GB2453656A

GB2453656A - Method and apparatus for processing scrap textile for recycling

Info

Publication number: GB2453656A
Application number: GB0818423A
Authority: GB
Inventors: Mark William Reed; Martin Peter Cairns
Original assignee: REEDS CARPETING CONTRACTORS Ltd
Current assignee: REEDS CARPETING CONTRACTORS Ltd
Priority date: 2007-10-08
Filing date: 2008-10-08
Publication date: 2009-04-15
Also published as: GB0818423D0; GB0719634D0

Abstract

A method for processing scrap material such as used carpet for recycling includes a coupling operation to couple sections of scrap textile together to form a length of scrap textile 200. A preferably substantially continuous length of scrap textile undergoes a cleaning operation for removing or dislodging dirt or debris from the scrap textile. The cleaning operation is carried out after the coupling operation. The coupling operation may occur remote from the cleaning operation wherein the length of textile is arranged to extend between the coupling location and the cleaning location. The textile may be allowed to accumulate in a buffer zone 150 in a relaxed state, prior to the cleaning operation. Once cleaned, the length of textile may be arranged in rolls ready for transportation to a recycling location. The apparatus 100 comprises a coupling zone 130, inspection zones 140 and 170, the buffer zone 150 and a cleaning zone 160.

Description

Method and Apparatus for processing textile material The present invention relates to methods and apparatus for processing material, more particularly, but not exclusively, to methods and apparatus for preparing used textile for recycling.

The exhibition industry is responsible for generating large volumes of waste carpet.

For example, it is typical for an exhibition hail to be fitted out with carpet for the purpose of a single exhibition, and for the carpet to be removed after the exhibition.

Typically, the removed carpet will be scrapped and sent to landfill. However, given the large volumes of material involved and the need to reduce the amount of waste sent to landfill, it is sensible to try to recycle the scrapped carpet. S...

*.. 15 S. I *::* Carpet typically consists of a face fibre and a backing layer. The material used for the face fibres include polypropylene and polyester, and such materials can be readily S.....

recycled due to their thermoplastic properties. This involves chopping the carpet into small sections and melting down the carpet fibres to produce plastic pellets. However, the quality of the resultant product is dependent on the quality of the carpet to be * processed and therefore it is desirable to clean the carpet before the fibres are melted *SSS down.

Conventional carpet recycling techniques involve manually cleaning the carpet with a vacuum cleaner before it is broken down into pellets. However, this is a laborious process, particularly since the scrapped carpet typically consists of multiple irregular shaped pieces of carpet. Clearly, there is a need for an improved carpet recycling technique.

According to the invention, there is provided a method and/or an apparatus for use in processing material for recycling. The apparatus preferably includes a feed zone for receiving material to be processed, and exit zone through which the material can pass once processed, and at least one process zone in which the material is subjected to a cleaning operation. C,

The apparatus preferably includes a coupling zone at or adjacent the feed zone, for coupling together sections of the material, e.g. for creating a continuous length of material to be processed by the apparatus. The coupling zone preferably includes a sewing apparatus, for sewing together the sections of material.

The material is preferably coupled together using a coupling material which can be recycled with the textile material, e.g. ties, staples, twine or thread or suitable plastics material. If the apparatus is used for processing scrap carpet material, the sections of the scrap carpet are preferably coupled together using a tie, twine or thread that can be recycled with the carpet material, e.g. formed from the same material as the carpet.

Although a sewing operation is believed to be an advantageous method of coupling * : the material together, the coupling operation may take alternative forms, such as a *.** . . . . 15 stapling operation or an operation in which slits or apertures are formed in the ends of the material to be coupled together and a twine, thread or cable-tie type material is used to couple the two pieces of material together through the slits or apertures.

The apparatus preferably includes an inspection zone configured to permit visual inspection of both sides of the material passing through the apparatus. The inspection S...

zone preferably includes an arrangement of rollers for transporting the material through the inspection zone. The rollers are preferably arranged so as to pass the material beneath a walkway. More preferably, the rollers may be arranged to transport the stitched textile along a substantially U-shaped path, wherein the textile passes beneath the walkway and defines walls on either side of the walkway, such that an operator positioned in the walkway and between the walls of material is able to visually inspect the textile as it passes through the inspection zone.

One or more scrapers may be provided at or prior to the inspection zone for removing or dislodging unwanted surface debris. The scraper may be passive, e.g. the scraper may comprise a bladed element over which the material is intended to be pulled in order to remove debris from the surfaces of the material. Additionally or alternatively active scraper devices may be incorporated for movement relative to the material.

