Carpet, Broadloom, Tufted Carpet Tile, Underlay, Rug & Synthetic Turf Manufacturing HVAC Duct Guide

Why carpet manufacturing HVAC duct is its own engineering discipline

Carpet, broadloom, tufted carpet tile, underlay, rug, resilient flooring and synthetic turf manufacturing sits in a strange middle space between heavy industrial textile processing and consumer-grade finishing. The same plant will run a wool scouring line at 65 degrees Celsius and saturated humidity, a fibre opening hall full of explosive nylon, polyester or polypropylene dust at Kst 130 bar·m/s, a tufting line four to six metres wide producing 100 to 300 stitches per minute, a heat-set tunnel oven at 130-180 degrees Celsius firing on LPG or natural gas, a latex SBR back coating booth with styrene at 50 ppm STEL and butadiene at 1 ppm STEL, a thermoplastic polyurethane secondary back coater with MDI or TDI isocyanate at 0.005 ppm STEL — the killer in any flooring plant — a curing oven at 120-150 degrees Celsius, a shearing and trimming hall full of fine fibre lint, a packaging cell, and a finished-goods warehouse. Every one of those zones is a different duct material, a different velocity, a different hazardous-area classification, a different fire-protection regime and a different noise criterion. Specifying the whole plant with one ductwork specification is how a Godfrey Hirst-scale capital budget gets blown twice over.

The Australian context adds specific challenges. The Geelong corridor is the heart of Australian carpet manufacturing — Godfrey Hirst at Norlane and Pakenham in Victoria is the country's biggest carpet maker, owned by Mohawk Industries since 2018, producing broadloom, commercial and residential carpet across both natural and synthetic fibres. Cavalier Bremworth (the New Zealand parent of the legacy Feltex Carpets operation at Tottenham in Victoria) supplies the wool and wool-blend premium carpet trade. The legacy Beaulieu of Australia operation has since closed but its specifier base still drives replacement and warranty work across the residential market. Karndean Designflooring runs design and distribution out of Sydney and Melbourne for its luxury vinyl tile range. Tarkett Australia covers LVT, resilient flooring and sports flooring. Forbo Flooring Systems supplies linoleum and sheet vinyl. Polyflor and Armstrong Flooring cover commercial vinyl. Dunlop Flooring covers underlay. Interface Australia (with its global parent in Atlanta GA), Shaw Industries Australia, Milliken, Bentley Prince Street and Mohawk supply the commercial carpet tile trade. APT Asia Pacific Synthetic Turf, Polytan, TigerTurf, FieldTurf, Mondo and Conica polyurethane cover sport and athletic surface. SmartGrass, EnviroTurf, Australian Synthetic Lawn Pty Ltd and Synthetic Grass Pros cover the wider artificial-grass residential and commercial market. The Sydney Olympic Park complex, AAMI Park and the major school sports ovals are the headline synthetic-turf installations and the manufacturing supply chain runs through this same group.

Adjacent natural-fibre operators — Australian Wool Innovation, Mackies Carpet, Bremworth wool, Cavalier wool blend, MiniJumbuk wool quilt manufacture and the wider Coopworth and Romney sheep wool farming sector — feed wool-rich broadloom and rug yarn into Cavalier and Godfrey Hirst. The synthetic supply chain — Solomon Flooring, Carpet Court, Choices Flooring, Carpets Inn and Carpet One Floor & Home retail — distributes nylon, polyester and polypropylene-rich broadloom and tile. Carpet underlay is supplied through Dunlop Flooring underlay, Forbo, AirStep, Tredaire, Bridgestone underlay and Carlon underlay. The commercial carpet tile retail and specifier ecosystem extends through Total Carpets, Andersens Flooring, National Tiles, Beaumont Tiles and Smartwood Flooring on the wood-adjacent side. The industry bodies sitting over the top of all of this are the Carpet Institute of Australia (CIA), the Australian Wool Innovation (AWI), the Floorcoverings Industry Australia (FIA), the International Wool Mark Company, the Australian Made Campaign, the Cradle to Cradle Products Innovation Institute, Aquafil ECONYL recycled nylon, Mohawk Bloom carpet recycling, the Australian Light Floor Covering Industry (ALDFI) body and the National Carpet Standard Institute (NCSI).

This guide walks through every process zone from fibre arrival through scouring, dyeing, opening, carding, spinning, tufting, heat-set, back coating, finishing and packaging, plus the adjacent LVT vinyl, linoleum, synthetic turf and athletic-surface manufacturing operations. It calls out the specific duct, fan, material and standards decisions for each stage and ends with the SBKJ machine configuration we recommend for a fabricator serving the Australian carpet and synthetic turf supply chain. SBKJ Group ships to ARBS 2026 in Sydney in May and the working sample on the stand demonstrates the multi-coil change-over between galvanized G350 and 316L stainless that every serious carpet-plant project needs.

Standards stack that frames the specification

Before any process detail, the standards stack has to be set out in one place. Every carpet, broadloom, tufted tile, underlay, rug and synthetic turf ductwork specification we write in Australia traces back to the following documents. A fabricator who cannot evidence compliance with each is not building duct for a Carpet Institute of Australia-aligned plant.

• AS 1668.2 — The use of ventilation and air conditioning in buildings, Part 2 — Mechanical ventilation in buildings. Sets minimum outdoor-air rates, contaminant exhaust requirements and general industrial ventilation design rules. Every carpet process zone has a minimum outdoor-air rate that traces back to AS 1668.2. The duct sizing flows from that rate plus the local contaminant load — fibre dust, styrene, butadiene, MDI/TDI isocyanate, formaldehyde, CO from the heat-set burner, VOC from the latex coater.
• AS 4254 — Ductwork for air-handling systems in buildings. Sets the construction class, sheet thickness, reinforcement spacing, joint integrity and pressure-leakage class for HVAC ductwork. AS 4254 Class B is the default for most carpet-plant supply and general extract. AS 4254 Class C and Class D apply on the higher-pressure dust collection mains and the back coating booth extract feeding a regenerative thermal oxidiser. Heavy gauge 1.5 mm minimum is used on the 250 degree Celsius 2-hour fire-rated risers.
• AS 1530.4 — Fire-resistance tests of elements of building construction. Drives the 250 degree Celsius 2-hour fire-rated duct riser through any Class 8 industrial floor plate. The SBSF-1525 heavy-gauge tube line is the production tool for this riser.
• AS 1668.1 — The use of ventilation and air conditioning in buildings, Part 1 — Fire and smoke control in buildings. Covers the smoke-control duct, the fire damper interface, and the kitchen exhaust riser through a Class 8 industrial floor plate.
• NCC Class 8 industrial. The carpet, LVT, underlay and synthetic turf manufacturing hall is NCC Class 8. The dust-collection mains, latex SBR booth, heat-set tunnel oven and back coating cure oven sit inside the Class 8 footprint. The adjacent finished-goods warehouse and despatch is also Class 8.
• NCC Class 6 retail. The Carpet Court, Choices Flooring, Carpet One and the adjacent showroom is NCC Class 6. The HVAC criterion shifts from industrial heavy-extract to commercial showroom comfort: NC-40 acoustic, 50% RH, low-velocity supply, F7/F8 supply filtration, and clean fibre-free indoor air for the customer experience.
• AS/NZS 60079 — Explosive atmospheres. This is the critical standard for carpet manufacturing. Latex SBR styrene-butadiene rubber back coating, synthetic resin solvent and adhesive Zone 1 atmospheres, spray glue application, heat-set fibre burner LPG or propane atmospheres, ASR Aerogel synthetic resin handling, TPU thermoplastic polyurethane Zone 1 application, polymer dust and microfibre fluff Zone 21/22, and tyre regrind dust on the synthetic turf side all fall under AS/NZS 60079 zone classification. Any electrical or mechanical device inside the zone — duct-mounted dampers, fire dampers, exhaust fans, sensors, lights — has to be rated for the zone and the equipment temperature class.
• AS 3957 — Combustible dust hazard. This is the dust-side companion to AS/NZS 60079. Synthetic fibre dust, microfibre, polyester, nylon, polypropylene, wool, cotton fluff, yarn and lint produced at fibre opening, carding, tufting, shearing, cutting and binding are combustible dusts with Kst values in the 100-160 bar·m/s range, which places them in ST1 to ST2 hazard category. The international companion frameworks are NFPA 660 (which consolidated NFPA 654 combustible particulate solids and NFPA 664 wood-processing combustible dust in 2025), NFPA 68 deflagration venting and NFPA 69 explosion protection by inerting, isolation and suppression. Every metre of dust-collection duct in the plant is engineered to those frameworks.
• NFPA 33 — Standard for Spray Application Using Flammable or Combustible Materials. Applies to the latex SBR coater, the SBR styrene-butadiene rubber underlay backing coater, the TPU thermoplastic polyurethane secondary coater, the Stadex coater on commercial tile, the acrylic primary and secondary back coating booths, and any spray-application stage where finishing chemistry is applied to the tufted broadloom or carpet tile.
• AS 1940 — The storage and handling of flammable and combustible liquids. Applies to the latex SBR drum storage, the acrylic adhesive drum storage, the MEK and toluene solvent storage, the ethyl acetate, the urethane resin and the wider flammable-liquid handling that surrounds the back coater and the secondary coating room.
• NFPA 86 — Standard for Ovens and Furnaces. Applies to the heat-set tunnel oven (130-180 degrees Celsius for polypropylene, nylon and polyester fibre heat-set), the fibre dye dryer (60-100 degrees Celsius), the latex SBR cure oven (120-150 degrees Celsius), the TPU lamination oven (150-200 degrees Celsius), the adhesive cure oven (60-100 degrees Celsius) and the printer ink dryer on the LVT rotogravure line (60-80 degrees Celsius).
• AS 4332 — Specialty gas. Applies to the LPG burner on the heat-set tunnel oven, the propane burner on the back coating cure, and the natural gas supply where mains gas is used. The duct interface to the burner is part of the AS 4332 dossier.
• AS/NZS 1715 and AS/NZS 1716 — Respiratory protective equipment. The operator RPE programme is part of the ductwork specification because the duct sets the residual exposure profile on the floor. Inhalable fibre dust, respirable nylon, polyester, polypropylene, wool and cotton fibre dust, styrene, butadiene, MEK, toluene, isocyanate and formaldehyde residuals all have to sit under the WES with the duct in service, and the RPE is the last-resort control when a process upset puts an operator into a higher zone.
• FSANZ. Rare on a carpet plant — carpet is not food — but applicable where the same site handles food-contact textiles or where the warehouse stores carpet adjacent to food packaging in a mixed-tenant industrial estate. The cross-contamination clause is the one to watch.
• ISO 9001, ISO 14001 and ISO 45001. A carpet plant running to ISO 9001 quality, ISO 14001 environmental and ISO 45001 occupational health and safety has to document its environmental control regime including supply-air filtration, room pressure differentials and contaminant capture. The ductwork specification is part of the integrated management system evidence pack, not a separate document.
• State EPA waste licences. NSW EPA, VIC EPA, QLD DES, SA EPA, WA DWER and TAS EPA all license the carpet plant's emission to air, water and land. The latex SBR booth extract, the heat-set tunnel oven exhaust, the dye house exhaust and the regenerative thermal oxidiser stack are all licensed point sources. The duct termination, the stack monitoring and the emission factor are all in the EPA dossier.
• Carpet Institute of Australia (CIA), Wool Mark Company and Australian Made certification. The product-side certifications drive the ingredient list and the chemistry restriction. Cradle to Cradle, ECONYL and Mohawk Bloom drive the recycled-content side. These are not strictly HVAC standards but the chemistry exclusion list — phthalate plasticiser, antimony brominated flame retardant, urea-formaldehyde binder, Cr VI mordant, certain azo dyes — drives the duct material selection on a plant that is committed to the certification path.

