Kolon Industries has developed a 100% recycled polyester long-fiber nonwoven fabric for carpet backing applications, earning the IR52 Jang Young-sil Award in the 25th week of 2026 for its breakthrough in sustainable materials engineering.The newly developed nonwoven fabric is produced entirely from recycled PET bottles and is designed for demanding applications such as automotive carpets, where high thermal resistance, dimensional stability and mechanical strength are essential.
Overcoming the Challenges of Recycled Materials
Carpet backing, often referred to as a nonwoven substrate or “bubble,” plays a critical role in maintaining carpet shape and durability in automobiles and commercial environments.During automotive carpet production, the material must withstand molding temperatures exceeding 180°C while maintaining flexibility and resisting shrinkage or tearing.
According to Kolon Industries, the biggest technical challenge was overcoming the heat sensitivity of recycled polyester. Compared with virgin materials, recycled PET is more prone to deformation and shrinkage under high-temperature processing.
The company noted that many competing technologies have struggled to commercialize products containing even 50% recycled content because of these limitations.
Read more:Â Neumag BCF Technology Demonstrates The Potential for Carpet-to-Carpet Recycling
Proprietary Binder and Fiber Technology
To solve the problem, Kolon Industries developed an ultra-low melting-point binder that improves thermal stability while maintaining strong bonding between recycled fibers.The company also refined impurity removal processes and optimized adhesive viscosity during manufacturing.
Another key innovation was the development of an isotropic fiber structure, enabling fibers to be evenly distributed throughout the nonwoven fabric. This ensures consistent mechanical strength regardless of the direction in which the material is stretched.According to senior researcher Lee Min-ho, engineers repeatedly optimized yarn production and airflow conditions to successfully manufacture the material at spinning speeds exceeding 5,000 meters per minute.
Lower Carbon Emissions and Expanded Applications
Kolon Industries reports that the new manufacturing process reduces carbon emissions by approximately 43% compared with conventional production methods.The company plans to expand the technology beyond automotive carpet backing into a range of high-value applications, including:
- Â Automotive headliner materials
- Industrial filtration media
- Construction materials
- Other eco-friendly single-material composite products
According to Kolon Industries, the technology is expected to utilize approximately 4,500 tonnes of recycled raw materials while supporting the advancement of South Korea’s sustainable materials industry and circular manufacturing initiatives.
