentially viable RPC uses via development of incentive plans/grant programs to promote the establishment and sustainability of new environmentally safe RPC markets.

View RPC Report here.

View RPC Report Appendices here.

Below is a presentation on the Q3 2019 results from CARE’s California Carpet Stewardship Program. The 3rd quarter has proven to be a big one for CARE in several ways. It was a record quarter in terms of recycled output and recycling rate. The recycling rate for Q3 was 19.9%, vs. 18.4% in Q2. Carpet sales increased slightly (~ 100,000 yd2) in Q3.  In addition, Q4 is setting up nicely for new capacity to come online.