The apparatus may include a buffer zone, in which a length of the material can accumulate, preferably in a relaxed (non-tensioned) state. Means for tensioning the relaxed material may be arranged upstream of the buffer zone.

The apparatus preferably includes a cleaning zone including at least one of a suction device, a beater device and a brush device, for use in cleaning the material. The cleaning zone may include rollers for maintaining the material under tension during cleaning. In a preferred embodiment, the cleaning zone includes a suction or vacuum cleaning device for sucking dirt and debris from the material, a beater device for beating at least one surface of the material and one or more brushes for brushing at least one surface of the material. It is preferred if both sides of the material are subjected to the sucking andlor beating and/or brushing operations. Preferably, the *** . . *.. : suction device is provided downstream of the brush and/or beater device, for collecting debris which falls from the material as a result of the brush and/or beating S...

steps, andlor so that the material passes through the suction device before passing * through the other device(s). An additional suction device may be provided after each S...

* brush/beater stage. S. * ...

The apparatus preferably includes a metal detection device for detecting metallic *.** content in the material. This may be at any location in the apparatus, e.g. before the visual inspection zone or more preferably after the cleaning zone. Rollers can be controlled to interrupt the passage of the matenal if metal is detected. It is preferred if the rollers are arranged so as to extend the material in a wall or curtain type manner, e.g. to enable ready visual inspection of both sides of the wall/curtains.

It is preferred if the exit zone includes is configured for winding the processed material on to a tube, so as to create a roll of the processed material. The apparatus may include sensors to enable the weight and/or length of the processed material to be monitored.

According to a further aspect of the invention, there is provided an apparatus for use in processing material for recycling, the apparatus including a coupling zone for coupling sections of textile together to form a continuous length of textile, and a cleaning zone for cleaning the textile, wherein the cleaning zone is arranged downstream of the coupling zone, such that the textile can be first coupled together prior to cleaning.

The coupling zone preferably includes a sewing apparatus, for sewing together two sections of material using a substantially continuous stitched bond. Although a sewing operation is believed to be an advantageous method of coupling the material together, the sections of textile may be coupled in other ways. For example, the coupling zone may include an area in which the sections of textile are stapled together, or in which a twine, thread or cable-tie type material is used to couple the two pieces of material together through slits or apertures formed in the ends of the sections of material to be coupled together. *.** * S S S. I

*. 15 The apparatus preferably includes rollers for pulling the length of textile from the coupling zone and through the cleaning zone. More preferably, the apparatus includes *.S.,S * a buffer zone for accumulating the textile after coupling and prior to cleaning. I... * S *.SS

* : * The apparatus preferably includes a winding mechanism arranged downstream of the cleaning zone for creating a roll of the cleaned textile.

The apparatus may include one or more features of the first mentioned aspect of the invention.

According to another aspect of the invention, there is provided a method for use in processing scrap textile for recycling, the method including a coupling operation to couple sections of scrap textile together to form a length of scrap textile, and a cleaning operation for removing or dislodging dirt or debris from the scrap textile, wherein the cleaning operation is carried out after the coupling operation.

The coupling operation preferably occurs at a coupling location and the cleaning operation occurs at a cleaning location, wherein the coupling location is remote from the cleaning location.

The coupling operation may include the use of a sewing apparatus, to provide a substantially continuous stitched bond between two sections of textile. In other embodiments, the coupling operation may involve the use of staples arranged in a spaced array, or the use of a series of spaced ties passing through slits or apertures formed in the ends of the material to be coupled together.

Once coupled together, the length of textile is preferably is substantially continuous and is arranged to extend between the coupling location and the cleaning location.

Most preferably the textile is allowed to accumulate in a buffer zone in a relaxed state, after the coupling operation, but prior to the cleaning operation.

After the cleaning operation, the textile is preferably wound to form a roll of cleaned textile ready for a recycling operation.

S.....

* The cleaning operation preferably includes subjecting the length of textile to a suction S's. cleaning operation and/or a beating operation and/or a brushing operation, for ::.... removing or dislodging dirt or debris from the textile. *...

The cleaning operation preferably includes passing the textile through a suction cleaning device and a beating device and/or a brushing device, wherein the suction cleaning device is arranged beneath the beating device and/or brushing device.

Prior to or after the cleaning operation, the length of textile is preferably subjected to a metal detection process for detecting metal content in or attached to the textile.

Once coupled together, the length of textile is preferably subjected to a visual inspection process, in which the textile is transported along a substantially vertical path for visual inspection of the textile. in such embodiments, it is preferred if the textile passes beneath a platform and the operator stands on the platform to inspect the textile.

The method preferably utilises an apparatus according to either of the above aspects of the invention.

