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Re-Start ofEvergreen Nylon Recycling

Shaw Industries, Inc.

Re-Start ofEvergreen Nylon Recycling

Shaw Industries, Inc.

2006 CARE ConferenceMay 3, 2006

Russ DeLozier(706) 275-4134

2006 CARE Conference2006 CARE ConferenceMay 3, 2006May 3, 2006

Russ DeLozierRuss DeLozier(706) 275(706) 275--41344134

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Nylon RecyclingNylon Recycling

• Ev·er·green (ev’ er-gren)Adjective:

• Something that remains perennially fresh, interesting, or well liked.

•• EvEv··erer··greengreen ((evev’’ erer--grengren))Adjective:Adjective:

•• Something that remains perennially fresh, Something that remains perennially fresh, interesting, or well liked. interesting, or well liked.

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Evergreen Closed Loop RecyclingEvergreen Closed Loop Recycling

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Evergreen Nylon Recyclinginitially a JV between Honeywell & DSMEvergreen Nylon Recyclinginitially a JV between Honeywell & DSM

• Started in late 1999• Shut down in Sept 2001

• Poor economics for caprolactam (monomer for N6)

• Plant’s inability to operate at full rate

•• Started in late 1999Started in late 1999•• Shut down in Sept 2001Shut down in Sept 2001

•• Poor economics for caprolactam Poor economics for caprolactam (monomer for N6)(monomer for N6)

•• PlantPlant’’s inability to operate at full rates inability to operate at full rate

PC Carpet Collection not the issue!PC Carpet Collection not the issue!PC Carpet Collection not the issue!

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Shaw is restarting EvergreenShaw is restarting Evergreen

• Facility located in Augusta, GA• Responsibilities

• DSM operates the process• Shaw provides N6 PC & PI feed supply

• Shaw owns 100% of the Evergreen asset• Plant restart will include a Life Cycle Analysis

•• Facility located in Augusta, GAFacility located in Augusta, GA•• ResponsibilitiesResponsibilities

•• DSM operates the processDSM operates the process•• Shaw provides N6 PC & PI feed supplyShaw provides N6 PC & PI feed supply

•• Shaw owns 100% of the Evergreen assetShaw owns 100% of the Evergreen asset•• Plant restart will include a Life Cycle AnalysisPlant restart will include a Life Cycle Analysis

Shaw will own 100% of recovered CaprolactamShaw will own 100% of recovered Shaw will own 100% of recovered CaprolactamCaprolactam

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Status of Evergreen Nylon Recycling PlantStatus of Evergreen Nylon Recycling Plant

• DSM identified substantial process improvements• DSM’s plant idle procedures were very thorough –

system integrity and recovery has gone very good• Shaw is investing significant funding to implement

improvements

•• DSM identified substantial process improvementsDSM identified substantial process improvements•• DSMDSM’’ss plant idle procedures were very thorough plant idle procedures were very thorough ––

system integrity and recovery has gone very goodsystem integrity and recovery has gone very good•• Shaw is investing significant funding to implement Shaw is investing significant funding to implement

improvementsimprovements

Resulting process more Flexible and Robust!Resulting process more Flexible and Robust!Resulting process more Flexible and Robust!

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Evergreen Nylon Recycling PlantEvergreen Nylon Recycling Plant

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Operational TargetsOperational Targets

• 30MM ppy of world class Caprolactam• Requires approx 100M ppy of N6 PC carpet

• Plant will startup when all systems are fully functional. No targets published until full assessments are complete

• Since 2001, a great deal of development in PCC Collection has occurred• ENR’s use of N6 PCC is believed to aid the supply/demand

balance of all fiber types• Quality and purity of the N6 stream are extremely important!

•• 30MM ppy of 30MM ppy of world classworld class CaprolactamCaprolactam•• Requires approx 100M ppy of N6 PC carpetRequires approx 100M ppy of N6 PC carpet

•• Plant will startup when all systems are fully functional. No Plant will startup when all systems are fully functional. No targets published until full assessments are completetargets published until full assessments are complete

•• Since 2001, a great deal of development in PCC Collection has Since 2001, a great deal of development in PCC Collection has occurredoccurred•• ENRENR’’ss use of N6 PCC is believed to aid the supply/demand use of N6 PCC is believed to aid the supply/demand

balance of all fiber typesbalance of all fiber types•• Quality and purity of the N6 stream are extremely important!Quality and purity of the N6 stream are extremely important!

