Procotex Corporation serves as the Belgian headquarters of a family-owned enterprise led by the four Douchy brothers, with subsidiary companies located in Lithuania, Turkey, and France. One of the greatest challenges of our time is building a sustainable global economy one that can be supported by the planet indefinitely. Previous and current generations have often been criticized for compromising the ability of future generations to meet their needs in the pursuit of satisfying their own.
Procotex aims to become a leading global provider of sustainable fibres, driving innovation in everyday life and culture while offering these solutions at a more affordable cost than less sustainable, virgin alternatives. Sustainability and the conservation of raw materials remain the fundamental pillars of our corporate philosophy.
Sustainability
By utilizing recycled raw materials, Procotex achieves an 85% reduction in greenhouse gas (GHG) emissions compared to the processing of virgin raw materials. The embedded carbon footprint of Procotex’s recycled carbon and aramid fibres is 2.0 kg CO₂-equivalent per kilogram, significantly lower than the average 12.9 kg CO₂-equivalent per kilogram associated with virgin fibres.
Functionality of Fibres in Friction Applications
Fibrillated Fibres (Aramid, PAN):
Designed to enhance processing by improving the homogeneity of the mixture, while also increasing the mechanical strength of the friction material.
Short Fibres (Milled Carbon):
Used to maintain surface integrity and ensure consistent friction performance.
Long Fibre Strands (Cut Carbon):
Provide improved impact and crack resistance, contributing to stable friction performance.
Aramid and PAN
To evaluate performance relative to a commercial Aramid fibre (RAF CF001), two types of recycled Aramid (AR7313 and AR7302) and recycled PAN were incorporated into the friction formulation TR119 by replacing 1.5 weight % of Aramid fibres.
The results of this comparison are presented in the graph below. The recycled Aramid fibres demonstrated enhanced impact strength and improved second fade, while the recycled PAN exhibited increased impact strength and superior wear performance.
The Impact of Recycled Carbon Fibres on Friction Behavior (EB2025–COM–003)
The objective of this study was to investigate the application of recycled carbon fibres in low-steel friction materials, with a focus on understanding their behavior and functional properties.
| Tested fibres | |
| CF 6 mm | Precision cut Carbon fibre |
| CF 4 mm | Precision cut Carbon fibre |
| CF LS MLD 100 | Milled Carbon fibre desized |
| PREOX MLD 2 mm | Milled O-PAN fibre |
The composition of the low-steel Commercial Vehicle Disc Pad (CV-DP) friction formulation is presented in the table below. Recycled carbon fibres were incorporated as additional components. The mixtures were homogenized using a Lödige mixer and subsequently moulded via a direct-fill hot moulding process at 160 °C. Post-curing was conducted over 11 hours, with the temperature gradually increased from 120 °C to 220 °C.
| Component | Weight [%] |
| Resin | 7-10 |
| Fibres | 5-23 |
| Fillers | 10-30 |
| Abrasives | 5-12 |
| Friction Modifiers | 3-15 |
| Lubricants | 2-11 |
| Carbon Fibres | 3 or 6 |
| Total | 100 |
The friction performance of the formulations was evaluated using a Chase test in accordance with SAE J661 standards. Compared to the benchmark, all formulations exhibited a more stable coefficient of friction, enhanced fade resistance, and improved recovery characteristics. A summary of these results is presented in the graphs below.
The incorporation of carbon fibres resulted in improved wear performance. The corresponding data are provided in the table below. In comparison to the benchmark, all formulations demonstrated enhanced wear resistance.
| Wear results Chase SAE J611 in weight percentage | |||
| 3 Weight % Carbon fibres | 6 Weight % Carbon fibres | ||
| Bench (without fibres) | 1.67 | 1.67 | |
| CF 6 mm | 1.13 | 1.09 | |
| CF 4 mm | 1.13 | 1.09 | |
| CF LS MLD 100 | 0.96 | 0.79 | |
| PREOX MLD 2 mm | 1.31 | 1.39 | |
To conclude this study, the shear strength was evaluated in accordance with ISO 6312. The corresponding data are presented in the table below. In comparison to the benchmark, all formulations demonstrated enhanced wear Shear Strength.
| Shear Strength in MPa | ||
| 3 Weight % Carbon fibres | 6 Weight % Carbon fibres | |
| Bench (without fibres) | 6.4 | 6.4 |
| CF 6 mm | 6.8 | 7.0 |
| CF 4 mm | 6.9 | 7.6 |
| CF LS MLD 100 | 7.4 | 7.7 |
| PREOX MLD 2 mm | 7.5 | 7.7 |
Summary
The utilization of recycled raw materials in friction formulations can enhance material performance while simultaneously reducing greenhouse gas (GHG) emissions relative to the production and processing of virgin materials.
Both recycled Aramid and PAN fibres offer performance benefits (impact strength) over commercial Aramid fibres, with PAN excelling in wear resistance and Aramid in thermal fade behavior.
All recycled carbon fibre types enhanced friction stability, wear resistance, and mechanical strength. Milled fibres (especially CF LS MLD 100) showed the most significant improvements, particularly at 6 weight %.
For more information about this article or Procotex, please contact the individuals listed below.
Dieter Henau, Sales Manager, [email protected]
Arno Kerssemakers, Technical Consultant, [email protected]
More information can also be found at https://en.procotex.com/.
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