Workplace exposure standards drive the residual ventilation rate. Respirable nylon, polyester, polypropylene, wool and cotton fibre dust sit at 5 mg/m³ respirable and 10 mg/m³ inhalable — the baker's asthma equivalent for the carpet tufting, shearing, cutting, binding and trimming operator. Latex SBR styrene-butadiene rubber sits at 0.1 ppm with residual monomer. Styrene is 50 ppm STEL. Butadiene is 1 ppm STEL. Toluene is 50 ppm STEL (and being phased on the legacy adhesive and primer). MEK methyl ethyl ketone is 200 ppm STEL. Ethyl acetate is 200. Acetone is 250. IPA isopropyl alcohol is 400. Isocyanate TDI/MDI is 0.005 ppm STEL — the killer for endocrine and asthma sensitisation. Formaldehyde is 1 ppm STEL — IARC Group 1 carcinogen. General VOC, CO at 30 ppm, CO2 at 5000 ppm, and the modern low-GWP refrigerants R32, R410A, R454B and R744 round out the gas list. Every duct termination has to deliver the residual concentration on the floor under the WES with all sources running at design rate.

Process zone 1 — Wool, fibre prep, scouring and dye bath (Cavalier Bremworth, Mackies, Australian Wool Innovation supply chain)

The wool-rich premium carpet end of the supply chain starts at the wool scour. Cavalier Bremworth at the New Zealand parent and the Tottenham Victoria legacy Feltex operation, Mackies Carpet, the Australian Wool Innovation supply base, MiniJumbuk for the wool quilt and bedding adjacency, and the Coopworth and Romney sheep wool farms feed scoured wool top into the spinning and tufting lines.

Scouring detergent and chemistry

The scouring line uses NaOH (caustic soda) and KOH (caustic potash) for the alkali bath, an anionic and cationic surfactant package for the fibre wetting, and a sequence of hot-water bowls at 50-65 degrees Celsius to remove the lanolin, suint and farm dirt. The airspace above the scouring bowl is saturated with water vapour, detergent aerosol, trace ammonia and a fine grease droplet. Duct over the scouring line is 316L stainless steel with welded longitudinal seams, sloped at 1:100 to a condensate drain that ties to the wool-grease recovery sump. The grease is a high-value by-product and the recovery is part of the line economics. Galvanized fails through pinhole corrosion at the longitudinal seam inside 18 months in this service.

Dye bath chemistry

The dye house feeds the dyed wool top into the spinning line. The chemistry covers reactive dye, acid dye, basic dye, disperse dye, vat dye, azo dye and pre-metallised dye, applied through pH adjustment with acidic and alkaline bath, fixed with a fixative chemistry, and rinsed through a wash line. The legacy chrome VI mordant on some pre-metallised dye lines has been phased out across the major Cavalier Bremworth and Mackies operations in favour of low-impact dye chemistry, but the duct material specification still has to handle the worst-case acid and alkali residual through the rest of the chemistry. The reference duct specification is 316L stainless steel with welded longitudinal seams for general dye exhaust, FRP fibreglass-reinforced polyester for any sulphuric-acid exhaust, and polypropylene-lined steel for the caustic alkali exhaust. Each section is marked on the outside with the material designation so the installer cannot cross them up.

Separate climate and humidity zone

The dye house operates at 60-80% RH because high humidity reduces yarn breakage during dyeing and stops the dye bath from concentrating through evaporation. The exhaust carries water vapour, fine droplet aerosol, dissolved chemistry, salt, levelling agent, pH adjuster and reactive dye vapour. The duct termination feeds either an FRP wet scrubber for the acid- and alkali-rich exhaust or a 316L stainless welded heat exchanger for general humidity recovery. A separate make-up air handler delivers tempered and de-humidified make-up to keep the room mass balance neutral.

Wastewater treatment and acid/alkali pH adjust

Dye-house wastewater is acid- and salt-laden and is not allowed into the storm system. The duct condensate sump under each exhaust trunk ties to the dye-house effluent treatment plant. The sump has a level alarm wired to the BMS and a pump-out cycle every shift. Cr VI legacy residue is captured to a separate dedicated treatment line where any handling remains.

Process zone 2 — Fibre opening, carding, combing, drafting, spinning, twisting, plying (Godfrey Hirst, Mackies, the broader synthetic fibre line)

Mechanical fibre opening, carding, combing, drafting, spinning, twisting and plying form the fibre into a usable carpet yarn. The materials cover wool, cotton, synthetic polypropylene, polyester, nylon and increasingly ECONYL recycled nylon and Mohawk Bloom recycled polyester. The mechanical action generates fine fibre dust and fluff at a rate that depends on the fibre type, the staple length and the line speed. Wool dust is around Kst 110 bar·m/s. Polypropylene fluff is around 130. Nylon 6.6 short-staple is around 130. Polyester is around 140. All four sit in the ST1 to ST2 combustible dust category under AS 3957 and the international NFPA 660 framework.

Dust collection main

The dust collection main runs from hooded extract points above each card, comber, drafter, spinner and twister to a central baghouse or cyclone-plus-filter collector. The duct material is galvanized G350 spiral for the general fibre opening and carding lint return. The duct transitions to 316L stainless for any section feeding a downstream wet scrubber on the dye-house side. The SBFB-1500 round spiral tubeformer is the production tool for the dust collection main. Spiral seam with a 1.5 mm minimum wall thickness. Transport velocity 18-22 m/s to keep wool, polypropylene, nylon and polyester dust suspended without bridging or fall-out. No-flat-bottom hoppers under any horizontal run longer than 6 m. Bonded and grounded joints end to end with a measured continuity test on each section after installation.

Explosion protection

Deflagration vents per NFPA 68 on the dust collector itself and at every isolation valve location on the collection main. Chemical and mechanical isolation valves per NFPA 69 between branches feeding a common collector to prevent flame propagation back to the source. Fast-acting isolation valves on the duct connection to the collector. Spark detection and extinguishing systems on the trunk before the collector inlet. Direct-drive explosion-protected fan (Ex d IIB T4 minimum) on the collector outlet. Internal duct surfaces are smooth-welded to prevent fibre deposit accumulation. The classification inside the dust collection main is AS/NZS 60079 Zone 21. The classification within 1 m of any leakage point is Zone 22.

Synthetic recycled fibre line

The recycled nylon ECONYL and recycled polyester Mohawk Bloom lines run a slightly different chemistry on the fibre opening side because the regrind material has more residual moisture, more dust and more variable staple length than virgin material. The duct sizing increases the transport velocity by 2-3 m/s to handle the additional dust load. The collector sizing increases by 20-30%. The deflagration vent rating holds at the same Kst because the dust hazard is the same fibre, just regenerated.

Process zone 3 — Warping, weaving, tufting, knitting, needle-punch, needle tufting, woven, bonded (Godfrey Hirst Geelong tufting line, Cavalier Tottenham Victoria)

Tufting is the primary carpet technology in the Australian market. The tufting machine takes a primary backing — typically polypropylene woven scrim — and inserts pile yarn through the backing using a row of needles operating at 100-300 stitches per minute across a 4-6 m machine width. The needle gauge selects the pile density (1/8 inch for high-density commercial loop, 3/16 inch for mid-range residential and 1/4 inch for broadloom shag). The pile yarn forms a loop pile, a cut pile, a Berber, a twisted, a velvet, a Wilton, an Axminster or a shag depending on the cut-and-loop pattern and the post-tufting finishing.

