New way to deal with carpet tile waste developed in New Zealand

New Zealand company SaveBoard, in partnership with American industrial manufacturer Milliken, has developed a new way to recycle carpet tiles that uses recycled plastic packaging.

When carpet tiles need replacing, there are different ways to dispose of the old, worn tiles. They can be simply thrown away in landfills, but this is not very environmentally friendly.

Several schemes collect waste carpet tiles, then separate the fibres from the backing. The separated yarn can be used in the production of new carpets, and the backing material used in various applications, including roofing and roads.

In SaveBoard’s process, carpet tiles and used soft plastic packaging are shredded and then compressed together to form new carpet tiles. This does not require additional chemicals.

The technology took more than two years to develop. Saveboard's founder, Paul Chateris, said that it was a major challenge to find the best formulation for the waste mix.

“For over two years, the team trialled and refined different formulas, balancing strength, flexibility, and finish. A key breakthrough came in developing a scratch-and wear-resistant top layer that could be applied mechanically – without the need for glue or chemical bonding agents.”

The recycled carpet tiles have a distinctive multicoloured look. They are being sold in New Zealand at a premium cost. If demand is high, they may be made available internationally.

Carpet tiles sold by Chester flooring retailers are available that contain recycled materials, which are suitable for domestic and commercial use.