Transcript of Carpet Industry Reality 4.5 Billion pounds of carpet are sent to landfills annually – That’s 2%...
- Slide 1
- Carpet Industry Reality 4.5 Billion pounds of carpet are sent
to landfills annually Thats 2% of annual US landfill volume. 20
years ago there were 18,000 public landfills that would accept
carpet today there are approximately 1,800 State landfill bans,
advanced disposal fees, and likely RCRA 6002 CPG designation by
Federal EPA in 2006.
- Slide 2
- Annual US Landfill Volume Annual US Landfill Volume (Actual and
Projected) sq yds pounds X 1000 = billions Solid waste is the
single largest environmental impact made by the carpet industry.
Transitional strategies like monofills and WTE will precede
C2C.
- Slide 3
- Carpet Industry Environmental Footprint 47% increase in yd 2
produced 1990 to 2220
- Slide 4
- Paradigms of the Past Cradle-to-grave production has been the
carpet norm since introduction of tufting in the 1950s. Shaw grew
to industry dominance in 1980s through efficiency and scale. We
began reducing waste and recycling 60 different waste streams
before it was considered environmentally correct. The industry was
challenged in 1994 to move toward sustainability, but it has
largely remained a marketing issue. Sustainable technologies are
more talk than action.
- Slide 5
- Establishing Cradle-to-Cradle Innovation at Shaw Industry must
see the business case for sustainability. Doing things right is not
enough. The commercial carpet industry was an early adopter of
sustainability as a competitive issue. Most carpet industry efforts
were initially aimed at raw material and resource use reductions.
Reducing waste had a positive financial effect. Shaw had already
been doing these things since the mid-1980s. Carpet tile backing
presented an opportunity for sustainable innovation due to PVC
toxicity concerns and high backing weights of emulsion coating.
Metallecene polyolefin offered a pathway to a flexible backing that
could be extruded at low weight without the use of plasticizers
(1997 Scientific American article).
- Slide 6
- Champions Are Key To Success A partnership between Middle
Management and Senior Management is critical to setting realistic
goals and development budgets. Early successes are essential.
Senior Management funded EcoWorx backing development in two stages
based on material formulations run on outside equipment that
demonstrated the path forward at the same or lower price than PVC.
Design parameters were lower weight, equal cost and performance,
sustainable recycling, and competitive advantage protected by IP.
By June 1999 we had perfected the EcoWorx formulation and developed
marketing materials for its introduction at Neocon in Chicago.
EcoWorx won Most Innovative Product at Neocon, manufacturing
management saw that the market perceived value.
- Slide 7
- A Five Million Dollar Investment The biggest hurdle for the
project was the 1996 construction of a 1 million sq. ft. carpet
tile facility with state-of-the-art PVC backing capabilities. Shaw
had the most stable PVC backing in the industry. Shaw spent $1
Million in the pilot phase on a single station extrusion line that
produced first quality tile. Production of significant amounts of
material for test installations was critical to further funding.
Senior Management decided to fund an EcoWorx extrusion line with a
capital cost of $5 Million based on early tile success and the
promise of a single technology platform for tile and broadloom.
Beyond the pressure on PVC, the magnitude of PC carpet and
regulatory threat of landfill bans encouraged further development.
We expected an exit from PVC in 6 to 8 years (and did it in 4
yrs).
- Slide 8
- Cradle to Cradle McDonough and Braungart In 2000 we approached
Bill and Michael to learn more about their work to apply it to our
own with more rigor. EcoWorx offered a truly recyclable material,
but it took optimization under the MBDC Toxicity Protocol to
achieve a true technical nutrient. EcoWorx offered a truly
recyclable material, but it took optimization under the MBDC
Toxicity Protocol to achieve a true technical nutrient. At this
time Evergreen depolymerization was running and Shaw was taking
over 50% of the output. EcoSolution Q nylon 6 was recoverable as a
technical nutrient. All dyes, pigments, and auxiliaries were tested
and optimized under MBDC. At this time Evergreen depolymerization
was running and Shaw was taking over 50% of the output. EcoSolution
Q nylon 6 was recoverable as a technical nutrient. All dyes,
pigments, and auxiliaries were tested and optimized under MBDC. Our
work with Bill and Michael has provided clarity in our pursuit of
sustainable solutions since that time. Our work with Bill and
Michael has provided clarity in our pursuit of sustainable
solutions since that time.
- Slide 9
- Reaching Out To A Cradle-to-Cradle Audience The William
McDonough Design Portfolio reflects the sophisticated design
interpretation of Bills photographs from China. Its a statement
that environmental excellence does not have to sacrifice
cutting-edge design and color. Specifiers and owners have made the
portfolio one of the fastest growing carpet tile offerings in the
industry.
- Slide 10
- EcoWorx% of Shaw% of Industry 199942,000 sy.5%.1% 2000723,000
sy8.8%2% 20012,516,000 sy30.5%6% 20023,159,000 sy39.6%7.7%
20034,584,000 sy53.8%10.7% 20047,890,000 sy77.5%19% 2005 (est.)