Tufting hall HVAC profile

The tufting hall runs at 60-65% RH because dry fibre generates static and increases needle breakage. The acoustic target is NC-60 — anything quieter is masked by the tufting machine itself, which runs at 85-92 dB(A). Supply duct is insulated galvanized G350 rectangular with low-velocity drum diffusers overhead. The supply rate sets the air change at 6-10 per hour depending on the tufting machine count and the floor area. The SBAL-V auto duct production line in galvanized G350 mode is the production tool for the rectangular supply duct. Floor-level fibre lint extraction runs into a separate dust trunk that ties to the central baghouse.

Lint extraction trunk

The lint extraction trunk runs from floor-level hood inlets along each tufting machine to a baghouse. Duct is galvanized G350 spiral, bonded and grounded, NFPA 660 classified, with deflagration venting on the collector. Transport velocity 18-22 m/s. No-flat-bottom hoppers under every horizontal run. Isolation valves between adjacent tufting machine branches to prevent deflagration propagation.

Weaving, knitting and needle-punch variants

Weaving (woven carpet — Wilton, Axminster) operates on a smaller scale in Australia and is concentrated in the premium and specialty end of the market. Knitting (raschel knit, warp knit) is rare in Australian carpet but more common in technical and industrial textiles. Needle-punch (used for entrance matting, automotive and acoustic underlay) is a felt-like construction where short fibres are mechanically interlocked through repeated needle penetration into a bat. Each variant has the same fibre dust extract requirement and the same NFPA 660 classification but the dust loading differs. Needle-punch generates the highest dust loading because the mechanical action is the most aggressive. Weaving generates the lowest because the yarn is already formed and the warp-weft interlacing is gentler than tufting needle insertion.

Process zone 4 — Heat-set fibre, tunnel oven, steam fix (heat-set tunnel oven 180 degrees Celsius carpet)

Heat-set fibre processing fixes the pile yarn twist into the finished pile shape. Polypropylene PP, nylon and polyester are heat-set at 130-180 degrees Celsius through a tunnel oven or a steam-fix chamber, with dye fixation running at 60-100 degrees Celsius. The major equipment suppliers are Tortolini, Superba, Power Heat-Set, Suessen, Saurer and Schlafhorst. The heat-set oven sits in a separate climate zone with a dedicated HVAC make-up air system, steam recovery, heat recovery, CO monitoring from the LPG or natural gas burner, and a NFPA 86 industrial oven exhaust classification.

Tunnel oven exhaust

The exhaust duct from the heat-set tunnel oven is 316L stainless steel with welded longitudinal seams, R-1.5 insulation, slope 1:100 to a condensate sump on the cool end, and an air-to-air heat exchanger upstream of the stack on the worst-case dirty side. The SBSF-1525 heavy-gauge tube line in 316L stainless 1.5 mm is the production tool for the 250 degree Celsius 2-hour fire-rated riser through any Class 8 industrial floor plate. AS 1530.4 fire-resistance grading. Slope, condensate sump, insulation and welded seam are all critical because the oven exhaust carries condensable hydrocarbons from the fibre lubricant carrier and the dye carrier residue. The condensate is an oily plasticiser-rich liquor that attacks galvanized rapidly.

Steam fix chamber

The steam-fix chamber runs at 100-130 degrees Celsius with saturated water vapour. The exhaust duct is 316L stainless steel with welded seams, R-1.0 insulation, slope to a condensate sump. The condensate is treated as steam-condensate water and can return to the boiler feed system through a heat recovery loop.

Heat recovery

The air-to-air plate or rotary heat exchanger on the heat-set tunnel oven exhaust is the single biggest energy recovery opportunity in a tufted broadloom plant. The clean side feeds the burner make-up air and the secondary dye-house preheat. The dirty side carries the worst-case 180 degree Celsius condensate-rich exhaust and is sized with a wash-down cycle on the dirty side that ties to the plant cleaning schedule. CO and CO2 monitors on the burner side are wired to the BMS to trip the oven if combustion deteriorates and CO climbs above 30 ppm or CO2 above 5000 ppm.

LPG and natural gas burner

The heat-set tunnel oven and the back coating cure oven both fire on LPG, propane or natural gas. AS 4332 specialty gas applies to the burner supply and the burner train. The duct interface to the burner — the flue, the secondary air inlet, the make-up air supply — is integrated into the burner train and the BMS interlock. The combustion air supply rate sets the burner efficiency and the residual CO in the exhaust.

Process zone 5 — Latex back coating, SBR latex back coating, PU/TPU secondary back coating (latex SBR back coating extract)

The back coating stage applies the secondary backing chemistry to the tufted carpet. The chemistry options cover styrene-butadiene rubber SBR latex, acrylic latex, ASR Aerogel synthetic resin, thermoplastic polyurethane TPU and ethylene-vinyl acetate EVA. The primary backing is typically a polypropylene woven scrim that holds the tufted yarn during tufting. The secondary backing is applied after tufting through a coater (Black Bros, Coat Coater or Spuhl machine) at 150-300 g/m² coating weight, then cured in an oven at 120-150 degrees Celsius. A scrim mesh is laminated onto the back to add dimensional stability for certain commercial broadloom and tile constructions. The application process exhausts a mix of MEK, toluene, ethyl acetate, acetone, residual styrene and butadiene monomer from SBR, MDI or TDI isocyanate from TPU, and VOC general from the acrylic.

Back coating booth enclosure

The back coater is enclosed in a NFPA 33 spray-finishing booth with mechanical exhaust. The booth face velocity is 0.5-1.0 m/s. The booth interior is classified AS/NZS 60079 Zone 1 and the leakage envelope within 1 m of any opening is Zone 2. Every electrical and mechanical device inside the zone is rated to the zone and the equipment temperature class — booth lights are Ex-rated, dampers are Ex-rated actuators, the exhaust fan is direct-drive with an explosion-protected motor (Ex d IIB T4 minimum). The duct from the booth to the regenerative thermal oxidiser or activated-carbon adsorber is 316L stainless steel with welded longitudinal seams. The SBAL-V auto duct line in 316L stainless coil mode is the production tool. Welded seam, slope 1:100 to a condensate sump, R-1.0 insulation on the supply side and R-0.5 on the extract side.

Latex SBR styrene-butadiene rubber chemistry

SBR latex is the workhorse secondary backing for residential and mid-range commercial broadloom. The latex emulsion carries residual styrene (WES 50 ppm STEL — also the IARC reference), butadiene (WES 1 ppm STEL — IARC carcinogen), trace ammonia for emulsion stability, calcium carbonate filler at high loading, carbon black pigment, and a sulphur-based curing system. The booth extract has to clear styrene and butadiene to under the WES at the operator breathing zone with the line at design rate. The duct sizing flows from that residual concentration calculation, not from a generic air-change rate.

PU and TPU thermoplastic polyurethane secondary back coating

Polyurethane and thermoplastic polyurethane secondary back coating uses MDI methylene diphenyl diisocyanate or TDI toluene diisocyanate prepolymers. Isocyanate is the killer in carpet back coating. The WES is 0.005 ppm STEL — one of the lowest occupational limits in the entire flooring industry. Chronic respiratory sensitisation from isocyanate is irreversible. The extract duct on a TPU coater is 316L stainless welded seam, fully enclosed application booth, continuous direct-reading isocyanate monitor wired to the BMS, emergency dump-and-purge sequence, AS/NZS 60079 Zone 1 inside the booth and Zone 2 within 1 m. Operator respiratory protection per AS/NZS 1715/1716 with full air-line or PAPR positive-pressure mask for any operator inside the booth envelope. The exhaust ties to a regenerative thermal oxidiser sized for the full TDI/MDI load. Polyurethane TPU is phasing toward bio-based and water-based alternatives in the Australian premium carpet market in line with Cradle to Cradle and Green Star requirements, but the legacy plants and several global carpet tile suppliers still run isocyanate chemistry.

Cure oven exhaust

After the coater the carpet passes through a cure oven at 120-150 degrees Celsius to set the back coating. The cure oven exhaust duct is 316L stainless steel with welded seams, R-1.5 insulation, slope 1:100 to a condensate sump. NFPA 86 industrial oven exhaust. The exhaust feeds the same regenerative thermal oxidiser as the coater booth extract on most modern plants because the residual VOC from the cure is the same chemistry as the coater exhaust, just hotter and post-reaction.

Flammable liquid storage

The MEK, toluene, ethyl acetate, acetone, IPA and urethane resin drum storage room is classified AS 1940 flammable liquid storage. The room is bunded, fire-rated, and exhausted at 6 air changes per hour through an AS/NZS 60079 Zone 2 extract duct in 316L stainless. The duct termination is at high level, away from any ignition source. The drum pump is bonded to the drum and to the receiver tank.

Process zone 6 — Carpet tile and modular carpet (Interface Australia, Shaw, Milliken, Mohawk)

Modular carpet tile — Interface Australia (Atlanta GA parent), Shaw Industries Australia, Milliken, Bentley Prince Street, Mohawk — covers the commercial office, retail and institutional flooring market with 500x500 mm, 600x600 mm or 250x1000 mm modular tile constructions. The tile backing is thermoplastic polyurethane TPU, PVC (legacy and phasing out), bitumen (legacy and largely phased), or ECONYL recycled nylon backing. Wear-side fibre is typically solution-dyed nylon 6 or 6.6 for the premium product and polypropylene for the mid-range product. Low VOC certification, Cradle to Cradle and Green Star compliance drive the chemistry selection.

Tile manufacturing line

The tile manufacturing line takes broadloom or roll stock through a coating, a lamination, a cooling, a cutting and a packaging cell. The lamination cures at 150-200 degrees Celsius on a TPU back coater or runs cooler on a bitumen or PVC backing line. The duct on the lamination exhaust is 316L stainless steel with welded longitudinal seams, R-1.5 insulation, slope to a condensate sump. The SB-ZF1500 carpet tile trim main station is the production tool for the dust trunks serving the modular tile finishing area. The trim dust trunk is galvanized G350 spiral bonded and grounded, NFPA 660 classified. Transport velocity 18-20 m/s. No-flat-bottom hoppers.

