These trials marked an important developmental milestone for the carpet industry. For the first time, the bicomponent technology—already known from other synthetic fiber applications—was successfully transferred to the BCF process and validated across the entire carpet value chain. The trials demonstrate the potential of a new class of yarn that combines improved performance characteristics with new possibilities for modern carpet constructions.

More volume, elasticity, and performance

“The tests show that a BICO BCF carpet offers more volume, high elasticity, and proven heavy-duty performance compared to standard carpet yarn. The PET-based material combination also enables recyclable carpet concepts,” says Product Manager Markus Reichwein, summarizing the test results.

Proven technology meets new applications

The yarn was manufactured on a Neumag S8 BCF line equipped with a BICO spinning beam. The principle of bicomponent yarn is already well-established in other synthetic fiber spinning processes—what is new, however, is its successful integration into the BCF process. Due to the differing shrinkage and elongation properties of the polymers used, the unique material combination causes the yarn to self-crimp, thereby creating its characteristic voluminous structure.

The successful trials on a Neumag S8 BCF system now demonstrate that this approach can also be implemented on an industrial scale for the carpet industry. Likewise, all subsequent process steps—from cabling and heat setting to tufting and coating—consistently yielded good results.

Impressive results throughout the entire process chain

After heat setting, the yarn exhibited pronounced bulk combined with high elasticity. The material also performed well in the tufting process: despite the increased titer, the yarn could be processed without any problems. Thanks to the yarn’s elasticity, it was also possible to produce more running meters of raw fabric than initially anticipated.

Furthermore, the yarn is characterized by its good coverage of the substrate. Process reliability was further confirmed during the coating process—both woven and knitted fabrics could be processed.

Successful quality testing for continuous use

The developed carpet constructions were extensively tested, including chair-castor and Vettermann tests in accordance with DIN EN 1307. Result: All constructions are suitable for continuous use in commercial settings and achieved a wear class of up to Class 33, depending on the carpet construction. “The results impressively demonstrate that BICO BCF technology can not only be reliably integrated into existing production processes but also offers significant advantages in product performance,” said Markus Reichwein.

A future-proof solution for a wide range of applications

The overall conclusion of the tests is clear: BICO BCF yarn impresses with its high opacity, excellent processing properties, and strong performance. The technology thus offers a promising solution with new options for developing high-performance and differentiated products for carpet manufacturers—in both the residential and commercial sectors. The successful industrial validation demonstrates that BICO BCF is not only technically feasible but also has the potential to shape future carpet constructions in a sustainable way.