Flatbed Mat Washing

Why change the current way of cleaning mats ?

Mats have a nylon, polyester, cotton or polyester/cotton top and rubber backing.
The rubber backing 60-70% of the mat weight, needs to be strong and flexible to withstand industrial washing and drying.
The flexible backing makes mats move (walk) over the floor under certain conditions, for example shopping carts.
Rippled borders are an industry wide problem, the number 1 cause for a low lifetime. (average 4-6 years, used to be 8-10 years in the past) Ripples are a trip hazard and too many rippled mats are placed at customer locations. (reason costs ??)
Drying mats consumes the most energy, even when using recovered heat.
Rubber being 60-70% of the weight absorbs lots of energy. This is wasted energy !

The current way of washing and drying needs the highest quality rubber to withstand the harsh washing and drying.
The use of recycled content in rubber is not possible, this brings down quality and lifetime.
Recycled content can only be used in the textile part. (Econyl Nylon 6)
Recycled polyester has a too short lifetime, is unable to withstand industrial wash/dry.
Rubber contains virgin carbon black (made by burning oil) Zinc oxide, not eco friendly.
Most current mat manufacturers use a 100% polyester non woven primary backing for tufting yarn on. When yarn and rubber can be separated for recycling (under testing) this (high polyester content) prevents the depolymerization / reuse of nylon to make new nylon for mats (econyl)

Solutions

No need for gas, green generated electricity for co2 neutral cleaning can be used.
Water and energy consumption far lower than current way of washing.(inline with EU Green Deal)
Almost no mechanical action on the rubber as mats are cleaned flat.
The rubber no longer needs to withstand industrial washing, just flat washing.
The use of recycled content in the rubber would be possible, rubber from recycled mats can be used.
Shrinkage of current mats is delayed using this wash process, even current mats will last far longer.

Using our new modified primary backing we can reduce carpet shrinkage (current non woven) from 3-4% to less than 0.5% making mats last even longer.
Current mats are flexible in order to be washed, small carts make them move, they are too flexible. When washed flat, mats can be less flexible, reducing movement on the floor thus increasing performance and safety.
Using a different carpet construction, the new way of cleaning can be optimized.
Cleaning performance of the new construction will be better than current mats.
Instead of big centralized laundries, machines can be placed in distribution centers, reducing logistical cost. (extra co2 saving)