Shaw seeking serious suppliers Shaw seeking serious suppliers Shaw seeking serious suppliers

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Shaw’s Collection SupportShaw’s Collection Support

• Patented Sorting Technology• Diversity of vertical integrated carpet industry leader• Distribution and Transportation Network• Regional presence facilitates reverse-logistics

•• Patented Sorting TechnologyPatented Sorting Technology•• Diversity of vertical integrated carpet industry leaderDiversity of vertical integrated carpet industry leader•• Distribution and Transportation NetworkDistribution and Transportation Network•• Regional presence facilitates reverseRegional presence facilitates reverse--logisticslogistics

Economies of ScaleEconomies of ScaleEconomies of Scale

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Feed Stock RequirementsFeed Stock Requirements

• Quality > 98% N6 PC carpet• Level loop / cut pile expected at ENR• No N66, Urethane material to ENR• No tiles to ENR, but EcoWorx N6 stream is OK

• A formal quality program in place• Extensive testing at supplier & ENR

• Utilize CarPIDs for supplier sorting

•• Quality > 98% N6 PC carpetQuality > 98% N6 PC carpet•• Level loop / cut pile expected at ENRLevel loop / cut pile expected at ENR•• No N66, Urethane material to ENRNo N66, Urethane material to ENR•• No tiles to ENR, but No tiles to ENR, but EcoWorxEcoWorx N6 stream is OKN6 stream is OK

•• A formal quality program in placeA formal quality program in place•• Extensive testing at supplier & ENRExtensive testing at supplier & ENR

•• Utilize CarPIDs for supplier sortingUtilize CarPIDs for supplier sorting

Must build quality into every bale!Must build quality into every bale!Must build quality into every bale!

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CARE instrumental in Re-startCARE instrumental in Re-start

• Shaw is very please to enter into this great effort• Sustainability by design vs. regulation

• CARE will help maintain focus on all aspects of recycling:• Market driven solutions• Outlets for all products• Identification of serious suppliers• Recognition of product / process improvements

•• Shaw is very please to enter into this great effortShaw is very please to enter into this great effort•• Sustainability by design vs. regulationSustainability by design vs. regulation

•• CARE will help maintain focus on all aspects of CARE will help maintain focus on all aspects of recycling:recycling:•• Market driven solutionsMarket driven solutions•• Outlets for all productsOutlets for all products•• Identification of serious suppliersIdentification of serious suppliers•• Recognition of product / process improvementsRecognition of product / process improvements

CRI/CARE support CRITICAL toachieving sustainability

CRI/CARE support CRITICAL toCRI/CARE support CRITICAL toachieving achieving sustainabilitysustainability

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SummarySummary

• Shaw IS re-starting Evergreen•• Shaw IS reShaw IS re--starting Evergreenstarting Evergreen

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ChallengeChallenge

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SummarySummary

• Shaw IS re-starting Evergreen• Evergreen is a Closed-Loop process• Collection wasn’t the issue last time…it won’t be this time• Plant upgrades will make process more flexible and robust• Shaw will own 100% of caprolactam product• Shaw actively starting to collect…seeking serious

collectors• Quality is essential• CARE is vital part of the process!

•• Shaw IS reShaw IS re--starting Evergreenstarting Evergreen•• Evergreen is a ClosedEvergreen is a Closed--Loop processLoop process•• Collection wasnCollection wasn’’t the issue last timet the issue last time……it wonit won’’t be this timet be this time•• Plant upgrades will make process more flexible and robustPlant upgrades will make process more flexible and robust•• Shaw will own 100% of Shaw will own 100% of caprolactamcaprolactam productproduct•• Shaw actively starting to collectShaw actively starting to collect……seeking serious seeking serious

collectorscollectors•• Quality is essentialQuality is essential•• CARE is vital part of the process!CARE is vital part of the process!

Let’s have a great time!LetLet’’s have a great time!s have a great time!

