Research Highlights

Since its inception in 1994, TIP has funded more than 200 research and development projects. Recent activities in each industry sector are highlighted below.

Textiles/Carpet

New recycling plant:

Georgia's textiles/carpet industry transports over 200 million pounds of solid waste to Georgia landfills each year at a cost of more than $5 million in tipping fees alone. Honeywell International, in cooperation with DSM, developed technology that will significantly reduce the amount of carpet going to Georgia's landfills. The company built an $80 million recycling plant in Augusta to convert carpet waste into virgin quality nylon for use in new carpet and automotive parts. The facility, called Evergreen Nylon Recycling Center, began operations in November 1999. Evergreen will process 200 million pounds of carpet waste annually and employ 75 workers. Eighty used-carpet suppliers have already signed up, and the company expects to have a nationwide supply chain of 200 within three years. Two Georgia carpet makers and Ford Motor Company have expressed interest in purchasing Evergreen's recycled product. Honeywell partnered with TIP to develop a computer logistics model to minimize Evergreen's cost of collecting used carpet for its production process.

Wrinkle-free clothes:

TIP researchers found a solution for a major economic threat to Georgia's cotton textile manufacturers and apparel makers. Demand for wrinkle-free apparel is growing steadily, with the domestic market alone valued at more than $10 billion. But most wrinkle-free finishes contain formaldehyde, a chemical banned in many international markets because of potential health risks. UGA researchers developed a cost-effective finish that is formaldehyde-free and exhibits better wrinkle resistance and strength retention than the finish commonly used by textile and apparel makers. Columbus-based Callaway Chemical Company licensed the finish and formed a joint venture with Cotton, Inc. and another Georgia company. They expect the new finish to gain a major share of the U.S., European, and Japanese markets.

Microorganism growth in carpets:

Georgia's commercial carpet makers called on TIP to help solve a problem threatening their market share. School districts in 31 states have removed carpet from classrooms because of concerns about mold and mildew growth and its impact on children's health. TIP lab work identified the leading microorganisms in mold and mildew growth as well as the two carpet finishes that best inhibit its growth. In early FY2000, TIP researchers installed test carpets in two classrooms in Florida. The test carpets will remain in place until August 2000 while researchers from UGA analyze the presence of microorganisms. The TIP team is also looking at different carpet constructions (various weaving techniques and backing materials) to prevent microorganism growth.

Reducing toxicity in carpet wastewater:

Carpet companies in Dalton called on TIP to help reduce COD, or chemical oxygen demand loads, in their wastewater. More than 50 carpet mills are served by Dalton Utilities whose treatment system will soon reach or surpass its design limits if industry cannot reduce its wastewater volume. TIP researchers found that the major cause of COD is the finish, or lubricant, applied to yarn during the carpet-making process. Last year, they worked with Shaw Industries and Solutia to develop a new process that reduces total lubricant usage by 40 percent, lowering both wastewater toxicity and chemical costs. Shaw Industries is constructing and testing a pilot-scale system with plans to implement a full-scale system in 2000. Georgia's carpet industry can save $3 million per year by implementing this technology.

Reducing chemicals in denim manufacturing:

Georgia is home to five denim manufacturers employing over 6,000 workers. The process of making denim requires large amounts of indigo and sulfur dyes - a typical denim plant spends $13 million per year on chemicals, not including the cost of treating chemical-laden wastewater. UGA and Georgia's denim makers worked on reducing the amount of dyes and chemicals used in the manufacturing process. In less than a year, one mill reduced its chemical costs by more than $100,000 and another mill save $80,000.

Reducing textile wastewater:

At Springs Industries in Griffin, TIP researchers helped the company modify its towel-manufacturing processes and reduce wastewater by half to 900,000 gallons from 1.8 million gallons per day. At the company's yarn-dyeing plant, researchers suggested changes that reduced that facility's wastewater by 25 percent. Because these technologies can be applied to other textile operations, managers from dozens of textile companies across Georgia visited Griffin to see Springs' system and learn firsthand how it might work in their mills.

Internet Recyclers:

To help Georgia's carpet and textile companies find appropriate waste handlers, TIP developed an Internet site - http://www.fcs.uga.edu/tmi/wastedb/ - which lists more than 200 waste dealers and material recyclers, and gets more than 500 "hits" every month. More than 150 textile/carpet companies around the state have used the site to solve waste disposal problems.