The production of BCF yarn and machine carpet from recycled polypropylene pellets

Polypropylene (PP) is a polyolefin class fiber known as its low density, low thermal conductivity, very low moisture absorption, good abrasion resistance, power contamination and wool-like properties. The most common use of Polypropylene fiber is production of BCF (Bulk Continuous Filament) yarns for use as loop yarn in machine carpets. Despite its various advantages, PP raw material is imported from abroad. PP yarn coils used as pile yarn in carpet weaving are separated from waste by leaving a certain amount of yarn on loom and BCF carpet yarn is collected together with wastes produced during production. Decomposed wastes are recycled using different sectors subject to recycling operations. Our main aim with this study is to re-evaluate PP yarn wastes obtained from commercially imported PP raw materials, to prevent economic loss and to reduce environmental impacts of production process. With the thesis, reuse of wastes in carpet sector has emerged and mechanical recycling process is applied on waste PP yarns and PP yarns containing recycling additive have been produced. Yarn production was made by changing spin shape (cross-sectional area of yarn) and number of filaments; thus, it was observed whether machine parameters were effective alongside recycling additive ratios. Yarns obtained from recycled polypropylene waste were subjected to mechanical yarn tests and compared with standard polypropylene yarn properties. At the end of study, carpet production was made in order to observe the effect of recycled PP yarns on carpet and compared with standard polypropylene carpet test values.