PureCycle to supply resin to Emerald Carpets

PureCycle Technologies Inc., Orlando, Florida, has announced a partnership with Emerald Carpets, a Dalton, Georgia-based manufacturer of trade show carpets.

As part of the partnership, Emerald signed a commercial supply agreement with the advanced recycler for approximately 5 million pounds per year of PureFive polypropylene (PP) resin. PureCycle says its PureFive Choice resin will be blended into Emerald’s existing fiber production, enabling the carpet maker to immediately exceed the current policy-mandated recycled content requirement in California. The partners say they qualified the resin for numerous applications and currently are testing additional applications to expand the portfolio offering.

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The companies say the partnership includes PureCycle recycling used trade show carpets from Emerald, designed to transform the material into purified fiber-grade recycled PP pellets. Successful recycling of the materials would allow Emerald to then manufacture new carpets out of the recycled PP, creating a carpet-to-carpet solution and allow Emerald to meet California’s recycled content requirements, which take effect in 2028.

Throughout 2025 and 2026, the companies say they plan to work together at their respective production facilities in Dalton, Georgia, and Ironton, Ohio, to develop, test and ultimately scale the process, anticipating the use of more than 5 million pounds annually, with the goal of delivering circular trade show carpets to the marketplace.

“We are thrilled to partner with PureCycle,” Emeral President Tom Boykin says. “Our commitment to circularity in our material procurement and use aligns perfectly with PureCycle’s mission, as well as our customers’ expectations. We believe using recycled polypropylene will help us create carpets that not only perform exceptionally well on the conference circuit but also contribute positively to resource efficiency and waste reduction.”

The companies say their partnership has experienced successful trials by Emerald using purpose-formulated PureFive Choice, including postconsumer recycled (PCR) material. They say the trial demonstrated the potential of high-performance carpets made with recycled PP content to meet the demands of trade show environments. They claim that, tradiationally, sourcing drop-in recycled PP for carpet production has been a challenge due to the complex nature of carpet fiber manufacturing and the limitations of mechanically recycled PP.

“Partnering with Emerald Carpets marks an important step toward advancing circularity in the carpet sector,” PureCycle CEO Dustin Olson says. “They are a trusted partner for many of the largest general contractors and special event producers in the trade show industry, and we see this as a great growth opportunity for PureCycle. As the carpet industry faces pressing sustainability challenges, our PureFive Choice resin offers a drop-in solution to create durable and environmentally friendly flooring options.”

Currently, PureCycle says PP represents a significant part of carpet fibers, with scarce alternatives.