Cutting and packaging

The tile is cut from the laminated roll to the finished tile size using a die-cut or rotary-cut station. The cutting dust trunk handles fine fibre and backing dust. Galvanized G350 spiral with bonded joints. The packaging line uses a Multivac or Variovac flow-wrap or shrink-wrap machine; the exhaust over the heat-shrink tunnel is galvanized G350 with R-0.5 insulation.

Process zone 7 — Carpet finishing, shearing, trimming, binding, edge overlock, roll up, packaging

The carpet finishing stage covers shearing the pile to the finished height, trimming the edges, binding the roll edges for broadloom, edge overlock for rugs, rolling up the broadloom into 4 m or 5 m rolls, and packaging for despatch. The major equipment suppliers are Hi-Therm and Schaubeck on the shearing side, dedicated binder and overlock machines, and Multivac, TIPPER or Variovac on the packaging side.

Shearing dust

Shearing the pile to the finished height generates a fine fibre dust trunk that ties to the central baghouse. Galvanized G350 spiral with bonded joints, NFPA 660 classified. Transport velocity 18-22 m/s. Hood capture velocity 1.0-1.5 m/s at the shearing head. The shearing dust is the second highest dust loading on a broadloom line after the tufting hall.

Trimming and binding

The trimming station produces trim waste that drops into a vacuum collection system. The binder applies a binding tape to the rug or broadloom edge using a heat-set adhesive. The binder exhaust is local 316L stainless with R-0.5 insulation, feeding the same activated-carbon adsorber as the back coater overflow.

Roll up and packaging

The roll-up station and the packaging cell are ambient HVAC. Supply duct is insulated galvanized G350 rectangular with low-velocity drum diffusers. Acoustic criterion NC-50. The packaging tunnel exhaust is local with R-0.5 insulation.

Process zone 8 — LVT luxury vinyl tile, sheet vinyl, linoleum, resilient floor (Karndean LVT vinyl manufacturing, Tarkett, Forbo, Polyflor, Armstrong, Dunlop)

Luxury vinyl tile, sheet vinyl, linoleum and the wider resilient flooring category cover the Karndean Designflooring range, Tarkett Australia LVT and resilient flooring, Forbo Flooring Systems linoleum and sheet vinyl, Polyflor commercial vinyl, Armstrong Flooring and Dunlop Flooring. The LVT construction is a layered build of a PVC plastisol or thermoplastic base, a printed décor layer applied through rotogravure, a wear-layer urethane top-coat, an embossing roller, and a click-lock cutting and edge profile. The chemistry covers PVC, vinyl chloride monomer VCM residual (legacy and phasing), phthalate plasticiser (legacy and phasing toward DOTP, DINP and bio-based alternatives), stabiliser, pigment, antimony brominated flame retardant (legacy and phasing), and urethane wear-layer chemistry.

Rotogravure print booth

The rotogravure print booth applies the printed décor layer to the LVT base. The print solvent is typically MEK, ethyl acetate, acetone or a proprietary low-VOC blend. The booth is enclosed and exhausted under NFPA 33 spray-finishing classification. The booth interior is AS/NZS 60079 Zone 1 and the leakage envelope is Zone 2. The duct is 316L stainless steel with welded longitudinal seams. The SBLR-600 laser welder is the production tool for the welded seam on the high-pressure print booth extract. The exhaust ties to a regenerative thermal oxidiser or activated-carbon adsorber.

Heat-set lamination

The lamination press heat-sets the wear layer onto the printed décor layer and the PVC base at 180-200 degrees Celsius. The lamination exhaust is 316L stainless steel with welded seams, R-1.5 insulation, NFPA 86 industrial oven exhaust. Slope 1:100 to a condensate sump.

Embossing and click-lock cutting

The embossing roller and the click-lock cutting station produce fine PVC and urethane dust. The trim trunk is galvanized G350 spiral with bonded joints, NFPA 660 classified. Transport velocity 18-20 m/s. The dust loading is lower than a tufted broadloom line but the classification is the same combustible dust category.

Linoleum specific

Linoleum (the Forbo flagship product) is a bio-based material — linseed oil, pine rosin, wood flour, limestone and pigment on a jute backing. The oxidation cure for the linseed oil runs in a long curing chamber over 14-28 days at 25-40 degrees Celsius. The cure chamber exhaust is galvanized G350 with R-0.5 insulation, sized for the slow continuous oxidation off-gas. The chemistry is benign compared to PVC and the duct material does not need to be stainless.

Process zone 9 — Synthetic turf and artificial grass (synthetic turf TigerTurf+APT manufacturing)

Synthetic turf and artificial grass — TigerTurf Australia, APT Asia Pacific Synthetic Turf, SmartGrass, EnviroTurf, Australian Synthetic Lawn Pty Ltd, Synthetic Grass Pros, Polytan and FieldTurf — supplies the Sydney Olympic Park complex, AAMI Park, school sports ovals, council sports fields and the private residential and commercial market. The construction is polyethylene PE, polypropylene or polyamide nylon fibre tufted into a primary backing, TPU or SBR secondary back coating, and rolled with rubber crumb infill (often recycled tyre crumb) and silica sand infill at the site.

Fibre tufting

The synthetic turf tufting line is similar to broadloom carpet tufting but with a longer pile (40-60 mm versus 6-15 mm on carpet) and a coarser needle gauge. The tufting hall HVAC profile is the same as carpet — 60-65% RH, NC-60 acoustic, galvanized G350 rectangular supply, galvanized G350 spiral lint extraction with NFPA 660 deflagration venting on the baghouse.

Back coating

The synthetic turf back coater applies TPU or SBR secondary backing in a heavier coating weight than carpet (300-600 g/m² versus 150-300 g/m²) and cures the back through a longer tunnel oven at 120-160 degrees Celsius. The duct specification is the same 316L stainless welded seam, NFPA 33 spray finish, AS/NZS 60079 Zone 1 booth interior, regenerative thermal oxidiser on the stack.

Tyre crumb infill handling

The factory may also handle bulk tyre crumb infill for the integrated supply contracts. Tyre crumb dust is a combustible dust in its own right. The duct on the crumb dosing and storage is galvanized G350 spiral bonded and grounded, NFPA 660 classified with deflagration venting and dedicated explosion isolation. Silica sand infill is non-combustible but generates a respirable crystalline silica dust at the dosing station, which carries its own respiratory hazard under AS/NZS 1715/1716 and is exhausted through a HEPA-filtered dust collector.

Athletic surface and shock-pad

The athletic track, futsal court and tennis court surfaces — Conica polyurethane, Mondo, Polytan — use a polyurethane or acrylic pour-and-cure construction over a shock-pad underlay and a sub-base. The pour, the cure, the paint and the line marking happen on site, not in a factory, but the shock-pad and the precast surface tile manufacture happens in a factory cell with a 316L stainless ducted exhaust on the curing oven and a NFPA 33 classification on the paint and line-marking application.

Process zone 10 — Underlay, foam rubber and felt (Dunlop Flooring underlay, AirStep, Tredaire, Bridgestone, Carlon)

Carpet underlay covers Dunlop Flooring underlay, AirStep, Tredaire, Bridgestone underlay and Carlon underlay. The construction options are rubber crumb (often recycled tyre crumb), felt (wool, jute or synthetic fibre), polyurethane foam, or thermoplastic polyurethane foam. The factory ductwork sits between carpet manufacturing and tyre-recycling depending on the construction.

Rubber crumb underlay

The rubber crumb underlay line uses recycled tyre crumb bound with a polyurethane binder, pressed into a continuous mat and cured at 80-120 degrees Celsius. The dust trunk on the crumb dosing is galvanized G350 spiral bonded and grounded, NFPA 660 classified. The cure oven exhaust is 316L stainless welded seam, NFPA 86 classified.

Polyurethane foam underlay

The polyurethane foam underlay line uses MDI or TDI isocyanate prepolymer and a polyol blend to form a continuous foam mat. The duct specification is the same isocyanate-grade 316L stainless welded seam with continuous isocyanate monitor and emergency purge as the TPU back coater on the carpet line.

Felt and wool underlay

The felt and wool underlay line uses needle-punch fibre construction and a minor thermal bonding step. The dust extract is galvanized G350 spiral with NFPA 660 classification. The thermal bonding exhaust is local 316L stainless with R-0.5 insulation.

Process zone 11 — Fibre recycling, ECONYL, Mohawk Bloom, end-of-life carpet recycling (Interface, Shaw, Mohawk, Cavalier, Godfrey Hirst)

End-of-life carpet recycling is the closing loop on the supply chain. Interface (through the EcoWorx and ReEntry programmes), Shaw (with EcoWorx and Re[CYCLE]), Mohawk (with Bloom), Cavalier (with wool recycling) and Godfrey Hirst all run carpet recovery and recycling programmes. The recycling routes cover Aquafil ECONYL chemical depolymerisation of nylon 6 back to caprolactam monomer, mechanical recycling of polypropylene face fibre, Bridgestone tyre crumb infill recycling, PVC vinyl recycle for LVT, fibre regrind for the recycled-content broadloom, and the longer-term ChemPath chemical recycling and pyrolysis routes.

Carpet shredding and separation

The carpet shredding line cuts end-of-life carpet into manageable pieces, separates the face fibre from the backing through density separation or chemical dissolution, and feeds the regenerated fibre back into the fibre opening line. The shredding dust is heavy and the duct is galvanized G350 spiral bonded and grounded with NFPA 660 classification. Transport velocity 22-24 m/s because the shredded carpet fibre is coarser and heavier than virgin fibre.