Other aspects and features of the invention will be apparent from the claims and the following description of the exemplary embodiment illustrated in Figure 1, which is a schematic side view of an apparatus for use in processing textiles as a preliminary step in a recycling method.

The apparatus is indicated generally at 100 in Figure 1 and includes an entrance zone 110, an exit zone 120 and a plurality of process zones 130, 140, 150, 160, 170 arranged between the entrance and exit zones 110, 120.

In this embodiment, the entrance zone 110 is in the form of a table or bay 112 onto *.. : which sections of textile can be stored, ready for processing. Typically, the textile *::::* 15 will take the form of lengths or rolls of plastic-based carpet or other such recyclable material. The bay 112 is preferably mounted on wheels (not shown) so as to be movable with respect to the remainder of the apparatus 100, e.g. for transporting textile material from a remote location. S. * S..

The first process zone 130 is used for coupling sections of textile material together, *.S* for the purpose of forming a continuous length of the textile material, e.g. as indicated at 200 in Figure 1. Hence, the first process zone 130 can be referred to as a coupling zone.

In this embodiment, the first process zone includes a bed 132 on to which two or more pieces of textile can be laid in overlap. There is also provided a pneumatic clamping device 134 for clamping the textile to the bed 132, as well as a sewing machine 136 (movable along a horizontal guide rail) for stitching the clamped textile together (e.g. to provide a substantially continuous stitched bond between two sections of textile).

A series of friction rollers 138 are provided for pulling the stitched material further into the apparatus 100, as well as for tensioning the stitched length of textile 200.

The entrance zone 110 may be omitted, in which case the coupling zone 130 serves effectively as a feed zone for textile to the apparatus 100.

An inspection zone 140 is provided adjacent the friction rollers 138, wherein the stitched and tensioned length of textile can be visually inspected. In this embodiment, the inspection zone 140 includes a platform or walkway 142 and an array of rollers 144 arranged to transport the stitched textile along a substantially U-shaped path defining walls 202, 204, as can be seen from Figure 1. The textile 200 passes beneath the walkway 142. An operator may stand on the walkway 142, to visually inspect the textile 200 as it passes through the zone 140.

Although not shown, the textile 200 may be pulled through or over one or more scrapers at or prior to the inspection zone 140, wherein the scrapers are intended for *:::: removing or dislodging unwanted surface debris, e.g. chewing gum. **S

* * 15 S...

The apparatus 100 includes a buffer zone 150, wherein a length of the stitched and *S*...

visually inspected textile can be allowed to pile up. In particular, the textile 200 passes over a friction roller 152 and falls down into a storage bay 154, where the textile 200 can be allowed to accumulate in a relaxed (non-tensioned) state. * S

A further series of rollers 156, 158 are arranged for re-tensioning the textile 200 after passing through the buffer zone 150, and for transporting the textile to a cleaning zone 160. The cleaning zone 160 includes rollers 162 for maintaining the textile 200 under tension during cleaning. The cleaning zone 160 includes a suction or vacuum cleaning device 164, a beater device 166 and one or more brushes 168. The suction device 164 is intended for sucking dirt and debris from the textile 200 and the brush and beater devices 166, 168 are intended for dislodging dust and debris.

It is preferred if the suction device 164 is provided downstream of the brush and beater devices 166, 168, so that the textile 200 passes through the vacuum device 164 before passing through the brush and beaters 166, 168. An additional suction device 164 may be provided after of the brush and beaters 166, 168.

Once cleaned, the textile 200 is transported via rollers 172, 174 through a second inspection zone 170, which includes a metal detection device 176 for detecting any metallic contact in the textile 200. The rollers 172, 174 can be controlled to interrupt the passage of the textile 200 through the zone 170 if metal is detected. It is preferred if the rollers 172, 174 are arranged so as to extend the textile 200 is in a wall 206 or curtain type manner at the second inspection stage, to enable ready visual inspection of both sides of the wall/curtains, e.g. as shown in Figure 1 wherein the textile is substantially vertical when passing through the detection device 176.

A further series of rollers 122, 124 are arranged for pulling the textile 200 into the exit zone 120. In this embodiment, the exit zone 120, is advantageously arranged for winding the processed textile 200 on to a tube so as to create a roll 126 of the processed textile 200. The exit zone 120 may include sensors to enable the weight and/or length of the processed material to be monitored. The roll 126 can then be transported to a recycling location. Alternatively, the exit zone 120 may include or form part of a feed device for feeding the processed textile 200 into a recycling unit, * e.g. a unit configured to turn the processed textile in to pellets. S... * S *5*S

It is preferred if the apparatus 100 is used for processing scrap carpet material, wherein sections of the scrap carpet are coupled together using a polypropylene twine S...

or thread that can be recycled with the carpet material.