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Waste-to Energy and Other Shaw

Environmental Initiatives

Waste-to Energy and Other Shaw

Environmental Initiatives

2006 CARE ConferenceMay 3, 2006

Steve Bradfield

2006 CARE Conference2006 CARE ConferenceMay 3, 2006May 3, 2006

Steve BradfieldSteve Bradfield

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Carpet Gasification Unit in Dalton, GACarpet Gasification Unit in Dalton, GA

• Partnership with Siemens Building Automation & Technology

• Clark Wiedetz, Business Dev Mgr for Energy & Environ Solutions

• First gasification facility in carpet industry• Will provide 50,000 lbs/ hr. of steam to Plant 81 dyeing operations• Designed to utilize up to 16,000 tons/yr carpet waste and 6000 tons/yr

of wood flour from laminate operations• Primary steam source for plant allows reduced use of coal-fired boilers• Savings of over $1 million/ yr. (avoids volitility of natural gas prices)

• Served by Shaw PC Carpet Collection System• Gets Shaw largely out of Dalton landfill and will also utilize PC carpet

waste

• Featured in WSJ article and CNBC video

•• Partnership with Siemens Building Automation & TechnologyPartnership with Siemens Building Automation & Technology

•• Clark Clark WiedetzWiedetz,, Business Dev Mgr for Energy & Environ SolutionsBusiness Dev Mgr for Energy & Environ Solutions

•• First gasification facility in carpet industryFirst gasification facility in carpet industry•• Will provide 50,000 lbs/ hr. of steam to Plant 81 dyeing operatiWill provide 50,000 lbs/ hr. of steam to Plant 81 dyeing operationsons•• Designed to utilize up to 16,000 tons/yr carpet waste and 6000 tDesigned to utilize up to 16,000 tons/yr carpet waste and 6000 tons/yr ons/yr

of wood flour from laminate operationsof wood flour from laminate operations•• Primary steam source for plant allows reduced use of coalPrimary steam source for plant allows reduced use of coal--fired boilersfired boilers•• Savings of over $1 million/ yr. (avoids Savings of over $1 million/ yr. (avoids volitilityvolitility of natural gas prices)of natural gas prices)

•• Served by Shaw PC Carpet Collection SystemServed by Shaw PC Carpet Collection System•• Gets Shaw largely out of Dalton landfill and will also utilize PGets Shaw largely out of Dalton landfill and will also utilize PC carpet C carpet

wastewaste

•• Featured in WSJ article and CNBC videoFeatured in WSJ article and CNBC video

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Carpet Gasification Unit in Dalton, GAEnvironmental Benefits

Carpet Gasification Unit in Dalton, GAEnvironmental Benefits

• Gasification leaves greenhouse gas pollutants in the ash as synthetic gas liberated for combustion.

• Expect emissions profile similar to natural gas

• Carpet waste has same pound for pound BTU range as coal• Nearing end of final testing phase. Fully operational.• Plans to extend technology to other Shaw locations that may

include cogeneration.• Enhances efficiency and lowers cost of PC carpet collection

• Important step in recovering energy value, collecting all carpet types, and providing access to sorted materials for higher value uses.

• Transitional strategy in Shaw’s cradle to cradle efforts.

•• Gasification leaves greenhouse gas pollutants in the ash as Gasification leaves greenhouse gas pollutants in the ash as synthetic gas liberated for combustion.synthetic gas liberated for combustion.

•• Expect emissions profile similar to natural gasExpect emissions profile similar to natural gas

•• Carpet waste has same pound for pound BTU range as coalCarpet waste has same pound for pound BTU range as coal•• Nearing end of final testing phase. Fully operational.Nearing end of final testing phase. Fully operational.•• Plans to extend technology to other Shaw locations that may Plans to extend technology to other Shaw locations that may

include cogeneration.include cogeneration.•• Enhances efficiency and lowers cost of PC carpet collectionEnhances efficiency and lowers cost of PC carpet collection

•• Important step in recovering energy value, collecting all carpetImportant step in recovering energy value, collecting all carpet types, types, and providing access to sorted materials for higher value uses.and providing access to sorted materials for higher value uses.

•• Transitional strategy in ShawTransitional strategy in Shaw’’s cradle to cradle efforts.s cradle to cradle efforts.

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EcoWorx Carpet TileEcoWorx Carpet Tile

• Introduced in 1999• Market success allowed Shaw to completely exit PVC by end of

2004.• Fastest growing part of Shaw’s business• Presidential Green Chemistry Award 2003 • Design For Sustainability Award from Society of Plastics

Engineers 2006• Every backing and nylon 6 input over 100 ppm tested and

optimized under MBDC toxicity protocol for human and environmental health and safety.