11,040,000 sy91%23% Growth of EcoWorx Sales Shaw exited PVC carpet
tile production at the end of 2004, 4 years after introduction.
EcoWorx was responsible for annual double-digit tile growth since
2001. About 9% of 2005 tile sales will be produced with the
EcoLogix PET cushion tile backing.
- Slide 11
- EcoWorx Environmental Guarantee Every square yard of EcoWorx
carpet tile is sold with an environmental guarantee. A toll-free
number is imprinted on the back of every tile. Shaw will transport
and recycle its EcoWorx carpet tiles at the end of the useful life
of the installation, at Shaw expense, back into more EcoWorx tile
of the same quality. No EcoWorx backing need ever go to a landfill
if the occupier will call this number at the time of uplift,
regardless of who originally purchased the tile and regardless of
what product may be replacing the tile.
- Slide 12
- Elutriation of Eco/Eco Grinding and air classification of
backing and fiber streams Current capacity of 3.75 million sy
annually. Current return rate of 50,000 sy annually. 2005
production est. of 11 million sy. Current elutriation capacity
should suffice through 2010. EcoWorx stream is immediately returned
EcoWorx production. Nylon 6 materials pooling agreement with BASF
Arnprior not yet utilized.
- Slide 13
- Additional Waste Streams Recent addition of post-industrial
filler from EVA automotive sound insulation. Replaces 5% to 20% of
polymer weight without loss of performance or recyclability.
Polyethylene stretch film can also be pelletized and used to reduce
virgin polymer weight. Fillers necessary in order to maintain
sufficient mass and backstitch coverage. Polyethylene stretch film
can also be pelletized and used to reduce virgin polymer weight.
Fillers necessary in order to maintain sufficient mass and
backstitch coverage. Current EVA latex precoat is now being
converted to an EVA hotmelt formulation that will boost
thermoplastic content and give higher wet/dry strength. Current EVA
latex precoat is now being converted to an EVA hotmelt formulation
that will boost thermoplastic content and give higher wet/dry
strength. EcoWorx was designed to be a robust low-melt polymer
platform. This lowers cost and increases recycled content sources.
Focus is on noncarpet sources, but much more needs to be done to
identify and evaluate opportunities. EcoWorx was designed to be a
robust low-melt polymer platform. This lowers cost and increases
recycled content sources. Focus is on noncarpet sources, but much
more needs to be done to identify and evaluate opportunities.
- Slide 14
- The Philosophy Behind Shaws Vision of A Cradle- to-Cradle
Future
- Slide 15
- Take Raw material extraction and synthesis Make Manufacturing,
production, distribution, use Waste Landfill, incineration
Cradle-to-Grave Production
- Slide 16
- It would require four more planets the size of earth for every
person in the world to reach present US levels of consumption.
Cradle-to-Grave Production Resource consumption in China, India,
and other rapidly industrializing nations in the global economy is
already affecting capacities and pricing.
- Slide 17
- Thermoplastic polymer chemistry allows products to be
sustainably recycled. Thermosets are difficult to separate into
their original components. Thermoplastics vs. Thermosets EcoWorx
embodies intelligent design for disassembly. Sustainable carpets
must evolve beyond the use of inexpensive thermosets like SBR
latex.
- Slide 18
- The traditional environmentalist response is an unacceptable
solution to industry goals of growth and profitability.
Cradle-to-Cradle Design offers the only demonstrated path to a
sustainable future. Take Less Make Less Waste Less Sustainability
Must Be A Standard Business Practice
- Slide 19
- Environmental Influences Shaw had a desire to go beyond simple
recycling and the goal of zero waste with sustainable technologies
that could become strategic to operational excellence and profit
improvement. We chose to treat sustainability as an extension of
quality and drive it with a management system approach.
- Slide 20
- Biological Nutrients Technical Nutrients Products of
Consumption Products of Service Biological MetabolismTechnical
Metabolism Cradle To Cradle Metabolisms EcoWorx and EcoSolution Q
conform to the concept of technical metabolism as described by
McDonough and Braungart. Both metabolisms are valid pathways to a
C2C future.
- Slide 21
- Shaw Adapts Cradle-to-Cradle Principles
- Slide 22
- Cradl eto Cradl e Shaw has adapted Cradle-to-Cradle concepts to
describe a future where our carpets are made of technical nutrients
that are safe for humans and the environment, make intelligent use
of nonrenewable energy, and are returned to sustainable
manufacturing through recycling infrastructure.
- Slide 23
- Safe and Healthy Materials By what toxicity measure? MBDC
Chemical Protocol testing of EcoWorx, Eco Solution Q, and all
additives and colorants, tested to 100 ppm level in supply chain.
Consensus standards CRI seeking Unified Carpet Standard as a
voluntary, consensus, LCA-based approach. Open to 3 rd party and
self-certification. Thermoplastics vs. thermosets Recycling of
thermoplastics must be weighed against the low cost and high
performance of traditional thermosets. Infrastructure of collection
must channel thermosets into non-carpet recycled uses. (NyBoard, LA
Fibers, Remlon automotive nylon).
