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UltraBond The green way to bond Theres so much more to gain when - PowerPoint PPT Presentation

Sep 08, 2023 •109 likes •293 views

UltraBond The green way to bond Theres so much more to gain when bonding goes green B.I.G. at a glance Global industrial group > 2.0 billion Euro Turnover 2018 Key player in Polymers, Engineered Products & Flooring Solutions

  1. UltraBond The green way to bond There’s so much more to gain when bonding goes green

  2. B.I.G. at a glance ▪ Global industrial group ▪ > 2.0 billion Euro Turnover 2018 ▪ Key player in Polymers, Engineered Products & Flooring Solutions ▪ Headquartered in Belgium ▪ > 5000 employees in 27 plants, 16 sales offices and distribution centers spread across 16 countries ▪ Family owned, financially solid 2

  3. Turnover B.I.G. in 2018 2018 EST. CONSOLIDATED TURNOVER >2,0 billion EUR ENGINEERED FLOORING POLYMERS PRODUCTS SOLUTIONS 800 mio EUR 400 mio EUR >1000 mio EUR Technical Textiles Fibres Yarns

  4. BEAULIEU FIBRES INTERNATIONAL Capabilities & Locations ▪ European manufacturing leader of polyolefin mono-component and bi-component fibers ▪ Most diversified product portfolio ▪ Business model driven by innovation BELGIUM - Wielsbeke ITALY - Terni Beaulieu Fibres International Capacity of 110.000 t/y Fibres BELGIUM - Kruishoutem Beaulieu Fibres International Terni Capacity of 40.000 t/y Fibres

  5. BEAULIEU BEAULIEU FIBRES FIBRES INTERNATIONAL INTERNATIONAL Applications Automotive Automotive Geotextiles Geotextiles Hygiene Hygiene Floor coverings Floor coverings Filtration Filtration Upholstery Upholstery 5

  6. Why UltraBond? ◼ 100% recyclable fabrics made possible ◼ Highest value recycled products by having a 100% PP solution ◼ Retain mechanical properties of chemical bonded fabrics ◼ Decrease environmental impact by clean processes 6 Proprietary and Confidential to Beaulieu Fibres International Brussels, 21/11/2018

  7. BEAULIEU BEAULIEU FIBRES FIBRES UltraBond Proof of the Need INTERNATIONAL INTERNATIONAL Pile Binder ◼ Technical needs ◼ Need to replace the use of SBR-Latex, a water-based dispersion, as ◼ a pile binder to increase wear and abrasion resistance ◼ a contributor to the strength and body of the carpet in order to recycle the material ◼ Current market solutions do not meet the performance targets ◼ Deformation and creases need to be avoided ◼ Wear performance need to be maintained Deformation & Creases ◼ Commercial needs ◼ Need a cost competitive solution for all different applications ◼ No compromise on quality for different structures Wear 7 Proprietary and Confidential to Beaulieu Fibres International

  8. BEAULIEU BEAULIEU FIBRES FIBRES UltraBond – Data Comparison INTERNATIONAL INTERNATIONAL Reference UltraBond MC UltraBond BC system system system Total Weight (g/m²) 300 260 235 PolyPropylene Weight 240 260 235 (g/m²) Bonding Type 20 wt% SBR Latex 20 wt% UltraBond MC 100 wt% UltraBond BC -80% -80% Energy Reduction 0% (-93% during (-93% during (production) consolidation) consolidation) Maintenance Cost 0% -40% -40% Reduction Consolidation Hot air Furnace (110°C) Hot air Furnace (145°C) Hot air Furnace (145°C) equipment 5 Proprietary and Confidential to Beaulieu Fibres International Location, date

  9. BEAULIEU BEAULIEU FIBRES FIBRES Binding a fabric without latex INTERNATIONAL INTERNATIONAL ◼ Option 1: Blending of PP fibres + UltraBond MC • 100% recyclable • Bonding strength dependent on wt% and quality of PP Fibre blending of the UltraBond Oven MC UltraBond MC • 2 SKU 10-20 % UltraBond MC • Blending required ◼ Option 2: Bicomponent fibre – UltraBond BC • 100% Recyclable • High bonding strength as all fibers are contributing Low melt • 1 SKU Oven sheath • No Blending required High • Perfect color matching strength • Best TCO in the market core 100 % UltraBond BC 5 Proprietary and Confidential to Beaulieu Fibres International Location, date

