carpet technology

Project Description

worker testing carpet fiber type — A GreenWaste worker tests for fiber type

Identifying the type of fiber in a carpet is one of the first and most critical steps in carpet recycling. The fiber type may be polyester, nylon, polypropylene, polytrimethylene terephthalate (PTT) or a mix of two or more fibers. Once identified, a collector/sorter typically bales the carpet by fiber type for sale, or the recycler bales or pelletizes like processed fibers for sale to a manufacturer, which turns the fiber or pellets into a final consumer product.

Traditionally, collector/sorters and recyclers used hand-held microPhazir devices for identification, however, the manufacturer stopped producing these devices in 2022. Since then, CARE has been seeking and supporting new fiber identification technology that is equally or more effective and cost efficient.

BASF’s TrinamiX was identified as the best choice among several devices during CARE’s first attempt at seeking a microPhazir replacement. A 2022 CARE micro grant funded GreenWaste MRF to purchase two of the devices to test in the field and report data back to CARE.

The following year CARE funded the company Electronic Fix under a product testing grant to explore new methods of repairing existing microPhazir devices until new technology can be perfected.

Project Timeline:
GreenWaste MRF: January 2023-January 2024
Electronic Fix: December 2023-December 2024

Location:
GreenWaste Material Recovery Facility (GWMRF), San Jose, CA
Electronic Fix, Tampa, FL

Grant Amount:
GreenWaste MRF: $15,000
Electronic Fix: $50,000

Total Project Cost:
GreenWaste MRF: $18,000
Electronic Fix: $50,000

Electronic Fix works to repair fiber ID equipment

“Electronic Fix is proud to have been given the opportunity to work with CARE. Together we accomplished the common goal of finding feasible ways to repair these units, to make them reliable and affordable for recyclers around the world.” – Andreas Haeussler, Owner, Electronic Fix

Implementation Process

GreenWaste MRF purchased two TrinamiX devices for testing in the field.

During the course of the grant, Electronic Fix researched and ultimately successfully repaired nine units that were previously thought to be irreparable. In addition, they have reverse engineered several key replacement parts and traced the source of an error to particular circuits. The work continues and additional outcomes are expected.

Project Challenges
For GreenWaste MRF (GWMRF), challenges included Identifying mixed fiber types and ergonomics –the device does not read out the fiber types; the user needs to hold a separate device such as an iPhone to see the fiber type, which is unwieldy. In addition, read-out times were slightly slower than with the prior tool. Identifying different nylon types in commercial broadloom was also a challenge. GWMRF also initially had hardware and software challenges but worked with BASF to remedy those.

Electronic Fix found that the chips and components needed were time-consuming and difficult to acquire.  It took persistence to accomplish, repair and improve several different aspects of the machines. The most complicated issue encountered has been finding or creating compatible replacement parts and completing rigorous testing to ensure 100% accuracy.

“GreenWaste MRF is excited to pilot and test new technologies and encouraged by advancements that strengthen our ability to recover and recycle carpet.” – Fredrick Ghai, Director of Communications, GreenWaste MRF

Project Benefits and Outcomes

GreenWaste MRF confirmed that the TrinamiX costs much less than the original microPhazir device, however the device’s design makes it difficult to use in the field.

As word of the their work spreads, Electronic Fix has begun receiving requests from carpet recycling companies to repair or replace the batteries for the Polychromix phazir. The company has also reverse engineered replacement parts and identified the sources of particular errors.

This is one of a series of case studies that illustrate the impact and logistics of grant funding on the carpet recycling industry in California.