Chemical depolymerisation

The ECONYL chemical depolymerisation of nylon 6 runs at 280-320 degrees Celsius under steam and catalyst. The exhaust is 316L stainless welded seam with R-2.0 insulation, NFPA 86 industrial oven exhaust, slope 1:100 to a condensate sump on the cool end. The chemistry is contained inside a closed reactor but the leakage envelope is AS/NZS 60079 Zone 2.

Process zone 12 — Carpet warehouse, distribution and showroom (Carpet Court, Choices Flooring, Carpet One, Total Carpets, Andersens, National Tiles, Beaumont Tiles)

The carpet warehouse, distribution and showroom side covers Carpet Court, Choices Flooring, Carpet One Floor & Home, Total Carpets, Andersens Flooring, National Tiles, Beaumont Tiles and Smartwood Flooring (wood-adjacent). The warehouse and distribution centre is NCC Class 8 industrial. The retail showroom is NCC Class 6.

Warehouse

The warehouse stores broadloom rolls, carpet tile cartons, LVT cartons, underlay rolls, adhesive drums and sundry sample books. The HVAC criterion is industrial warehouse — 4-6 air changes per hour, galvanized G350 spiral or rectangular, NC-55 acoustic. Temperature and humidity stable enough to protect the adhesive and the pigment from degradation (12-25 degrees Celsius, 40-60% RH). The adhesive drum store is classified AS 1940 flammable liquid and bunded.

Showroom

The retail showroom is NCC Class 6 with NC-40 acoustic, 50% RH, F7 supply filtration, and clean fibre-free indoor air for the customer experience. Supply duct is insulated galvanized G350 rectangular with low-velocity linear or drum diffusers. Floor-level extract clears any settling dust from the sample handling.

WES exposure summary table

The workplace exposure standards drive the residual ventilation rate on the floor. Every duct termination is designed to deliver under each of these limits with all sources at design rate.

• Respirable nylon, polyester, polypropylene, wool, cotton fibre dust. 5 mg/m³ respirable, 10 mg/m³ inhalable. Tufting, shearing, cutting, binding, trimming.
• Latex SBR styrene-butadiene rubber residual. 0.1 ppm general, monitored as residual styrene and butadiene monomer.
• Styrene. 50 ppm STEL. SBR latex, unsaturated polyester, vinyl resin.
• Butadiene. 1 ppm STEL. SBR latex, ABS thermoplastic.
• Toluene. 50 ppm STEL. Legacy adhesive and primer, phasing.
• MEK methyl ethyl ketone. 200 ppm STEL. Carpet adhesive, primer, secondary back coating solvent.
• Ethyl acetate. 200 ppm STEL. Adhesive, primer solvent.
• Acetone. 250 ppm STEL. Adhesive, primer solvent.
• IPA isopropyl alcohol. 400 ppm STEL. Surface cleaning, primer.
• Isocyanate MDI and TDI. 0.005 ppm STEL. PU and TPU thermoplastic polyurethane back coating, adhesive, spray foam underlay. THE KILLER. Phasing toward bio-based and water-based alternatives.
• Formaldehyde. 1 ppm STEL. IARC Group 1 carcinogen. Urea-formaldehyde and melamine-formaldehyde binder in carpet backing and secondary back coating. Phasing.
• VOC general. Site-specific. Adhesive, primer, pigment, dye, ink.
• CO carbon monoxide. 30 ppm STEL. LPG, propane, natural gas burner combustion.
• CO2 carbon dioxide. 5000 ppm. Combustion and human occupancy.
• R32, R410A, R454B, R744 refrigerant. Site-specific leak detection. Chiller, cooling tower, HVAC condenser.

Process flow summary table

The full process flow from raw fibre to packaged carpet, with the duct material, velocity, acoustic and standards reference for each stage, is summarised below as a quick-reference for the engineer drafting the project specification.

• Wool scouring (Cavalier, Mackies). 316L stainless welded seam. 12-15 m/s. NC-55. AS 1668.2, AS/NZS 60079.
• Wool dyeing (general). 316L stainless welded seam. 10-15 m/s. NC-55. AS 1668.2 and AS/NZS 60079.
• Dyeing (acid). FRP. 10-12 m/s. NC-55. AS 1668.2 and AS/NZS 60079.
• Dyeing (caustic). Polypropylene-lined steel. 10-12 m/s. NC-55. AS 1668.2 and AS/NZS 60079.
• Fibre opening and carding (synthetic and wool). Galvanized G350 spiral bonded and grounded. 18-22 m/s. NC-60. AS 3957, NFPA 660 with deflagration venting and isolation.
• Combing, drafting, spinning, twisting, plying. Galvanized G350 spiral bonded. 16-20 m/s. NC-58. AS 3957, NFPA 660.
• Tufting hall (Godfrey Hirst, Cavalier). Galvanized G350 rectangular insulated supply, spiral lint. 8-10 m/s supply, 18-22 m/s lint. NC-60. AS 1668.2 and NFPA 660.
• Heat-set tunnel oven. 316L stainless insulated welded seam with heat recovery. 15-20 m/s. NC-55. NFPA 86 and AS 1530.4.
• Latex SBR back coating booth. 316L stainless welded seam. 12-18 m/s. NC-55. NFPA 33 and AS/NZS 60079 Zone 1.
• PU/TPU isocyanate back coating booth. 316L stainless welded seam with continuous isocyanate monitor. 12-18 m/s. NC-55. NFPA 33, AS/NZS 60079 Zone 1, AS/NZS 1715/1716.
• Back coating cure oven. 316L stainless insulated welded seam. 15-20 m/s. NC-55. NFPA 86.
• Carpet tile lamination (Interface, Shaw, Mohawk). 316L stainless insulated welded seam. 15-20 m/s. NC-55. NFPA 86.
• Carpet tile cutting and packaging. Galvanized G350 spiral bonded. 18-20 m/s. NC-55. NFPA 660.
• Shearing and trimming. Galvanized G350 spiral bonded. 18-22 m/s. NC-58. NFPA 660.
• Binding and edge overlock. 316L stainless local. 12-15 m/s. NC-55. NFPA 33.
• Roll-up and packaging. Galvanized G350 rectangular insulated. 8-10 m/s. NC-50. AS 1668.2.
• LVT rotogravure print booth (Karndean, Tarkett). 316L stainless welded seam. 12-18 m/s. NC-55. NFPA 33 and AS/NZS 60079 Zone 1.
• LVT lamination press. 316L stainless insulated welded seam. 15-20 m/s. NC-55. NFPA 86.
• LVT click-lock cutting and embossing. Galvanized G350 spiral bonded. 18-20 m/s. NC-55. NFPA 660.
• Linoleum cure chamber (Forbo). Galvanized G350 insulated. 8-10 m/s. NC-50. AS 1668.2.
• Synthetic turf tufting (TigerTurf, APT). Galvanized G350 rectangular insulated supply, spiral lint. 8-10 m/s supply, 18-22 m/s lint. NC-60. AS 1668.2 and NFPA 660.
• Synthetic turf back coating. 316L stainless welded seam. 12-18 m/s. NC-55. NFPA 33 and AS/NZS 60079 Zone 1.
• Synthetic turf crumb dosing. Galvanized G350 spiral bonded. 20-22 m/s. NC-58. NFPA 660 with deflagration venting.
• Athletic surface paint and line marking. 316L stainless local. 12-15 m/s. NC-55. NFPA 33.
• Underlay rubber crumb (Dunlop, Bridgestone). Galvanized G350 spiral bonded. 20-22 m/s. NC-58. NFPA 660.
• Underlay PU foam. 316L stainless welded seam with isocyanate monitor. 12-18 m/s. NC-55. NFPA 33 and AS/NZS 60079.
• Underlay felt and wool. Galvanized G350 spiral bonded. 16-18 m/s. NC-58. NFPA 660.
• Carpet recycling (ECONYL, Bloom). 316L stainless welded seam with R-2.0 insulation. 18-22 m/s. NC-58. NFPA 86 and AS/NZS 60079 Zone 2.
• Warehouse (Carpet Court distribution). Galvanized G350 spiral or rectangular. 6-10 m/s. NC-55. AS 1668.2 and AS 1940 for the adhesive store.
• Retail showroom (Carpet Court, Choices, Carpet One). Galvanized G350 rectangular insulated. 4-6 m/s. NC-40. AS 1668.2 NCC Class 6.

Why galvanized fails — the engineering audit on a carpet plant

Most ductwork failures we see on Australian carpet, broadloom, tufted tile, underlay and synthetic turf plants come from a single root cause: someone specified galvanized steel for a duty cycle that called for stainless, the project came in under budget, and the duct lasted 18-36 months before the operator started seeing rust marks on the finished carpet or a regulator started asking why the styrene reading on the operator breathing zone is above the WES. The five most common failure modes on a carpet plant are worth listing in detail.

