VERNON, CALIF.— Invista, maker of Stainmaster carpet, recently entered into a license agreement with Los Angeles Fibers/Reliance Carpet Cushion (LA Fibers) to produce EcoSoft, a 100% recyclable carpet cushion, made from 90% postconsumer and 10% pre-consumer recycled content.

The reclamation alliance, which began in March, came about as a response to an industry need, said Tony Morakis, business director of Invista’s specialty segment. “Diverting carpet from landfill is an industry initiative and Stainmaster wants to do its part in increasing the rate of carpet recycling, which is currently only at 5%.”

LA Fibers, in operation since 1983, has been recycling post-consumer products since 2000, said Ron Greitzer, president. To make EcoSoft, used Stainmaster carpet is removed from homes and sent to a reclamation center, rather than a landfill. At the center, the carpet is sorted by fiber type using infrared technology and the 6,6 nylon fibers are sent to the LA Fibers manufacturing plant to be transformed into cushion.

This closed-loop cycle of transforming old Stainmaster 6,6 nylon fibers into carpet cushion will eventually result in a 100% post-consumer recycled product as more used carpet is reclaimed and incorporated.

The result is three types of cushion that can extend a Stainmaster brand carpet’s warranty by three- to five- years, depending on the style installed over the EcoSoft cushion, explained Morakis. Modeled on a good-better-best system, EcoSoft 28 and 32—good and better— can extend the warranty for Stainmaster’s Xtra Life and Master Life by three years, while Ecosoft 40—best—adds five years to products using the Active Life or Ultra Life yarns.

After a year of development, including custom designed carpet recycling machinery, LA Fibers has diverted about one billion pounds of carpet from landfills since collaborating with Invista. Working with Invista has ensured that the recycled product also has a place to go. “It’s easy to recycle—it’s hard to sell the product,” said Greitzer. “Invista gets it.”

The alliance between LA Fibers and Invista is beneficial for both companies. “With LA Fibers as one of the largest carpet recyclers in the U.S., it reclaims all types of fibers, including Stainmaster’s nylon 6,6,” said Morakis. “It can provide regional reclamation services to flooring retailers and contractors in California and Arizona.” He also praised the reputation of Reliance [LA Fibers’ parent company] on its 75-year position in the cushion industry and one of the first to produce carpet cushion made from 100% post consumer carpet material.

Initially, EcoSoft will be sold at Stainmaster Flooring Centers, said Bobby Berrier, global sustainability director for Invista’s performance surfaces and materials division. The company plans to expand distribution in the near future.

For more on EcoSoft Stainmaster cushion, call 323.321.2300.