How to manufacture polyester fiber/polyester filament:

Creating a Monomer: The process begins with the reaction of ethylene glycol with dimethyl terephthalate at high heat, resulting in a monomer.

Creating a Polymer:

Further addition of dimethyl terephthalate with the resulting monomer creates a polymer.

Extruding:

This molten polyester polymer is extruded from the reaction chamber in long strips, allowed to cool and dry, and then broken into small pieces.

Spinning:

Polyester goes through a melt spinning system, where the resulting chips melt again to create a honey-like substance. This substance is then extruded through spinnerets to form fibers. Next, the fibers transfer to a winding machine, producing a sliver that looks like noodles. Subsequently, the slivers move to the creel stage, the first stage of the drawing section.

From Slivers to Final Product

In the roller of the drawing machine, the slivers draft in several steps using chemicals such as lubricants and titanium dioxide. Consequently, this process yields 1.4 denier primary fiber. Next, the primary fiber automatically runs into the dryer, where it becomes moisture-free and smooth. Afterward, it transfers to the cutting machine, which cuts it into the desired length according to buyer requirements, resulting in smooth polyester staple fibers.

Staple Recycle Fiber:

Dried flakes are melted and molded into the desired shape or further processed into granules. The flakes are melted with regulated temperatures using specialized equipment to ensure they are not destroyed.

Identification and Classification:

In this step, workers test small plastic particles to determine their quality and class. The first test checks density by placing the particles in a large tank of water; denser particles sink, and less dense ones float.

Determining Particle Thickness, Melting Point, and Color

Compounding or Extruding:

In this step, shredded plastic is melted and extruded into pellets used for future plastic product production.

Why recycle plastic PET?

Reduces Pollution:

Recycling plastic instead of producing it from scratch significantly reduces toxic greenhouse gas emissions. Additionally, improper disposal of plastic waste can contaminate soil and water, which harms wildlife. In contrast, recycling sends plastic to proper centers, where workers process and make it reusable efficiently.

Conserves Energy:

Producing one ton of plastic requires almost 5,774 kilowatt-hours of energy, 16 barrels of oil, 1,000 to 2,000 gallons of gasoline, and 30.4 cubic yards of landfill space. In contrast, recycling plastic can save up to 66% of the energy and conserve non-renewable resources. Furthermore, recycling plastic helps save approximately 7.4 cubic meters of landfill space per ton of plastic.

Decreases Demand for Fossil Fuel:

Recycling plastic reduces the demand for non-renewable resources such as fossil fuel, crude oil, natural gas, and coal.

Increases Employment Opportunities:

Collecting and recycling plastics generate jobs and create new business opportunities, which improve the economy and living standards.

Advantages:

The production of recycled polyester yarn uses 2/3 less energy and almost 90% less water than virgin polyester production. No new petroleum is required, reducing environmental impact.

What can be saved by plastic recycling?

• Landfill:

  Eight plastic drink bottles are kept out of landfill for each meter of polar fleece made from 80% recycled PET bottles.

  Fossil Fuels:

  Virgin polyester is derived from petroleum, so recycling saves on fossil fuels.

  Patagonia’s Impact:

  Patagonia estimates that 25 drink bottles go into each jacket, saving a barrel of oil and avoiding half a ton of toxic air emissions compared to virgin polyester production.

Key Facts:

• 10 plastic bottles = 1 pound of polyester fiber
• Recycling 1 ton (2,000 lbs) of plastic bottles saves 3.8 barrels of oil
• Recycling 1 million plastic bottles saves 250 barrels of oil
• Recycling 1 million plastic bottles eliminates 180 metric tons of CO2 emissions
• 10% of all US oil consumption (2 million barrels per day) is used to make plastics

The Energy and Environmental Savings of Recycling Plastic Bottles

• Recycling plastic bottles takes 8 times less energy than producing new ones
• 150 fleece garments made from recycled bottles save 1 barrel of oil
• 500 t-shirts made from recycled bottles save 1 barrel of oil
• 50 backpacks made from recycled bottles save 1 barrel of oil
• Supplying the plastic bottles Americans consume each year requires 47 million barrels of oil and releases 1.0 billion pounds of CO2

The Construction Capabilities of Fiber and Yarn:

• Fibers: All natural and manmade fibers and blends
• Open-End: .4Ne to 14Ne or .67Nm to 23.6Nm in singles and plies
• DREF Spun: Customized solutions and proprietary capabilities
• Twisting: Up to 16 components

Global Statistics:

In 2011, the world collected approximately 7.5 million tons of PET, which resulted in 5.9 million tons of flakes. In comparison, in 2009, manufacturers used 3.4 million tons of PET to produce fiber, 500,000 tons for bottles, 500,000 tons for APET sheets used in thermoforming, 200,000 tons for strapping tape, and 100,000 tons for miscellaneous applications (Source: PCI).

1.6 Million Tons Collected in 2011 and 81% Recycled in Switzerland in 2012

In 2011, Europe alone collected 1.6 million tons of PET bottles, and producers generated 1.12 million tons of PET flake after accounting for exported bales (Source: PCI for Petcore and EuPR). Additionally, in 2012, 81% of the PET bottles sold in Switzerland were recycled.

Recycled PET bottles used for a range of items:

Recycled PET bottles can be recycled back into bottles, but the fiber market is currently the major outlet. Fibers from recycled PET bottles are used to make clothing and carpeting.

Successful Yarn Applications:

• Colored recycled fiber blends producing economical colorfast yarns
• Integrating recycled fibers in the yarn center to create a core filler
• Matching a recycled fiber percentage within a high value, yet economical performance blend
• Optimizing a higher valued recycled fiber percentage in a commodity-driven yarn to enhance product value without significant price disruptions