• Dyeing-house humidity and chemistry corrosion. Galvanized steel exposed to 60-80% RH and acid, alkali, salt or azo-dye chemistry corrodes through the zinc layer in 12-24 months. The zinc oxide flake falls into the dye bath. The operator reports colour-fastness failures and the duct is condemned. Reference fix: 316L stainless welded seam for general dye exhaust, FRP for sulphuric exhaust, polypropylene-lined steel for caustic exhaust.
• Latex SBR back coating corrosion. Galvanized steel exposed to the styrene, butadiene, MEK, toluene, ethyl acetate, acetone and trace ammonia residual from the SBR latex coater extract pits and corrodes inside 12-18 months. The pit progression accelerates because the condensate is acidic. Reference fix: 316L stainless welded seam for the booth extract trunk.
• Heat-set tunnel oven condensate. Heat-set tunnel oven exhaust at 130-180 degrees Celsius condenses on the inside of any duct section that drops below the dewpoint. The condensate is an oily, plasticiser-rich liquor from the fibre lubricant carrier. Galvanized fails inside 18 months. Reference fix: 316L stainless welded seam, R-1.5 insulation, slope to condensate sump, AS 1530.4 fire-resistance grading on the riser through the Class 8 floor plate.
• Fibre dust accumulation and deflagration risk. Fine nylon, polyester, polypropylene or wool fibre dust accumulates in horizontal duct runs longer than 6 m, in flat-bottom hoppers, in transitions and at any joint discontinuity. Bridged dust becomes a fuel deposit. An ignition source from a static discharge, a hot bearing, a maintenance grinder spark or a stray cigarette becomes a deflagration. The duct itself is not failing but the dust deposit makes the whole installation unsafe. Reference fix: no-flat-bottom hoppers, slope on every horizontal run, 22 m/s minimum transport velocity, bonded and grounded joints end to end, NFPA 660 deflagration venting on the collector and isolation valves on the trunk.
• Isocyanate sensitisation incident. A TPU back coating booth running at the design rate may sit under the 0.005 ppm WES on average but produce a sensitisation incident from a single transient excursion (a hose disconnect, a stuck valve, an operator entering the booth without RPE). Once an operator is sensitised, even a vanishingly small subsequent exposure triggers an asthmatic response. Reference fix: continuous isocyanate monitor wired to the BMS, emergency dump-and-purge sequence, AS/NZS 1715/1716 RPE programme with PAPR for any operator inside the booth envelope, fully enclosed booth with interlocked access.

SBKJ machine configuration for an Australian carpet-sector fabricator

For an Australian duct fabricator serving Godfrey Hirst at Geelong, Cavalier Bremworth at Tottenham Victoria, Karndean, Tarkett, Forbo, Interface, Shaw, TigerTurf and APT, the reference SBKJ machine configuration is built around the SBAL-V auto duct production line with the multi-coil and material change-over feature, an SBFB-1500 round spiral tubeformer for the fibre dust collection and lint return mains, an SBSF-1525 heavy-gauge tube line for the 250 degree Celsius 2-hour fire-rated stainless risers, an SB-ZF1500 station for the carpet tile and LVT trim mains, an SBPC1500 plasma cutter for branch and stub-in work, an SBLR-600 laser welder for the high-pressure stainless seam, and an SBTF-1500/1602/2020 family of larger-diameter spiral tubeformers for the synthetic turf and athletic-surface plant trunk mains.

SBAL-V auto duct production line

The SBAL-V is a five-line auto duct line that takes coil stock through decoiling, levelling, notching, longitudinal seaming and corner folding to deliver a finished rectangular duct section. For carpet sector work we recommend the multi-coil feature so the operator can change between galvanized G350 and 316L stainless steel in under one hour with PLC recipe selection. The TDF flange end-forming is integrated. The line accepts coil from 0.5 mm to 1.5 mm thickness across the full galvanized and stainless range. This is the production tool for the rectangular supply duct in the tufting hall, the dye house make-up air handler, the heat-set tunnel oven make-up, the back coating booth supply, the carpet tile lamination supply, the LVT rotogravure print booth supply and the warehouse and showroom supply.

SBFB-1500 round spiral tubeformer

The SBFB-1500 forms round spiral tube duct from coil stock at production rates suitable for a carpet-plant fibre dust collection main. The 1500 model handles 80-1500 mm diameter and is configured for both galvanized G350 and 316L stainless coil. Lockformed seam is the default for general fibre extract; for the higher-pressure SBR booth extract and the heat-set tunnel oven exhaust the seam is welded by a follow-on TIG or laser station. The SBFB-1500 produces continuous spiral seam suitable for the 18-22 m/s transport velocity sizing on the lint-return and dust-collection mains. Bonded and grounded joints with measured continuity test on each section after installation.

SBSF-1525 heavy-gauge tube line

The SBSF-1525 is the production tool for the 250 degree Celsius 2-hour fire-rated stainless riser through any Class 8 industrial floor plate. The line handles 316L stainless 1.5 mm minimum wall thickness, welded longitudinal seam, full pressure-test on each section. AS 1530.4 fire-resistance grading. This is the riser specification for the heat-set tunnel oven exhaust, the latex SBR cure oven exhaust, the back coating cure oven exhaust, the carpet tile lamination cure oven exhaust, and the LVT lamination press exhaust where each riser passes through a Class 8 floor plate.

SB-ZF1500 carpet tile and LVT trim main station

The SB-ZF1500 is configured for the carpet tile and LVT trim main fabrication — the dust trunks serving the Interface, Shaw, Milliken, Mohawk modular tile finishing area and the Karndean, Tarkett, Forbo, Polyflor LVT cutting and embossing area. Galvanized G350 spiral with bonded and grounded joints. NFPA 660 classified. Transport velocity 18-20 m/s sizing. The 80-1500 mm diameter range covers the typical tile and LVT trim main sizes.

SBPC1500 plasma cutter

The SBPC1500 plasma cutter is the production tool for branch and stub-in cutting on the latex SBR booth extract trunk, the heat-set tunnel oven exhaust riser, the dust collection main isolation valve cut-outs, and any one-off fabrication where a precise large-diameter cut is required. The plasma cutter handles 1.0-2.0 mm 316L stainless steel and 1.0-2.0 mm galvanized G350 with clean burr-free edge suitable for follow-on welding.

SBLR-600 laser welder

The SBLR-600 laser welder is the production tool for the high-pressure 316L stainless seam on the rotogravure print booth extract, the isocyanate TPU booth extract and the carpet tile lamination press exhaust. Laser seam is faster, cleaner and produces a smaller heat-affected zone than TIG seam, which keeps the 316L corrosion resistance intact through the weld. Pressure-tight to AS 4254 Class D for the higher-pressure runs.

SBTF-1500, SBTF-1602 and SBTF-2020 large-diameter spiral tubeformer family

The SBTF-1500, SBTF-1602 and SBTF-2020 family covers the larger-diameter spiral tube duct required for the synthetic turf and athletic-surface plant trunk mains. The 2020 model handles up to 2000 mm diameter, which is the typical trunk size for a TigerTurf or APT factory main feeding multiple back-coating booths. The 1602 handles up to 1600 mm. The 1500 handles up to 1500 mm. Galvanized G350 and 316L stainless coil. Lockformed or welded seam.

Optional auxiliary stations

For a fabricator serving the full carpet, LVT, underlay and synthetic turf sector we typically recommend four optional auxiliary stations: a hydraulic press brake for FRP and polypropylene flange forming for the dye-house acid-resistant sections, an automatic flange-bolt-hole punching station for the high-volume galvanized rectangular work serving the tufting hall and the warehouse, a dedicated 316L stainless coil prep line for the back coating and heat-set oven runs, and a portable TIG seam welder for site repair and modification work.

Godfrey Hirst Geelong tufting line — reference project profile

Godfrey Hirst at Geelong is the largest carpet manufacturer in Australia. Mohawk Industries acquired the operation in 2018 and the integrated plant covers broadloom, carpet tile, residential and commercial construction across both natural and synthetic fibre. The Norlane and Pakenham Victoria sites run the tufting halls, the heat-set tunnel ovens, the back coating booths, the cure ovens, the shearing and trimming, the roll-up, the packaging and the warehouse and despatch.

A reference ductwork specification for a Godfrey Hirst-scale tufting hall covers the SBAL-V supply duct in galvanized G350 rectangular running overhead with low-velocity drum diffusers at NC-60 acoustic, the SBFB-1500 lint extraction spiral trunk in galvanized G350 with NFPA 660 deflagration venting on the central baghouse, the SBSF-1525 heat-set tunnel oven exhaust riser in 316L stainless 1.5 mm with AS 1530.4 fire-resistance grading, the SBAL-V in 316L stainless coil mode for the back coating booth extract trunk feeding a regenerative thermal oxidiser, the SBLR-600 laser-welded 316L stainless seam on the cure oven exhaust, and the SB-ZF1500 trim main station for the shearing, trimming and cutting dust trunks. Total duct package on a Godfrey Hirst-scale tufting hall runs to several kilometres of duct across the galvanized supply, the 316L stainless extract and the FRP and polypropylene-lined dye-house sections.

Cavalier Bremworth Tottenham Victoria — reference project profile

Cavalier Bremworth is the New Zealand parent that acquired the Australian Feltex Carpets operation. The Tottenham Victoria plant is one of the major Australian wool-rich premium broadloom operations. The plant runs a wool scour line, a dye house, a fibre opening and carding hall, a tufting hall, a heat-set tunnel oven, a SBR latex back coater, a cure oven, a shearing hall and a packaging cell.

A reference ductwork specification for the Tottenham wool-rich plant covers the SBAL-V in 316L stainless coil mode for the wool scour exhaust and the dye-house general exhaust, FRP fabricated separately for the sulphuric and azo-dye exhaust runs, polypropylene-lined steel for the caustic exhaust, the SBFB-1500 galvanized G350 spiral for the wool fibre opening and carding lint trunk with NFPA 660 deflagration venting, the SBAL-V in galvanized G350 mode for the tufting hall supply, the SBSF-1525 in 316L stainless 1.5 mm for the heat-set tunnel oven riser, and the SBAL-V again in 316L stainless mode for the SBR latex back coater booth extract.

Karndean LVT vinyl manufacturing — reference project profile

Karndean Designflooring runs design and distribution across Sydney and Melbourne for its luxury vinyl tile range. The reference project profile is the local distribution warehouse plus the sample-making and customer-experience showroom. The bulk LVT manufacturing happens through Karndean's global supply chain, but the Australian operation handles bulk-roll cutting, custom-design sample making and the customer-experience showroom that supports the Australian specifier and retailer base.

