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The key adaptation, however, was transforming the backing. The CO2-infused latex, which is sprayed on the carpet’s middle layer, was a helpful step. Second, by obtaining its materials from different sources - and using them in smaller amounts - Interface could further shrink its footprint. First, by reducing its emissions and using mostly recycled materials, its tiles could approach carbon neutrality. Over the next two decades, the company learned a couple of things. It was more like coming up with a recipe involving hundreds, if not thousands, of changes to ingredients and techniques. Pushing an Interface product to below zero, at least in carbon terms, was not about a big breakthrough, Bradford pointed out. The company began using recycled components for the backing, filler and yarns, and the factories were refitted with machines that were more efficient. “So, when you start to go from where Interface was in the 1990s, which was 20 kilograms per square meter, and subsequently make progress to get it to 12, then to nine, then to six, and now to get it to negative, the biggest levers we pulled were making the raw materials different,” Meezan told me. Most of these emissions - probably more than 70 percent - resulted from materials and processing, and a lesser portion from manufacturing, installation and maintenance (all that cleaning and vacuuming over the course of a carpet’s life adds up to significant CO2 emissions). In the mid-1990s, Interface calculated the carbon footprint of these layers and concluded that a square meter of the sandwich was responsible for releasing about 20 kilograms worth of CO2 into the atmosphere. Industrial carpet tile can be thought of as a kind of three-layer sandwich, made from tufting on top, filler in the middle and backing on the bottom. Things quieted down only when we visited the company’s design center: From floor to ceiling, in aisles resembling a supermarket that sold color rather than food, were huge spools of yarn, all recycled, in every conceivable hue. The noise was deafening as jumbo fabric shredders, extruders, hoppers and conveyors rumbled away. A short distance away, a recycling center the size of several gymnasiums was crowded with rows of fabric sacks overflowing with nylon filaments, rescued from factory trimmings, ready to be turned into the face cloth for new carpet. Some of the immense machinery, akin to blocklong newspaper presses, where hot sheets of vinylized carpet filler are rolled out, now runs at lower temperatures to save energy. Interface requires a detailed accounting of the company’s renewable energy sources, exhaust fumes, supply chains and waste streams. His work goes far beyond recycling, however. “We recycle every frigging thing,” he said. John Bradford, its chief science-and-technology officer, led me on a tour one afternoon as he explained the company’s reconfigured manufacturing processes. But the math does have a magical quality to it: In part because of how the carbon is sourced, carpeting a 10-feet-by-20-feet conference room, say, with these tiles can be seen as the equivalent of pulling roughly 12 pounds of carbon dioxide out of the atmosphere.įor decades, Interface has made most of its domestic carpets at a cluster of factories in LaGrange, Ga., about an hour southwest of Atlanta. “It’s not a magic material,” Erin Meezan, chief sustainability officer at Interface, told me recently. By Interface’s reckoning, the carpeting had a carbon footprint of negative 300 grams per square meter. And it had been manufactured in the least environmentally demanding way possible. It was topped and tufted with salvaged nylon. It incorporated a material made from recycled vinyl and processed vegetation it was infused with a latex created from smokestack exhaust. This carpeting was a result of four years of intensive research and development, according to Interface. Yet in their very composition, they were something new.
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How many miles had I walked on those carpets? When Interface sent me samples of its newest product earlier this year, at a glance they seemed banal, familiar: These were the marled gray patterns that cover the floors of airport terminals, corporate hallways and CVS pharmacies all over the world. The company, based in Atlanta, makes commercial flooring - carpet tiles, lightly napped, highly durable, easily overlooked in the commercial offices and educational facilities where they are mostly in use. You have probably set foot on Interface products. To hear more audio stories from publications like The New York Times, download Audm for iPhone or Android.