Carpet Recovery Technology

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This project is a revolutionary non-polluting environmental process, using proprietary technology, chemicals and mechanical devices, which efficiently separates and transforms used nylon carpeting into its original individual components for reuse, namely; nylon, polypropylene, and rubber adhesive. In the United States alone, over five billion pounds of new nylon carpeting is produced annually to replace old nylon carpeting. Since no economical or technical method of reclaiming or recycling nylon carpeting components currently exists, most nylon carpeting is dumped into landfills. Some is chopped up to be used as a cheap filler material.

Simply stated, we are an alternate producer of nylon and polypropylene resins at up to fifty per cent cost savings for the plastic fabrication and molding industries. But unlike all other plastics companies, our raw material feedstock is not oil---it is discarded nylon carpet--- thus it does not end up in landfills---and dependence on oil diminishes.

All research, development, and feasibility studies are complete. Now the project seeks funding to implement the first full manufacturing facility including storage, cleaning equipment, water recovery system, full scale processing units, plastic pelletizing and packaging, finished goods storage area, and operating cash to cover overhead and general and administrative expenses. This full turnkey facility has the capability to annually recycle a minimum of 20 million pounds of used nylon carpeting and with zero waste or byproducts-100 per cent of carpet turns into 100 per cent products . Clean pure nylon and polypropylene resins, with characteristics similar to virgin materials, will be pelletized for resale to the plastics molding industry and granulated rubber adhesive will be sold as an additive filler to the asphalt and concrete industries. Cloneable duplicate facilities are possible throughout the world.

Since nylon was introduced in 1940, there has been a constant need for more nylon that goes unfulfilled because the world's nylon producers cannot stay ahead even during economic crises, nor make enough to meet demands, currently growing at an average rate of more than five per cent per year. Oil is the raw material used in the production of nylon and most plastics. The Palcher process, which has been reviewed, tested and approved by the Underwriters Laboratory will allow us to produce additional nylon, for a world that continues to demand more. The fabricators that have held back using nylon to replace metal components or other materials shall now have the opportunity to do so without the cost or availability impeding their decisions. Additionally, several states have enacted, or are in the process of passing, legislation to forbid the dumping of nylon carpeting in already overtaxed landfills. A comprehensive detailed business plan maps out the first full manufacturing facility. This complete turnkey operation starts sales in one year and full scale-up capacity follows within six months.

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  • ABOUT THE ENTRANT

  • Name:
    Joe Palcher
  • Type of entry:
    individual
  • Profession:
    Scientist
  • Number of times previously entering contest:
    never
  • Joe's favorite design and analysis tools:
    Pencil, paper, brain.
  • For managing CAD data Joe's company uses:
    None
  • Joe's hobbies and activities:
    Golf, reading, exploring, weapons systems.
  • Joe belongs to these online communities:
    Compuserve forums.
  • Joe is inspired by:
    Unthinkable imagination.
  • Hardware used for this entry:
    Paper and Pencil
    Software used for this entry:
    MSWord, Irfanview
  • Patent status:
    none