A reference ductwork specification for the Karndean local operation covers the SBAL-V in galvanized G350 rectangular for the warehouse supply and the sample-making cell supply, the SB-ZF1500 trim main station for the cutting dust trunk, and the SBAL-V in galvanized G350 rectangular insulated for the showroom supply at NC-40 acoustic with F7 supply filtration. The bulk LVT manufacturing-scale ductwork (the rotogravure print booth, the heat-set lamination press, the embossing roller) belongs to the global plant ductwork specification and is not part of the local Australian package, but the same SBKJ machine configuration scales to the bulk manufacturing case when the global supply chain runs a new line.

TigerTurf and APT Asia Pacific synthetic turf manufacturing — reference project profile

TigerTurf Australia and APT Asia Pacific Synthetic Turf supply the major Australian sports and recreation installations including Sydney Olympic Park, AAMI Park, school sports ovals and council sports fields, plus the wider private residential and commercial market. The factory ductwork sits between broadloom carpet and rubber crumb processing.

A reference ductwork specification for a TigerTurf or APT plant covers the SBAL-V in galvanized G350 rectangular for the tufting hall supply at NC-60 acoustic and 60-65% RH, the SBFB-1500 galvanized G350 spiral for the lint extraction trunk with NFPA 660 deflagration venting on the central baghouse, the SBSF-1525 in 316L stainless 1.5 mm for the heat-set tunnel oven riser, the SBAL-V in 316L stainless mode for the TPU or SBR back coater booth extract feeding a regenerative thermal oxidiser, the SBLR-600 laser-welded 316L stainless seam on the cure oven exhaust, the SB-ZF1500 trim main station for the cutting and trim dust trunk, and a dedicated galvanized G350 spiral with NFPA 660 deflagration venting on the tyre crumb dosing extract. The SBTF-2020 large-diameter spiral covers the central trunk main where the multiple back-coating booth extracts manifold into the regenerative thermal oxidiser inlet.

Interface Australia commercial carpet tile — reference project profile

Interface Australia (with its global parent in Atlanta GA) supplies the commercial office, retail and institutional modular carpet tile market with the EcoWorx backing system, the ReEntry recycling programme and the wider Cradle to Cradle and Net-Works supply chain. The Australian operation focuses on design, sample-making, distribution and customer-experience showroom.

A reference ductwork specification for the Interface Australian operation is similar to the Karndean profile — local warehouse, sample-making cell and showroom. The bulk tile manufacturing happens through the global plant network. The same SBKJ machine configuration scales to the bulk manufacturing case when a global plant is built.

Dunlop Flooring underlay manufacturing — reference project profile

Dunlop Flooring underlay is one of the most recognisable Australian carpet underlay brands. The product range covers rubber crumb, polyurethane foam, felt and wool underlay constructions. The manufacturing plant runs a crumb dosing line, a binder application, a press cure, a cooling and a roll-up.

A reference ductwork specification for a Dunlop Flooring underlay plant covers the SBFB-1500 galvanized G350 spiral for the crumb dosing dust trunk with NFPA 660 deflagration venting, the SBAL-V in 316L stainless mode for the binder application booth extract (PU or SBR binder, NFPA 33 spray-finish), the SBSF-1525 in 316L stainless 1.5 mm for the press cure oven riser, and the SBAL-V in galvanized G350 rectangular for the cooling and roll-up area supply.

Recycling and end-of-life — ECONYL, Mohawk Bloom and the EcoWorx route

The end-of-life carpet recycling routes through Aquafil ECONYL (nylon 6 chemical depolymerisation), Mohawk Bloom (polyester mechanical recycling), Interface EcoWorx (PVC-free backing recycling), Shaw Re[CYCLE] (nylon and polyester recovery), Cavalier wool recycling and Godfrey Hirst recovery channels feed the recycled-content fibre back into the manufacturing supply chain. The factory ductwork for a chemical depolymerisation reactor covers a 316L stainless welded seam exhaust with R-2.0 insulation, NFPA 86 industrial oven exhaust at 280-320 degrees Celsius reactor temperature, slope to a condensate sump on the cool end, and AS/NZS 60079 Zone 2 within the leakage envelope. The mechanical recycling and shredding side covers a galvanized G350 spiral with bonded joints and NFPA 660 deflagration venting on the shred dust collector.

How SBKJ supports the carpet sector project

SBKJ Group supplies duct-fabrication machinery to mechanical contractors and integrated plant operators serving the Australian carpet, broadloom, tufted carpet tile, underlay, rug and synthetic turf manufacturing sector. Our typical engagement on a carpet-sector project covers five areas.

• Specification review. Our engineers review the project ventilation drawing pack against AS 1668.2, AS 4254, AS 1530.4, AS 1668.1, AS/NZS 60079, AS 3957, AS 1940, AS/NZS 1715/1716, NFPA 660, NFPA 68, NFPA 69, NFPA 33, NFPA 86 and the NCC Class 8 and Class 6 framing. We identify the material change-over points between galvanized G350, 316L stainless, FRP and polypropylene-lined sections and confirm the duct fabrication machinery is matched to the worst-case coil specification.
• Machine configuration. We supply the SBAL-V auto duct line with multi-coil feature, the SBFB-1500 round spiral tubeformer for the fibre dust collection main, the SBSF-1525 heavy-gauge tube line for the 250 degree Celsius 2-hour fire-rated risers, the SB-ZF1500 carpet tile and LVT trim main station, the SBPC1500 plasma cutter, the SBLR-600 laser welder for the high-pressure stainless seam, the SBTF-1500 / SBTF-1602 / SBTF-2020 family for the synthetic turf trunk mains, and any auxiliary stations matched to the project scope. Every machine ships with the matched roll set and PLC change-over programme.
• Factory Acceptance Test. Every line is FAT-tested in our workshop with the buyer's nominated coil — typically galvanized G350 at 0.8 to 1.2 mm and 316L stainless at 1.0 to 1.5 mm — before shipment. The FAT runs a full production cycle on each material the line will see in service. The FAT report is signed off by the SBKJ engineer and witnessed by the buyer or a buyer's representative.
• Installation, commissioning and training. SBKJ engineers travel to site for 5-10 days for installation, mechanical and electrical commissioning, operator training and a first-article duct sign-off. The training covers the change-over procedure between galvanized G350 and 316L stainless coil, the maintenance schedule for the multi-coil head, the deflagration vent rating verification on the dust collection main, and the AS 4254 ductwork construction conformance statement.
• ARBS 2026 Sydney — working sample on the stand. SBKJ Group exhibits at ARBS 2026 in Sydney in May. The stand carries a working sample of the SBAL-V multi-coil change-over and a 316L stainless seam-welded section in the carpet-plant specification. Visit us to see the production tool that delivers the Godfrey Hirst, Cavalier Bremworth, Karndean, Interface, TigerTurf and APT plant duct package.

Operator respiratory protection and the duct interface

The operator respiratory protection programme per AS/NZS 1715 (selection, use and maintenance) and AS/NZS 1716 (performance) is the last-resort control when a process upset puts an operator into a higher zone than the duct is designed to clear. The duct sets the residual exposure profile on the floor with all sources at design rate. The RPE catches the residual when a damper sticks, a hose disconnects, a hood seal fails or an operator enters a booth without authorisation.

The RPE selection for a carpet plant covers: P2 disposable filtering face piece for general dust on the tufting hall and the warehouse; P3 reusable half-face with combined particle and gas cartridge for the shearing, trimming and dye-house chemistry handling; full-face air-purifying respirator for the SBR latex booth and the cure oven proximity work; PAPR powered air-purifying respirator with a hood for any operator inside the TPU isocyanate booth envelope or any extended-duration booth entry; and air-line supplied breathing air for confined-space entry into the duct, the collector or the regenerative thermal oxidiser for maintenance. The RPE programme is integrated with the ISO 45001 occupational health and safety management system and audited every 12 months. The fit-testing programme runs annually for each operator on each respirator pattern they will wear.

State EPA waste licence — the duct termination dossier

The state EPA waste licence — NSW EPA, VIC EPA, QLD DES, SA EPA, WA DWER, TAS EPA — covers the carpet plant's emission to air, water and land. The duct termination at the stack is a licensed point source and the emission factor (mass per unit production for each pollutant) is in the licence dossier. The point sources on a typical Australian carpet plant cover:

• Latex SBR back coater booth stack. Styrene, butadiene, MEK, toluene, ethyl acetate, acetone, VOC general. Regenerative thermal oxidiser destruction efficiency 95-99% on the controlled emission.
• PU/TPU isocyanate back coater booth stack. MDI, TDI, VOC general. Regenerative thermal oxidiser destruction efficiency 99% on the controlled emission. Continuous monitoring on the inlet to verify isocyanate concentration before destruction.
• Heat-set tunnel oven stack. CO, CO2, NOx, VOC general from the LPG or natural gas burner. Heat-recovery exchanger upstream of the stack.
• Back coating cure oven stack. Same chemistry as the back coater booth, post-cure. Tied to the regenerative thermal oxidiser inlet on most modern plants.
• Carpet tile lamination cure oven stack. CO, CO2, VOC general from the lamination press exhaust.
• Wool scour exhaust stack. Water vapour, ammonia, lanolin grease aerosol. Wet scrubber and grease recovery upstream.
• Wool dyeing exhaust stack. Water vapour, acid, alkali, salt, residual dye chemistry. FRP wet scrubber upstream on the legacy lines.
• Fibre dust collector vent. Filtered through baghouse. Continuous opacity monitor on the outlet.
• LVT rotogravure print booth stack. MEK, ethyl acetate, acetone, VOC general. Carbon adsorber or RTO upstream.
• Synthetic turf back coater stack. Same chemistry as carpet SBR or TPU back coater. RTO upstream.

