Water-based polyolefin dispersions for 100% recyclable end products
Recycling starts with smart material choices.
Today, many products, from artificial grass to carpets and upholstery fabrics, still consist of different layers and materials. This makes recycling difficult, often even impossible.
Finipur offers a solution:
With our latest coating technology based on PES and polyolefin water dispersion, we create a single-material end product. Both the substrate and the coating consist of the same base material, making the product perfectly recyclable without any loss of quality. To realise this vision, we use advanced technologies with water-based polyolefin dispersion. This dispersion combines the performance characteristics of thermoplastic polyolefins with the processability of water-based systems.
đź’ˇ Why this is a game changer:
âś… One material = 100% recyclable
âś… Same production processes remain usable
âś… No need for expensive separation steps during recycling
âś… Applicable in grass, carpet, upholstery fabric, automotive & more
Where PVA or SBR latex used to be used (coatings that make recycling difficult), we are now switching to polyolefin dispersions that are compatible with the substrate. The result is a more sustainable product that is ready for the circular economy.
Trend in laminating & mono-material constructions
The trend is also clear in laminates (carpets, upholstery fabrics, artificial grass, automotive interiors): away from layered structures with multiple materials and towards end products consisting of a single material family. At Finipur, we can use our various lamination techniques to bond different substrates from the same material family into a single whole.
The need for circular production in Flanders - Europe
We are currently in a time when sustainability is no longer an option but a necessity. As a result, the coatings, carpets, upholstery fabrics, laminates and other industries are undergoing a clear transformation. At Finipur, we are closely following this trend and offering our customers technologies and solutions that help us design products using a single homogeneous material. This homogeneous material replaces the traditional “substrate + coating made from different materials” approach. In this article, we take a closer look at why this is relevant, which technologies make it possible and how the trend towards mono-material constructions is developing.
What do we mean by “mono-material”?
Historically, end products such as artificial turf, carpets, upholstery fabrics or other coated textiles have been constructed from multiple materials: a substrate (e.g. a woven or non-woven base) made of material A, a coating or latex layer of material B (e.g. PVA, SBR) on top of that, and sometimes even an intermediate layer or laminate of material C. This results in a complex structure consisting of different materials. This complex structure poses considerable challenges:
- At the end of its life, the waste/recycling stream must separate multiple materials mechanically or chemically.
- When materials are strongly laminated or bonded together, separating the different materials is technically difficult or even economically unfeasible.
- The presence of different types of plastic (or plastic + paper/aluminium) complicates sorting in the waste chain and reduces the quality of the recyclate.
In practice, this means that many such composite products are not recycled, or hardly recycled at all, which is contrary to circular objectives.
Technology in the spotlight: polyolefin water dispersions
The technology that makes this transformation possible is water-based polyolefin dispersion. This type of product illustrates how coating technology is evolving towards high performance and recyclability. Some key points:
- Relevant properties: good heat resistance, chemical and water resistance, flexibility at lower temperatures and the fact that the dispersion is solvent-free
- Why this is relevant for recycling: by choosing polyolefin dispersions in combination with a substrate that also belongs to the polyolefin family, Finipur's coating and the substrate will ultimately form the same material group. This makes recycling a lot easier.
At Finipur, this means we can support customers who want to switch to systems in which the substrate and coating are compatible, not only from a technical point of view, but also in terms of service life and end-of-life management or recycling.
Practical applications: artificial grass, carpets, upholstery fabrics & automotive
At Finipur, we translate this vision into concrete opportunities for customers in segments such as artificial turf, carpets, upholstery fabrics and automotive. Below is how we approach this:
- Selection of substrate and coating
– We analyse whether the substrate material (e.g. woven/non-woven) already belongs to a plastic group that is compatible with a polyolefin dispersion.
– We then select a coating/dispersion that matches the substrate in terms of material family, so that the end product comes from a single material family. - Processing
– Because the coating is water-based, it can often be integrated into existing coating or latex lines, provided it is correctly configured.
– The application requires attention to adhesion, drying, coating weight and compatibility. At Finipur, we can provide technical support in this regard.
– Finally, we provide quality control and validation to ensure that the end product delivers the same or better performance than the original conventional solutions. - End product and recycling profile
– Result: an end product consisting of a single material, which greatly simplifies separation at the end of its life.
– This makes sorting and recycling more efficient, reduces waste streams and improves the circular footprint of your product. - Market position & future-proofing
– Customers who invest in these systems now are at the forefront of sustainability commitments and can leverage this in their marketing and positioning.
– As mentioned earlier, innovations such as these are currently often a more expensive solution than conventional coatings, but their life cycle value (brand, recycling, compliance) is significantly higher.
Technical and commercial challenges
Every transition has its challenges, and this one is no different :
- Higher initial cost: Innovative dispersions and suitable substrates can be more expensive than traditional latex systems.
- Process adaptation: although many existing lines can be made compatible, technical adjustments (drying, adhesion, coating weight) are often necessary.
- Recycling infrastructure: Simply choosing mono-materials is an important step, but it is only effective if local sorting/recycling flows support this.
- Performance comparison: When switching, it is essential that the performance of the coating + substrate (durability, wear resistance, UV resistance, aesthetics) is maintained or improved.
- Education & acceptance: Additional information is often needed, both internally and externally, to get stakeholders (production, design, marketing) on board with the transition.
Why choose Finipur as your partner in circular coating solutions?
At Finipur, we combine technical expertise, process knowledge and a forward-looking view of upcoming market transitions. We can help you with:
- Identifying suitable substrate-coating combinations that fit within the mono-material philosophy.
- Technical support during implementation, from laboratory-level test coating to industrial production.
- A partnership that is not just about product or coating delivery, but about a sustainable, long-term solution.
Conclusion: the way forward for Belgian producers and recyclers
The world is changing. Coating and lamination systems as we knew them until recently, which were made up of multiple materials, are under pressure: recycling requirements, consumer expectations and market dynamics are driving a clear direction: one material instead of several. Technological breakthroughs such as water-based polyolefin dispersions make this possible. Finipur is ready to take that step with you: towards end products that are technically excellent, sustainable and circular. Are you active in textile coating, artificial turf, furniture fabrics or laminates? Do you have a project in which you would like to explore this approach? Contact us today and let's innovate together... and produce circularly.
Ready to discover the right solution for your product?