Recycling of Low Grade Clothing Waste - Oakdene Hollins

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© Oakdene Hollins Ltd, Salvation Army Trading Company Ltd Nonwovens Innovation & Research Institute Ltd September 2006 In addition, roofing contractors are seeking new lightweight solutions for green roofing substrates. Weight is a very important criterion as the roof structure has to be designed around holding significantly higher weights than a standard PVC roof structure, affecting costs accordingly. The air‐laying techniques are especially suited to processing recycled fibre whilst at the same time adding particulate matter. A second approach uses needle‐punching technology to encapsulate seed within the fabric architecture whilst minimising mechanical damage. 12.4.2 Experimental Work Air‐laying involves dispersing fibres and/or particles in air, transport of the solid/fluid mixture followed by separation to form a low density web. This approach was chosen owing to the ability to easily incorporate particulate matter, such as seeds, into the structure. A second approached utilised needle‐punching technology to limit seed damage. The fibre selection was limited owing to the biodegradability requirement. In terms of low‐grade clothing waste, many of the garments in the waste stream are composed of synthetic fibres or blends of natural fibres with synthetic fibres, for example cotton and polyester. The selection therefore had to be either 100% cotton or viscose garments or 100% cotton denim. The denim was selected on the basis of its availability. The garments were mechanically fiberised and blended with 20% low melt bicomponent polyester fibre to assist subsequent bonding. The fibre blend was processed through the air‐laying machine; the settings are given in Appendix VI. During processing, grass seed was added at an addition of 35g/m², the recommended coverage for the specified grade of seed. An initial 100g/m 2 of fibre was air‐laid, followed by the addition of the seed and subsequently a final 50g/m 2 of fibre was applied to create a sandwich construction with a thin top layer to allow the seed to germinate effectively. The web was further processed by bonding the structure in a through‐air oven at a temperature of 150°C and a speed of 2m/min. The second approach used a needle‐punching technique to bond the fibres together but also limit seed damage through the action of the needles. This approach was suited to the application because it required no additional non‐biodegradable low melt component to bond the structure coherently. Having treated the initial web with a fully set needle‐board, the seed was added at 35 g/m 2 . A second, lighter‐weight web was then placed on top and subsequently processed. Small sections of needles were removed from For Defra Page 116
© Oakdene Hollins Ltd, Salvation Army Trading Company Ltd Nonwovens Innovation & Research Institute Ltd September 2006 the needle‐board creating ‘unbonded’ zones of fibre where the seeds could be stored without mechanical damage. A final sample of seeded matting was manufactured using a fully set needle‐board to compare the level of mechanical damage to the seeds. 12.4.3 Evaluation, Feedback and Next Steps The fabrics essentially worked as a pre‐seeded grass mat. Propagation occurred with good coverage of grass seed as the random nature of the scattering application gives good distribution. The needle‐punched approach is preferred, as the short fibre used in the air‐laid approach limits the propagation owing to the decreased porosity. There was no noticeable difference between the selectively needled sample and the fully needled approach. Little or no damage to the seed was imparted by the needlepunching process. The basic pre‐seeded fabrics are very inexpensive owing to their limited technological approach. The addition of fertiliser within the fabric structure, to aid propagation, was discussed in detail but thought to be of limited use owing to the addition levels required and the multiple applications usually added. After initial technological success there was no interest in developing the concept further. 12.5 Automotive Head- and Boot-Liner Components 12.5.1 Overview The UK automotive manufacturing sector contributes around £8.4bn added value to the economy, accounting for 1.1% of GDP. Approximately 237,000 people are employed in the design and manufacture of vehicles and components in the UK 71 . The global volume of the automobile supply industry amounted to €932 billion in 1998 out of which €695 billion for Original Equipment (O.E.) and €237 billion for replacement of parts in the after‐sales market. The aftermarket is that part of the automotive components industry that provides services and equipment, i.e., parts, accessories, consumables etc. for the motor vehicle after it has gone into use. In 1998 there were around 2,000 UK component manufacturers supplying the aftermarket industry through approximately 2,500 distribution outlets and 55,000 retail outlets 72 . For Defra Page 117
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Recycling of Low Grade Clothing Waste - Oakdene Hollins

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