The duct fabrication conformance to AS 4254 is part of the EPA licence dossier because the duct is the engineering controls that contains the licensed emission. A duct that leaks downstream of the destruction equipment is a non-compliance event under the EPA licence regardless of whether the destruction equipment is functioning correctly.

Cradle to Cradle, Green Star, NABERS and the chemistry exclusion list

The product certification side of the Australian carpet industry — Cradle to Cradle, Green Star, NABERS, Australian Made, ECONYL, Mohawk Bloom, Interface EcoWorx and the wider Carpet Institute of Australia and Floorcoverings Industry Australia framework — drives the chemistry exclusion list and the recycled-content target. The chemistry exclusion list typically covers: phthalate plasticiser (DEHP, BBP, DBP, DnHP, DIDP, DINP), antimony brominated flame retardant, urea-formaldehyde binder, Cr VI mordant, certain banned aromatic-amine-precursor azo dyes, perfluorinated stain-repellent chemistry (PFOS, PFOA and the C8 chemistry phased out), and PVC where Cradle to Cradle Gold-tier or higher is targeted.

The ductwork specification is downstream of the chemistry exclusion list — a plant that has phased out the high-impact chemistry has a smaller duct material problem because the corrosion load and the VOC load are both lower. A plant that retains the legacy chemistry has a higher duct material specification because the corrosion load is higher. The Cradle to Cradle Gold or Platinum-tier plants we see in Australia run on the 316L stainless plus FRP-and-polypropylene-lined duct envelope with the regenerative thermal oxidiser sized for the worst-case VOC load.

Energy recovery on the carpet plant

The two biggest energy-recovery opportunities on an Australian carpet plant are the heat-set tunnel oven exhaust and the back coating cure oven exhaust. Both run at 130-200 degrees Celsius with full condensate load. An air-to-air plate or rotary heat exchanger sized for the worst-case dirty side delivers 60-75% sensible heat recovery to the make-up air supply. The make-up air supply feeds the burner secondary air, the dye-house preheat, the wool scour make-up and the tufting hall make-up depending on the layout.

The duct on the heat exchanger interface is 316L stainless welded seam with R-1.5 insulation on both sides. The dirty side has a wash-down cycle on the exchanger face that ties to the plant cleaning schedule. The cold side has a condensate drain and a thermal trim coil to maintain the make-up air supply temperature within the AS 1668.2 tolerance band. The annual energy saving from the heat-set and cure-oven heat recovery on a Godfrey Hirst-scale plant runs into millions of kWh equivalent and pays back the heat exchanger and duct package inside 2-3 years on current natural-gas and LPG pricing.

Acoustic environment across the carpet plant

The acoustic criterion across a carpet plant varies from NC-60 in the tufting hall to NC-40 in the showroom. The duct sizing, the terminal device selection and the acoustic treatment have to match the criterion of each zone, not a single plant-wide number.

• Tufting hall NC-60. Tufting machine noise at 85-92 dB(A) masks the duct. Velocity 8-10 m/s in supply, 18-22 m/s in lint extraction.
• Heat-set oven and back coating hall NC-55. Burner and coater noise masks the duct. Velocity 12-18 m/s.
• Shearing and trimming NC-58. Shearing machine noise masks the duct. Velocity 18-22 m/s.
• Packaging NC-50. Flow-wrap and shrink-tunnel noise. Velocity 8-10 m/s.
• Warehouse NC-55. Forklift and material handling noise. Velocity 6-10 m/s.
• Showroom NC-40. Customer experience criterion. Velocity 4-6 m/s with low-velocity diffusers and acoustic lining on the supply duct.
• Office and design studio NC-40. Same as showroom. Sample fabric protection from dust requires F7 supply filtration.

FAQ

Why is fibre dust from carpet tufting an explosion risk?

Nylon, polyester, polypropylene and wool fibre dust generated at tufting, shearing, trimming and binding stages is a combustible particulate solid with Kst values in the 100-160 bar·m/s range. Under AS 3957 and NFPA 660 (which consolidated NFPA 654 and NFPA 664 in 2025) the dust collection ductwork is classified Zone 21 inside and Zone 22 within 1 m of any leakage point. The duct has to be bonded and grounded end-to-end, fitted with deflagration vents per NFPA 68, isolated with chemical or mechanical isolation valves per NFPA 69, and constructed so internal surfaces do not accumulate fibre deposits.

What duct material handles latex SBR back coating extract on a carpet line?

The reference specification is 316L stainless steel with welded longitudinal seams for the extract trunk, NFPA 33 spray-finish classification for the coater enclosure, AS/NZS 60079 Zone 1 inside the booth and Zone 2 within 1 m, and a dedicated regenerative thermal oxidiser or carbon adsorber on the stack. The duct is sloped 1:100 minimum to a condensate sump that ties to the trade-waste treatment plant.

What ventilation suits a heat-set tunnel oven on a carpet line?

NFPA 86 applies. Duct is 316L stainless steel with R-1.5 insulation, welded longitudinal seams, slope 1:100 to a condensate sump, and an air-to-air heat exchanger sized for the worst-case dirty side. The clean side feeds the burner make-up air and the secondary dye-house preheat. CO and CO2 monitors are wired to the BMS to trip the oven if the LPG or natural gas burner combustion deteriorates.

How does isocyanate TPU back coating change the duct specification?

Isocyanate is the killer in carpet back coating with a WES of 0.005 ppm STEL. The extract duct is 316L stainless welded seam with a fully enclosed application booth, a continuous direct-reading isocyanate monitor wired to the BMS, an emergency dump-and-purge sequence, AS/NZS 60079 Zone 1 inside the booth and Zone 2 within 1 m, and operator respiratory protection to AS/NZS 1715/1716. The exhaust ties to a regenerative thermal oxidiser sized for the full TDI/MDI load.

How is formaldehyde managed in carpet secondary back coating and adhesive?

Formaldehyde is an IARC Group 1 carcinogen with a WES of 1 ppm STEL. The duct on a formaldehyde-using line is 316L stainless steel with welded seams, dedicated booth enclosure, continuous formaldehyde monitor, AS/NZS 60079 hazardous-area classification, and a regenerative thermal oxidiser or activated-carbon adsorber on the stack. Most current-generation Australian carpet manufacture has migrated to acrylic, EVA or low-formaldehyde binders to meet Green Star, NABERS and Cradle to Cradle certification.

How is the legacy chromium dye chemistry in wool dyeing managed?

Cr VI is an IARC Group 1 carcinogen and the practice has been phased out across the major Australian and New Zealand operators including Bremworth and Cavalier in favour of low-impact dye chemistry. Where any residual Cr VI handling remains, the duct specification is 316L stainless steel with welded seams, a dedicated wet scrubber on the exhaust, and AS/NZS 60079 hazardous-area classification through the chemistry handling room.

What SBKJ machine configuration suits an Australian carpet-sector duct fabricator?

SBAL-V auto duct production line with multi-coil for galvanized and 316L stainless change-over, SBFB-1500 round spiral tubeformer for the fibre dust collection main, SBSF-1525 heavy-gauge tube line for the 250 degree Celsius 2-hour fire-rated stainless risers, SB-ZF1500 station for the carpet tile and LVT trim mains, SBPC1500 plasma cutter for branch and stub-in work, SBLR-600 laser welder for the high-pressure stainless seam, and the SBTF-1500/1602/2020 family of larger-diameter spiral tubeformers for the synthetic turf trunk mains. Every machine ships with the matched roll set and PLC change-over programme.

What duct serves a Karndean or Tarkett LVT vinyl manufacturing line?

316L stainless steel with welded seams for the print solvent and lamination extract, galvanized G350 for the print room ambient and the cutting room ambient, FRP for any PVC stabiliser exhaust where vinyl chloride monomer residual is present, and AS/NZS 60079 Zone 1 inside the rotogravure print booth. Phthalate plasticiser is being phased toward DOTP, DINP and bio-based alternatives. Antimony brominated flame retardant in the wear layer is similarly phasing.

How does synthetic turf manufacturing differ from carpet on the HVAC duct side?

Synthetic turf — TigerTurf, APT, SmartGrass, EnviroTurf, Polytan, FieldTurf — uses the same broad carpet construction (fibre tufting, latex or TPU back coating, heat-set fixation) but with a coarser fibre gauge, a heavier coating weight and an additional tyre crumb infill and silica sand infill handling stage. The crumb dosing is a combustible-dust zone with NFPA 660 deflagration venting on the dust collector. Sydney Olympic Park, AAMI Park and the major school and council sports fields are reference installations.

How does SBKJ handle the change-over between galvanized and 316L stainless on a single carpet-plant duct package?

The SBAL-V auto duct line accepts a coil change-over in under one hour with the multi-coil head and PLC recipe selection. The SBFB-1500 spiral tubeformer handles both galvanized and 316L stainless. The SBSF-1525 heavy-gauge tube line is dedicated to the 250 degree 2-hour fire-rated stainless risers. We supply the matched roll set, PLC programme, FAT test on the buyer's nominated coil, and the site change-over procedure document for the fabricator's quality system.

SBKJ Group contact — get the carpet-plant duct package moving

SBKJ Group is based at Box Hill North VIC and supplies HVAC duct fabrication machinery to mechanical contractors and integrated plant operators serving the Australian carpet, broadloom, tufted carpet tile, underlay, rug and synthetic turf manufacturing sector. We exhibit at ARBS 2026 in Sydney in May with a working SBAL-V multi-coil sample on the stand. Email sales@sbkjduct.com, call +61 435 074 994, or visit sbkjduct.com.

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