The first and/or second inspection zones 140, 170 may be omitted, if desired.

However, these zones are useful for monitoring the quality of the material, before it is passed on for recycling. The metal detection device 176 may be provided before and/or after the cleaning zone 160.

The buffer zone 150 may also be omitted. However, it is advantageous in so far as it enables a store or buffer of continuous textile to be built up, whereby the cleaning zone 170 or exit zone 120 can continue to receive a feed of the textile 200, even if the intake or flow of the textile in the preceding zones is interrupted, e.g. if the sewing machine requires maintenance or if undesirable surface content is discovered at the first inspection zone 140. Likewise, the buffer zone 150 enables an operator to continue feeding material in to the apparatus 100, even if there is an upstream interruption in the flow of material through the apparatus 100, e.g. at the second inspection zone 170.

Although the illustrated embodiment uses a sewing machine to provide a substantially continuous stitched bond between two sections of textile, other coupling operations may be employed to create the length of textile for processing. For example, other embodiments may involve the use of staples arranged in a spaced array, and/or the use of a series of spaced ties passing through slits or apertures formed in the ends of the material to be coupled together. * * S S. S S. * . S... * . *.SS * S S*' * 55. 5.. * * 55S

Claims

Claims I. A method for use in processing scrap textile for recycling, the method including a coupling operation to couple sections of scrap textile together to form a length of scrap textile, and a cleaning operation for removing or dislodging dirt or debris from the scrap textile, wherein the cleaning operation is carried out after the coupling operation.
2. A method according to claim I wherein the coupling operation occurs at a coupling location and the cleaning operation occurs at a cleaning location, wherein the coupling location is remote from the cleaning location.

::::
3. A method according to claim 2 wherein the length of textile is substantially * 15 continuous and is arranged to extend between the coupling location and the cleaning location. * *

*
4. A method according to claim 3 wherein, after the coupling operation, but prior to the cleaning operation, the textile is allowed to accumulate in a buffer zone in a * 20 relaxed state. **** * * *.S*
5. A method according to any preceding claim wherein, after the cleaning operation, the textile is wound to form a roll of cleaned textile ready for a recycling operation.
6. A method according to any preceding claim wherein the cleaning operation includes subjecting the length of textile to a suction cleaning operation and/or a beating operation and/or a brushing operation, for removing or dislodging dirt or debris from the textile.
7. A method according to any preceding claim wherein the cleaning operation includes passing the textile through a suction cleaning device and a beating device andlor a brushing device, wherein the suction cleaning device is arranged beneath the beating device and/or brushing device.
8. A method according to any preceding claim wherein, prior to or after the cleaning operation, the length of textile is subjected to a metal detection process for detecting metal content in or attached to the textile.
9. A method according to any preceding claim, wherein the length of textile is subjected to a visual inspection process, in which the textile is transported along a substantially vertical path for visual inspection of the textile.
10. A method according to claim 9, wherein the textile passes beneath a platform and the operator stands on the platform to inspect the textile. * . * ** *
11. Apparatus for use in processing material for recycling, the apparatus including a coupling zone for coupling sections of textile together to form a continuous length of ****S* * textile, and a cleaning zone for cleaning the textile, wherein the cleaning zone is **** arranged downstream of the coupling zone, such that the textile can be first coupled together prior to cleaning. * S S...
12. Apparatus according to claim 11 wherein the coupling zone includes a sewing apparatus for sewing sections of textile together.
13. Apparatus according to claim 11 or claim 12, the apparatus further including rollers for pulling the length of textile from the coupling zone and through the cleaning zone.
14. Apparatus according to any of claims 11 to 13 further including a buffer zone for accumulating the textile after coupling and prior to cleaning.
15. Apparatus according to any of claims 11 to 14 wherein the cleaning zone includes a vacuum cleaning device and a beating device and/or a brushing device, wherein the suction cleaning device is arranged beneath the beating device andlor brushing device.
16. Apparatus according to any of claims 11 to 15 further including a metal detection device past or through which the textile is intended to travel for detecting metallic content in the textile.
17. Apparatus according to claim 16 wherein the metal detection device is located downstream of the cleaning zone.
18. Apparatus according to claim 17 further including a control system configured for interrupting the passage of the textile if metal is detected in the textile.

::::
19. Apparatus according to any of claims 11 to 18, further including a winding mechanism arranged downstream of the cleaning zone for creating a roll of the cleaned textile. * *

1
20. Apparatus for carrying out the method of any of claims I to 10. * ***

*... 20 * I *.**