• Supply chain energy 3x lower than the Permabac PVC product it replaced, with 30% reduction in backing mass (3rd party LCI)

•• Introduced in 1999Introduced in 1999•• Market success allowed Shaw to completely exit PVC by end of Market success allowed Shaw to completely exit PVC by end of

2004.2004.•• Fastest growing part of ShawFastest growing part of Shaw’’s businesss business•• Presidential Green Chemistry Award 2003 Presidential Green Chemistry Award 2003 •• Design For Sustainability Award from Society of Plastics Design For Sustainability Award from Society of Plastics

Engineers 2006Engineers 2006•• Every backing and nylon 6 input over 100 Every backing and nylon 6 input over 100 ppmppm tested and tested and

optimized under MBDC toxicity protocol for human and optimized under MBDC toxicity protocol for human and environmental health and safety.environmental health and safety.

•• Supply chain energy 3x lower than the Supply chain energy 3x lower than the PermabacPermabac PVC product it PVC product it replaced, with 30% reduction in backing mass (3replaced, with 30% reduction in backing mass (3rdrd party LCI)party LCI)

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EcoWorx Carpet Tile CollectionEcoWorx Carpet Tile Collection

• Utilizes same PC collection system as Evergreen and WTE• PC thermoplastic polyolefin backing and nylon 6 fiber separated

mechanically in Cartersville, GA• Backing fraction sized and returned to EcoWorx backing

extrusion.• Nylon 6 fraction to be “campaigned” at Evergreen to recover

EcoWorx co-product. (No compatibility issues.) • “Campaigning” important for recovery of EcoWorx broadloom

now under development. Same backing and fiber pathways as tile.

• EcoWorx limited to PI content until first generation polymer returned under Shaw “Environmental Guarantee”. Significant PC returns expected to begin in 2009.

•• Utilizes same PC collection system as Evergreen and WTEUtilizes same PC collection system as Evergreen and WTE•• PC thermoplastic polyolefin backing and nylon 6 fiber separated PC thermoplastic polyolefin backing and nylon 6 fiber separated

mechanically in Cartersville, GAmechanically in Cartersville, GA•• Backing fraction sized and returned to EcoWorx backing Backing fraction sized and returned to EcoWorx backing

extrusion.extrusion.•• Nylon 6 fraction to be Nylon 6 fraction to be ““campaignedcampaigned”” at Evergreen to recover at Evergreen to recover

EcoWorx coEcoWorx co--product. (No compatibility issues.) product. (No compatibility issues.) •• ““CampaigningCampaigning”” important for recovery of EcoWorx broadloom important for recovery of EcoWorx broadloom

now under development. Same backing and fiber pathways as now under development. Same backing and fiber pathways as tile.tile.

•• EcoWorx limited to PI content until first generation polymer EcoWorx limited to PI content until first generation polymer returned under Shaw returned under Shaw ““Environmental GuaranteeEnvironmental Guarantee””. Significant PC . Significant PC returns expected to begin in 2009.returns expected to begin in 2009.

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Cradle to Cradle RedesignCradle to Cradle Redesign

• EcoWorx broadloom will offer a sustainable thermoplastic high performance broadloom

• with high tuft bind unaffected by water• with pattern match and recovery similar to SBR latex• with lightest high performance broadloom weight• with same collection and recycling system as SBR broadloom, but

“campaigned” backing recovered for reuse in tile.

• EcoLogix polyester cushion backing for tile• Produced in acquired Synthetic Industries facility• High PC recycled content from “Sprite” bottles• Laminated to greige goods with EcoWorx polymer• Working toward delamination technology to allow recycling

•• EcoWorx broadloom will offer a sustainable thermoplastic high EcoWorx broadloom will offer a sustainable thermoplastic high performance broadloom performance broadloom

•• with high tuft bind unaffected by waterwith high tuft bind unaffected by water•• with pattern match and recovery similar to SBR latexwith pattern match and recovery similar to SBR latex•• with lightest high performance broadloom weightwith lightest high performance broadloom weight•• with same collection and recycling system as SBR broadloom, but with same collection and recycling system as SBR broadloom, but

““campaignedcampaigned”” backing recovered for reuse in tile.backing recovered for reuse in tile.

