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Case study

FALKE tests cardyon®-based TPU yarn to lower carbon footprint

We have been using CO₂ as an alternative raw material in polyol production since 2016, replacing up to 20% of fossil feedstock. With the German brand FALKE, we’re striving to lower the impact of elastic textile yarns using our cardyon®-based TPU and a melt spinning process that requires no solvents.
Task

More sustainable elastic yarn

Brands worldwide are trying to find ways to meet the rising consumer demand for more sustainable products.
Our groundbreaking Triturn®-technology turns carbon dioxide into added value by reusing it as a valuable raw material in polyol production. This way, up to 20% of fossil feedstock can be replaced with CO₂, yielding cardyon®, a more sustainable polyol that provides the same high quality as conventional solutions. Already used in mattress and sports floor production, cardyon® can also be included as an ingredient in thermoplastic polyurethanes (TPU). The challenge here was to spin elastic textile yarns from cardyon®-based TPU.
Challenge

Achieve more sustainable elastic yarns

We collaborate with academic process researchers and textile manufacturers to develop materials and processing methods for elastic yarns that offer a lower environmental impact without compromising on quality. The German brand FALKE is a key partner in implementing these more sustainable solutions.

Elastic yarns are predominantly made via a dry-spinning process, which usually requires substantial quantities of solvent. The challenge we faced together was how to integrate a higher share of more sustainable raw materials, and how to produce novel elastic yarns without the use of solvents.

At FALKE we see the great sustainability potential in cardyon®-based elastic yarns, and enthusiastically support the industrialization of the melt spinning process.

Angela Langer

Head of Product Development, FALKE

Solution

Melt spinning with cardyon®-based TPU

Our solution  is an elastic yarn made from cardyon®-based TPU.

Starting with CO₂ as an alternative raw material, which partially replaces fossil resources, we utilize a novel, efficient technologies to produce a more sustainable TPU solution. This cardyon®-based TPU already reveals attractive material properties, which predestine it to be utilized in elastic filaments.
In this case, a melt spinning process is used, which has been developed to advanced technical scale. By applying the melt spinning process the cardyon®-based TPU is molten, pressed into fine threads and then processed into a yarn of endless filaments. Unlike dry spinning, the melt spinning process doesn’t require substantial quantities of solvents.

The result is an elastic yarn, which could become a more sustainable alternative to conventional elastic yarns in the near future.

It's just fascinating to see how cardyon® is proving itself. Reusing CO₂ can really open up some unexpected applications – such as helping to make textiles fit better!

Dr. Jochen Norwig

Senior Project Manager CO₂, Covestro

Key Benefits

  • Circular: our cardyon® polyols are made with up to 20% CO₂, reducing fossil dependency.
  • Melt spinning: the melt spinning process does not require the use of solvents.
  • High-performance: yarns with cardyon®-based TPU can become an alternative to traditional elastic yarn.
  • More sustainable: using cardyon® can help underline your brand’s sustainability credentials.

Our CO₂-based polyol cardyon® is used in PU foam and TPU yarn and can lower your carbon footprint.

cardyon®-based TPU for elastic yarns

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