- Slide 24
- Safety is boring. Until the 30-foot waves start to hit. EcoWorx
and EcoSolution Q were assessed and optimized under the MBDC
Toxicity Protocol. Shaw will continue to utilize the protocol for
product development.
- Slide 25
- Coal Fly Ash Toxicity Profile Source: Georgia Power Plant
Robins Macon, GA
- Slide 26
- Energy Reduction By what energy measure? No adequate embodied
energy protocol as yet as an analog to MBDC Toxicity. LCA
calculation methods used to validate move from PVC. Matching supply
chain speciation down to 100 ppm may be difficult in practice. Role
of Life Cycle Analysis Sustainable attributes must be optimized
through good science. Shaw EcoWorx vs. Shaw PVC study 2005. Linking
Mass and Energy We have no additional future mass income. Material
is the focus today. The sun may provide ample future energy
income.
- Slide 27
- The Promise of Solar Energy True C2C anticipates a solar future
that relies on the current solar income of the earth. Adapted C2C
recognizes the need to continuously reduce the fossil reliance of
todays economy and make intelligent decisions about its use. As
part of Berkshire Hathaway, Shaws vertical integration plan does
not include energy demonstration technologies at present.
Berkshires MidAmerican Energy is planning the largest wind farm
project in the US a 310 megawatt project that will power the
equivalent of 330,000 homes each year.
- Slide 28
- Transitional Strategies Shaw Waste to Steam Facility 90% of all
landfilled carpet is a cleaner fuel source than coal Carpet Derived
Fuel
- Slide 29
- Shaw Gasifier
- Slide 30
- Shaw Gasifier Facts Transitional strategy to divert carpet from
landfill. Replaces old boilers that burned coal and #6 fuel oil.
16,000 tons/yr of carpet derived fuel and 6000 tons/yr of wood
flour from laminate operations will be converted to synthetic gas.
Steam production only. No power generation. Reduced emissions for
Plant 81. Carpet contains no heavy metals like mercury.
- Slide 31
- Value Recovery By what measures? Can we recover carpets for
recycling in ways that are economicly, ecologically and socially
sustaining? Includes use of LCA and Environmental Management and
Cost Systems. Economies of Scale Drivers of collection
infrastructure must be diverse and adaptive. WTE is a transitional
technology that diverts mass from landfills. Higher value use of
waste is the objective. C2C recycling may not yield the lowest LCA
impact, but technology can change that. Competition or Cooperation?
Alone, together, or with CARE? Eco/Eco products promise EOL
recovery. Elutriation is in place, but volume low until 2007-2009.
Restart or further development of nylon recycling is critical to
success. Material pooling will be difficult until thermoplastics
become more widespread in carpet.
- Slide 32
- Cradle to Cradle is a beautiful thing even to a bean counter $
if its profitable.
- Slide 33
- EcoWorx Backing Development
- Slide 34
- Slide 35
- Slide 36
- Alternative to PVC Cradle to cradle recycling 30% lighter
weight than PVC 40% recycled content Environmental guarantee
(e.g.)
- Slide 37
- Chemical Input Composition of EcoWorx and Permabac Process
- Slide 38
- List of additives in Permabac Carpet Tile
- Slide 39
- List of additives of EcoWorx Carpet Tile
- Slide 40
- Comparison of Permabac PVC and EcoWorx
- Slide 41
- ECOWORX Ctg energy, MJ/kg Mass, kg/sy Carpet supply chain,
MJ/sy Total, MJ/sy LDPE & HDPE19.346.6 Flyash00.850 Total,
approximate 6.6 EcoWorx process, gtg 8.715.3 PERMABAC PVC &
plasticizer340.9733 CaCO30.181.96.35 Total, approximate 33.4
Permabac process, gtg 9.843.2 CRADLE-TO-GATE ENERGY COMPARISON for
EcoWorx and Permabac Tile
- Slide 42
- ECOWORX and PERMABAC Process Energy Comparison ECOWORX energy,
kJ/sy Generation efficiency from natural fuel. ECOWORX natural fuel
energy, kJ/sy PERMABAC energy, kJ/sy PERMABAC natural fuel energy,
kJ/sy Electricity 36200.321130013804320 Heating steam
14000.85165015601830 Direct fuel 36701.0036707000 Energy
requirement 8690 16600991013100 In conclusion, at the carpet
manufacturing plant (gtg level) the two carpet systems differ by a
small amount in energy consumption. The higher energy use for
EcoWorx has been directly related to the physical/chemical
properties of the principal ingredients. However, this comparison
has only a slight dependency on carpet weight.
- Slide 43
- Benefits of Sustainable Redesign Chlorinated PVC concerns
Phthalate plasticizer concerns Heavy PVC coating for stability
Limestone filler Antimony trioxide flame retardant (patent
restriction) Nylon contamination Extrusion corrosion concerns Smoke
density