•• EcoLogixEcoLogix polyester cushion backing for tilepolyester cushion backing for tile•• Produced in acquired Synthetic Industries facilityProduced in acquired Synthetic Industries facility•• High PC recycled content from High PC recycled content from ““SpriteSprite”” bottlesbottles•• Laminated to Laminated to greigegreige goods with EcoWorx polymergoods with EcoWorx polymer•• Working toward Working toward delaminationdelamination technology to allow recyclingtechnology to allow recycling

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Other Environmental Developments:EMS Program

Other Environmental Developments:EMS Program

• Shaw began certification of its manufacturing facilities under an ISO 14001 compliant self-certification program in January of 2005.

• New EMS called Shaw Environmental System (SES),builds on Shaw ISO 9001 compliant quality management system (SQS).

• Shaw will have 52 manufacturing facilities certified or scheduled for certification by the end of 2006. (52 mfg facilities in 24 months)

• Plant 15, carpet tile facility, scheduled for third-partycertification by BSI as a system check for SES.

•• Shaw began certification of its manufacturing facilities under aShaw began certification of its manufacturing facilities under an n ISO 14001 compliant selfISO 14001 compliant self--certification program in January of certification program in January of 2005.2005.

•• New EMS called Shaw Environmental System (SES),builds on New EMS called Shaw Environmental System (SES),builds on Shaw ISO 9001 compliant quality management system (SQS).Shaw ISO 9001 compliant quality management system (SQS).

•• Shaw will have 52 manufacturing facilities certified or scheduleShaw will have 52 manufacturing facilities certified or scheduled d for certification by the end of 2006. (52 mfg facilities in 24 for certification by the end of 2006. (52 mfg facilities in 24 months)months)

•• Plant 15, carpet tile facility, scheduled for thirdPlant 15, carpet tile facility, scheduled for third--partypartycertification by BSI as a system check for SES.certification by BSI as a system check for SES.

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Industry Environmental IssuesIndustry Environmental Issues

• Suggested recycled content incentives under CARE. Direct insertion and discussion of equivalence of mass balance (averaging).

• Particularly important for solution dyed fiber recycled content claims that vary by color.

• Important for tracking the molecular level blending of caprolactam found in Evergreen and other carpet materials where direct insertion tracking problematic.

• Linking “credits” to market value (i.e. the same conditions approved for carbon credits applied to recycled materials)

• Application to CARE, LEED, and SCAS.

• Reporting of multiple environmental impacts on a standard spiderdiagram format to show comparative impact reductions in addition to recycled content.

• Provide a more complete environmental snapshot without de-emphasizing CARE goals.

• Show effects of recycled carpet materials kept out of landfills, but recycled into noncarpet products.

• Create a single industry report card that incorporates CARE’s mission.

•• Suggested recycled content incentives under CARE. Direct insertSuggested recycled content incentives under CARE. Direct insertion ion and discussion of equivalence of mass balance (averaging).and discussion of equivalence of mass balance (averaging).

•• Particularly important for solution dyed fiber recycled content Particularly important for solution dyed fiber recycled content claims that vary by claims that vary by color.color.

•• Important for tracking the molecular level blending of caprolactImportant for tracking the molecular level blending of caprolactam found in am found in Evergreen and other carpet materials where direct insertion tracEvergreen and other carpet materials where direct insertion tracking problematic.king problematic.

•• Linking Linking ““creditscredits”” to market value (i.e. the same conditions approved for carbon to market value (i.e. the same conditions approved for carbon credits applied to recycled materials)credits applied to recycled materials)

•• Application to CARE, LEED, and SCAS.Application to CARE, LEED, and SCAS.

•• Reporting of multiple environmental impacts on a standard spiderReporting of multiple environmental impacts on a standard spiderdiagram format to show comparative impact reductions in additiondiagram format to show comparative impact reductions in addition to to recycled content.recycled content.

•• Provide a more complete environmental snapshot without deProvide a more complete environmental snapshot without de--emphasizing CARE emphasizing CARE goals.goals.

•• Show effects of recycled carpet materials kept out of landfills,Show effects of recycled carpet materials kept out of landfills, but recycled into but recycled into noncarpetnoncarpet products.products.

•• Create a single industry report card that incorporates Create a single industry report card that incorporates CARECARE’’ss mission.mission.

Not just Green,

EVERGREEN

Recycling

Post-consumer

Carpet CAREStewardship

Environmental

Caprolactam

Recovery

Closed

Loop Recycling

EVERGREEN NYLON RECYCLING

Nylon 6

EVERGREEN NYLON RECYCLING

Sustainable

.