  10. BEAULIEU BEAULIEU FIBRES FIBRES UltraBond Performance INTERNATIONAL INTERNATIONAL ◼ 100% PP based solution – Fully recyclable ◼ Activation Temperature: 140 - 150 °C ◼ Residence Time in oven: 1-1,5 minutes ◼ Textile shape remains ◼ Performance drivers Blending Concentration (Latex wt%) ◼ Temperature stability of furnace ◼ Fiber-Fiber Bond Mixing Quality ◼ Fibre Length (shorter = more contacts) ◼ Denier count (lower = more contacts) ◼ Bonding strength Taber ◼ Equal bonding strength and wear resistance (N/% elongation ) test as Latex bonded materials Latex Bond 100% 4 ◼ VOC Reduction UltraBond 95-110% 4,5 Low VOC fibers ◼ PE Fibres 50-60% 2,5 No Latex ◼ Taber: Rubber wheels – 2 kg - 200 cycli 10 Proprietary and Confidential to Beaulieu Fibres International Location, date

  11. BEAULIEU BEAULIEU FIBRES FIBRES Value Curve Bonding technologies INTERNATIONAL INTERNATIONAL 11 Proprietary and Confidential to Beaulieu Fibres International Location, date

  12. BEAULIEU BEAULIEU FIBRES FIBRES Value Curve Fibre Technologies INTERNATIONAL INTERNATIONAL 12 Proprietary and Confidential to Beaulieu Fibres International Location, date

  13. BEAULIEU FIBRES UltraBond LCA data INTERNATIONAL ◼ Environmental impact ◼ -35% Global Warming potential Cradle-to-gate ◼ Energy consumption (-700 kJ/m²) ◼ Water consumption (-0,2 l/m²) ◼ CO 2 emission during production (-35% CO 2 eq/m²) kg CO2 equivalent/m² 0.8 0.7 -35% 0.6 Latex Latex 0.5 0.4 UltraBond Rewind 0.3 -100% 0.2 -83% 0.1 0 Total PP Electricity NF Energy NF Energy Consol Gas NF Latex Other CML 2001 – Jan. 2016 method 13 Proprietary and Confidential to Beaulieu Fibres International

  14. BEAULIEU BEAULIEU FIBRES FIBRES UltraBond - Fiber data INTERNATIONAL INTERNATIONAL UltraBond MC UltraBond MC UltraBond BC Coarse Dtex 3,3 - 17 3,3 – 11 33 - 300 Tenacity (cN/Tex) >25 Elongation (%) >100 Cut length (mm) 60 - 100 Crimps (#/cm) 2 - 6 0,5 - 2 Outdoor UV resistance (hrs) Up to 6.500 Up to 10.000 Iso 105:B04 FR performance Up to B FL -s1 – level possible Activation >140 Temperature (°C) 5 Proprietary and Confidential to Beaulieu Fibres International Location, date

  15. BEAULIEU BEAULIEU FIBRES FIBRES TCO advantage with UltraBond INTERNATIONAL INTERNATIONAL Reference UltraBond MC UltraBond BC Required technology for consolidation Water Evaporation Furnace with stable heat control Weight reduction Depending on Latex weight Reduction on Energy consumption -80% Maintenance intensity (no latex) -60% 2 step process Process conditions 1 step process 80/20 Blend 1 step process No Blending need SKU level 2 SKU (fiber + latex) 2 SKU per color 1 SKU 6 Proprietary and Confidential to Beaulieu Fibres International

  16. BEAULIEU BEAULIEU FIBRES FIBRES UltraBond - Summary INTERNATIONAL INTERNATIONAL ◼ Needlepunch carpets get sustainable ◼ Fully recyclable system by 100% Polyolefin solution ◼ Improved Total Cost of Ownership ◼ Weight saving by latex removal without loss in performance ◼ Products available in different counts and colors 16 Proprietary and Confidential to Beaulieu Fibres International

  17. Excellence covered by people Delight our Customer • Strive for Excellence • Focus on People • Create added Value • Act with Integrity

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