146 INTERVIEW A thread of genius Aquafil’s Born R2R project creates fully recyclable carpets, reducing waste, while championing circularity within the maritime industry. Cristina Stefani tells Laura Hyde more Regenerated nylon manufacturer Aquafil predicts its new Born R2R (Regenerated to be Regenerable) project will redefine how carpets for cruise ships and ferries are designed and recovered at the end of their lifecycle. “The Born R2R project was created to tackle a critical issue: the vast amount of carpet waste generated by cruise ships, ferries and other vessels, which typically ends up in landfill or incinerators due to the complexity of separating materials for recycling and the lack of both recycling facilities and reverse logistics infrastructure,” says Cristina Stefani, marketing manager for circularity projects at Aquafil. “We’re not a carpet manufacturer; we produce ECONYL, a nylon fibre which is 100 per cent made from discarded fishing nets, fabric scraps and industrial waste, and can be regenerated indefinitely. As such, the project requires close collaboration with carpet manufacturers to ensure every component, from fibres to adhesives, is compatible with our ECONYL regeneration system. We’ve also worked with carpet manufacturers to ensure the Born R2R carpets are certified by the International Maritime Organization.” Born R2R carpets have been designed with sustainability embedded at every stage, from material sourcing to end-oflife management. “Born R2R carpets have been designed with a ‘lifecycle thinking’ approach in mind,” explains Stefani. “Using ECONYL as a main ingredient for the pile enables us to significantly reduce reliance on crude oil derivates resources, as well as lower carbon emissions associated with raw material extraction oil. When installed and in use, Born R2R carpets maintain the same, if not better, durability and aesthetic appeal as conventional options. However, the true impact of lifecycle thinking becomes evident when they reach the end of life. Unlike traditional carpets, Born R2R products are designed for easy disassembly, allowing different components to be efficiently separated and recycled.” The lifespan of Born R2R carpets depends on several factors, including the area of installation and usage intensity, maintenance practices, maritime conditions and individual cruise lines’ choices and policies. However, depending on traffic levels and environmental exposure, Born R2R carpets have the same five to 10-year lifespan as conventional carpets, but offer the added benefit of long-lasting performance which reduces the need for frequent replacements. “Born R2R carpets do not entail higher costs compared to standard carpets,” says Stefani. “The R2R Bloom Back by Marine – used in our initial installations – features a polyamide backing that allows for direct adhesion to the subfloor, eliminating the need for an additional underlay. This not only reduces installation costs but also enhances sustainability. Moreover, at the end of their lifecycle, disposal costs are significantly lower because the carpets will be dismantled and sent for recycling at Aquafil premises.” Born R2R carpets were pilot tested in autumn 2023 onboard AIDA Cruises’ ship AIDAsol. All crew areas were refitted with carpet made by Radici R2R carpet
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