At Royalty, we care about the environment and take great strides to be an environmentally conscientious manufacturer. From water and waste reclamation, energy co-generation and heat recycling to reduced atmospheric emissions and indoor air quality, we are dedicated to the manufacture of quality carpet, while ensuring we do not harm our environment in the process. Please see our environmental page for more details on our environmental efforts.
Royalty’s success continues as we strive to maintain our small company atmosphere, while staying close to our family of customers. We will continue to focus on the three areas that have helped sustain Royalty’s consistent growth: quality products, unsurpassed service and exceptional value.
The following are just some of the many ways that Royalty Carpet Mill’s is working for a better tomorrow…
In 1996 Royalty Carpet Mills became one of the first businesses in Irvine, CA to connect to the city’s then newly-created reclaimed water distribution system. By using approximately 600,000 gallons of reclaimed water in the dyeing and manufacturing processes daily, we save over 150 million gallons of water per year. For this effort, we received the “Water Winner Award” from the Irvine Ranch Water District.
Reclaimed Water Re-Use
During the dyeing process, the dyestuffs are almost completely absorbed by the carpet and the post dyeing water runs virtually clear. We further clean it in a de-fuzzing process designed to remove any remaining nylon fiber. It is then returned to the Water District’s reclaimed water distribution system for further industrial use. Thus, the reclaimed water is used again and again for non-consumer purposes in a closed-loop environment.
A move that helped pioneer a new technology in energy efficiency was the installation of one co-generation engine in 1993, and two more a few years later. From one clean burning fuel – natural gas – we create steam for the turbines that generate electricity for our manufacturing facilities. The steam is then re-used to heat water for our dyeing equipment. Thus, one fuel source yields two types of energy – electrical and thermal. By generating our own electricity, we reduce demand on the local public utility company and the regional power grid. Another key benefit is that natural gas creates as little as one-twentieth the emissions of the coal or oil traditionally used to generate the electricity alone.
Heat recycling technology also came to us in the multimillion dollar modernization of our finishing line, which became operational in January 1997. The new system dramatically reduces energy use and eliminates tons of air emissions per year.
Historically, Royalty has been proactive in implementing environmental safeguards and in surpassing all environmental compliance regulations. In fact, we were named a “Clean Air Partner” with the South Coast Air Quality Management District (among the strictest environmental regulatory agencies in the USA) for achieving the 2004 target levels for NO2 (nitrous oxide) emissions This was all done five years ahead of schedule.
Indoor Air Quality Protection
All Royalty products exceed the “Green Label Plus” specifications for low emission of volatile organic compounds (VOCs) established by the Carpet and Rug Institute, by using the lowest VOC materials available in the backing process. Qualifying for this testing program means that we are committed to developing ways to minimize any adverse effects on indoor air quality.
Reclamation of Soft Waste
Nylon sheared from the surface pile of carpet as it goes through the finishing process is aggressively vacuumed as it is sheared. The nylon is then collected, bagged and sold to be melted down and used in the manufacture of automotive parts. This reduces the demand for virgin raw materials made from petroleum, one of the world’s most critical non-renewable resources.
Reclamation of Hard Waste
Hard waste from manufacturing, primarily factory-trimmed pieces or finished carpet which includes nylon fiber, the polypropylene backings, and the latex binder, has recently found new life. In a newly developed process, the waste is heated and pulverized to a grainy consistency, then used as a binder in asphalt paving projects. Other technologies are turning this scrap into mix-plastic materials for under-hood automotive applications, or as a substitute for gypsum drywall.
Carpet America Recovery Effort
Royalty was recently presented the Corporate Sponsor Award from the Carpet and Rug Institute – “In Recognition of your Support, Dedication and Leadership in the Development of Market-Based Solutions for the Recycling and Re-use of Post Consumer Carpet”.
Recycling in our Manufacturing Plants and Corporate Offices
- Scrap metal left over from the repair or retrofitting of equipment is sent to a metal recycler.
- The hard cardboard cones used to hold yarn during the tufting process are all sent back to our yarn processing plant to be reused.
- Carpet cores are used over and over as carpet are rolled and unrolled during the various stages of manufacturing.
- Cardboard boxes used in yarn transport are broken down and sent back to the yarn plant for repeat use.
- Water for pump seal cooling is re-circulated in a closed-cycle system.
- Shrink-wrap used in bundling yarn shipments is reprocessed in much the same way supermarket bags are turned into new packaging.
- Paper waste from office use is collected separately from other waste and is recycled.
- Special bins in lunch and break areas have been set aside to collect aluminum cans and plastic bottles for recycling.
- Dedicated preferred parking spots and other employee incentives have been established to encourage carpooling to reduce traffic and pollution.
- Plant hours have been arranged so that shift changes, and the resulting impact on local traffic, occur at non-peak hours.
- We use electric lift trucks in all manufacturing and shipping areas.
- All offices and plants are smoke-free zones.
- We use super granulated dyestuffs to eliminate dusting.
- Complete spill recovering procedures are in effect.
- Royalty provides used cardboard drums to local chemical suppliers for re-use, or uses returnable totes and drums.
- We return all used motor and machine oil for safe disposal.
- We are an active, participating member of the CRI West Coast Technical Committee, promoting and pushing for reform on many environmental issues, including use of recycled water, the Title V Clean Air Act, carpet recycling, scrim waste disposal and indoor air quality.
- Royalty works hand-in-hand with suppliers to educate them on California’s environmental standards, thereby encouraging suppliers to also promote good environmental practices.