Shaw Industries Group Inc. and DAK Americas LLC have created a new joint venture company, Clear Path Recycling LLC, to produce Recycled PET (RPET) from post-consumer PET, which is typically derived from recycled water and soda bottles. Both DAK, the second largest PET Resin and largest Polyester Staple Fiber producer in the Americas, and Shaw will use the RPET material primarily in the companies' polyester products. Shaw is the initial majority partner in Clear Path Recycling LLC.
“This joint venture investment
represents an important strategic benefit to Shaw’s PET filament product
lines,” said Vance Bell, Shaw's CEO. “The recycled content manufactured in this
facility, combined with Shaw’s patent-pending BCF manufacturing process, will
allow us to significantly enhance and expand our innovative Clear Touch BCF
family of products." Bell adds that the venture will help the company
realize its "25 percent energy intensity reduction pledge announced in
Clear Path Recycling LLC will build
a plant in Fayetteville, N.C. at DAK Americas' Cedar Creek site. The goal is to
recycle over 280 million pounds of PET bottles annually, or about 5 billion
bottles. The first phase of the new facility will process 160 million pounds of
PET bottles; construction is expected to begin in mid 2009, with the plant
operational in the first quarter of next year.
A second phase, planned for
completion in 2012, will bring the operation to capacity at 280 million pounds,
making Clear Path Recycling LLC the largest PET recycling operation in North
America, Shaw said. An estimated 25 percent of the total recycled material
produced will be sold through merchant sales.
“Clear Path Recycling is a major
milestone in the sustainability initiatives of DAK Americas and reinforces
DAK’s commitment to protect the environment for future generations,” said
Hector Camberos, president and CEO of DAK Americas. “The joint venture allows
DAK to deliver on the growing requirements of both its PET Resin and Polyester
Staple Fiber customer base for products with recycled content."
Additionally, the joint venture is
set to reduce the use of landfills and improve internal process economics for
Shaw and DAK. By recycling 280 million pounds of PET bottles, Shaw estimates
that over 1 million cubic yards per year of landfill space will be conserved.
The energy savings will be approximately 2.5 trillion BTUs of energy annually,
which is equal to the amount of primary energy necessary to power 18,000 U.S.
homes per year, Shaw noted.
DAK currently operates a PET resin
manufacturing facility on-site and has significant infrastructure in place that
the new joint venture will utilize.
Approximately 100 new jobs will be created at the facility at the
completion of both phases.
Shaw uses RPET product in
other areas of its business as well, most notably in its EcoLogix commercial
carpet cushion system, a technology it introduced in 2003 that contains 88
percent post consumer recycled content.