Neumag BCF Technology Demonstrates Carpet-to-Carpet Recycling Without Virgin Polymer
A joint project between Barmag, Object Carpet, the Institute for Textile Technology (ITA) Augsburg, and Next Generation Recyclingmaschinen (NGR) has demonstrated that a true closed-loop recycling system for polyester carpets is technically achievable. The trials, conducted at Barmag’s R&D centre in Neumünster, Germany, showed that 100% recycled PET from post-consumer polyester carpet can be spun into new BCF (bulk continuous filament) yarn on Neumag equipment without any addition of virgin polymer.
Until now, commercial rPET BCF processes have relied exclusively on recycled polyester derived from bottle-grade pellets. The Neumag trials represent the first successful demonstration of carpet-to-carpet recycling at production scale, using mono-material NEOO carpet supplied by Object Carpet as the feedstock. The recycled material was processed through NGR’s recycling technology and then spun on the Neumag BCF line, with the resulting yarn used to produce a new carpet sample.
Dr. Kirsten Prehn, responsible for Neumag BCF processes at Barmag, explained the significance: “During the trials, we observed that, as expected, material quality — particularly viscosity and purity — significantly influences process stability and yarn quality. Using the Neumag BCF system, we were able to adapt the process control specifically and flexibly to the particular requirements of the recycled polymer and thus produce BCF yarn.”
The flexible process control of the Neumag BCF system proved decisive. Unlike conventional spinning lines, the Neumag system allows targeted parameterisation of temperature profiles, pressure control, and draw ratios to accommodate the variable viscosity and contamination levels inherent in post-consumer carpet waste. This adaptability enables the processing of challenging recycled feedstocks that would cause instability on standard equipment.
The project partners emphasise that the demonstration goes beyond a laboratory proof-of-concept. The trials were conducted at practical production scale, and part of the recycled yarn was converted into a finished carpet sample meeting commercial specifications. This validates that a mono-material carpet design, combined with appropriate spinning technology, can deliver a genuine recycling loop in practice.
However, the project also identified areas requiring further development for stable industrial implementation. Variations in recycled polymer quality, particularly intrinsic viscosity and residual contaminants, demand robust process control strategies. The partners are now working on optimisation of material design — including mono-material carpet constructions that facilitate recycling — and advanced process monitoring to ensure consistent yarn quality at industrial throughput.
Barmag, a subsidiary of the Rieter Group, views the Neumag BCF platform as a key enabler for the textile industry’s transition to circularity. The company is engaging with carpet manufacturers and recyclers to define the specifications for recyclable carpet designs and to develop standardised recycling protocols. Object Carpet, a leading European carpet producer, has committed to expanding its NEOO mono-material product line based on the trial results.
The achievement aligns with the EU’s Circular Economy Action Plan and the forthcoming Ecodesign for Sustainable Products Regulation, which will set mandatory requirements for product recyclability and recycled content. Carpet-to-carpet recycling addresses a significant waste stream: the European carpet industry generates an estimated 1.6 million tonnes of post-consumer carpet waste annually, the majority of which is currently landfilled or incinerated.
Source: BARMAG press release via Textile World, June 2026; bioplastics MAGAZINE, July 2026.