Polyester Fiber from Recycled Bottles Providing Cost Efficiency in Textile Manufacture

Written by:  • Edited by: Lindsay Evans
Published Jan 21, 2010

The process of recycling is always equated with cost reduction and with lessening if not eliminating the wastes that go to landfills. Polyester fibers from recycled bottles are now used to cut down on manufacturing costs for textiles. Naturally, this will also mean cheap clothes for consumers.

A Brief Background About Polyester Fibers and PET Bottles

800px-Polyestershirt
click to enlarge
The development of polyester fiber from recycled bottles is actually a matter of re-channeling the use of the chemical “polyethylene terephthalate” which is also the chemical ingredient in PET bottles. Both polyester and PET bottles are basically made from the chemical “polyethylene terephthalate”. It was proven to be more cost efficient if polyester fabrics were manufactured by just recycling PET bottles, since there will be less heating and energy required in processing the polymer ingredient.

Half of the processing required by the chemical “polyethylene terephthalate” to reach the desirable consistency of a viscose liquid will be eliminated. Only the other half of the process, which starts from breaking down the PET plastic into chips up to applying finishing on the textile product, will be required in manufacturing polyester fabric from recycled plastic bottles. Hence, the recycling process is more cost efficient as well as eco-friendly since it provides another destination for PET bottle wastes instead of sending them to landfills.

In fact, PET is the acronym for Poly Ethylene Terephthalate and was used to distinguish plastic bottles from those that were made from the hazardous clear plastic bottles made from polycarbonate. Polycarbonate bottles have been found to leach even at room temperature. However, PET bottles for drinking water are recommended for single use only instead of being recycled through reuse.

How is Polyester Fiber from Recycled Bottles Made?

800px-PET bottles in a trash can (Prague)
click to enlarge

Bales of plastic bottle wastes will be supplied by recycle collectors. Workers of the yarn manufacturer will have to separate the colored bottles from the clear ones while every bottle will be inspected if free from any foreign materials including the labels and the caps.

The sorted PET bottles will be sterilized clean, dried and crushed into small chips still separating the clear PET bottle chips from colored PET bottle chips.

Once the chips are ready they will go through heating that will enable them to pass to the spinneret until they end up being wound up like yarn threads in spools. The fibers are drawn into smooth strings, and then go through a crimping machine which will give the polyester yarns the fluffy wooly texture. The crimped polyester yarns will be dried and baled and will have to pass quality control before they are considered fit for selling.

Textile manufacturers will buy the polyester yarns from the yarn makers. The white yarns will be bleached or dyed then fed to a circular knitting machine after the bleach or color has dried. The finished product is now the polyester fabric from recycled bottles.

However, in order to achieve different textures, the polyester fabric will go through a napper machine. Here, the polyester fabric will pass through mechanized bristles that will give the fabric texture by raising the fabric’s surface and shearing the raised threads with a yarn to even out the surface. The polyester fabrics from plastic bottles will become textiles like fleece wool, corduroy, velvet and other similar textiles with piled textures.

Environmental Impact of Polyester Fabrics Made from Recycled Plastic Bottles

The manufacture of polyester fabrics made from recycled plastic bottles is more energy efficient compared to the manufacture of virgin polyester fabrics since the latter has to start with the processing and heating of the chemical “polyethylene terephthalate” to achieve the required consistency .

An extra-large T-shirt is equivalent to 14 PET bottles while a sweater is equivalent to 63 PET bottles. A square foot of carpet uses up about 14 PET bottles while a sleeping bag is made of about 83 PET bottles. A ski jacket is equivalent to 20 PET bottles. If more and more people are into buying garments made of polyester fabrics from recycled plastic bottles, then fewer of the plastic bottles used by consumers will go into landfills. To date, it is said that at least 75% of plastic bottles manufactured during the year still end up in landfills.

Nevertheless, several PET recycled garment companies are now introducing business suits and trousers for both men and women. The suits are not only more economical but are easier to care for as well. The business suits can be machine washed, eliminating the need for dry-cleaning.

Images courtesy of wikimediacommons


Comments

Showing all 30 comments
 
ciel s cantoria Aug 5, 2011 2:32 AM
Reply to Pet Preform Suppliers's Post
Hello --- Thank you not only for your interest in reading this article but also for posting your very encouraging comment More power to your business and your company!
Pet preform suppliers Aug 4, 2011 11:35 PM
Pet preform suppliers
Very good post, I was really searching for this topic, as I wanted this topic to understand completely and it is also very rare in internet, that is why it was very difficult to understand.

Thank you for sharing this.

regards:

Pet preform suppliers
ciel s cantoria Mar 17, 2011 2:06 PM
RE: Polyester Fiber from Recycled Bottles Providing Cost Efficiency in Textile Manufacture
Hi Pam, thank you for reading the article. Unfortunately, I don't have a list of suppliers for recycled poly fabrics but i'm pretty sure Google's search engine will furnish you with some useful answers by using the search words: "supplier recycled poly fabric for massage linens". I hope this helps.
Pam Flowerday Mar 17, 2011 1:45 PM
ultra light weight recycled microfiber
I produce massage linens and would like to find a recycled polyester fabric suitable. do you have a listing of manufacturers who sell these kinds of recycled fabrics? Thanks!
ciel s cantoria Feb 16, 2011 6:44 AM
RE: Polyester Fiber from Recycled Bottles Providing Cost Efficiency in Textile Manufacture
Hi A.B.
Checkout a Google book called Handbook of Plastics Recycling authored by Francesco La Mantia. Hope that helps.
A. B. Telasang Feb 16, 2011 6:27 AM
Hi
Hi,
This is Telasang from Mumbai.

Coudl you pls let me know from where I can get the latest market data of PET recycled fibres.

Thanks in advance for your reply and

with regards,

A. B. Telasang
Julia Jan 21, 2011 9:52 PM
Machine
Dear Ciel s,
Thank you very much for your information.

I would like to buy that kind of machine and could you let me know where I can buy and how much it costs? If you could send me more information about that machine, I would be glad.

Thank you very much.
I look forward to your reply.
Tondo Oct 20, 2010 11:42 AM
PET into polyster
Can I know the name of the machine that can convert PET into polyster.
Or maybe someone can tell me, where I can buy this kind of machine ?
Thx all
M.P.Prajapati Aug 23, 2010 7:57 AM
Recycled Polyester Fibre from PET scrap
Hi ciels,
Thank you very much for your quick response and appreciate your stand of not revealing the contact details.
M.P.Prajapati
ciel s cantoria Aug 23, 2010 3:32 AM
Hi Prajapati
I'm sorry to say that we uphold the privacy rights of readers who provide us their email addresses, hence we cannot comply with your request.

Nevertheless, here's a business directory site where buyers, sellers or product info for recycled PET bottles are advertised. gulfbusiness.tradeholding.com
M.P.Prajapati Aug 23, 2010 2:26 AM
Recycled Polyester fibre from PET bottle scrap
Hi ciels, I am Prajapati from Baroda, India, a Textile Engineer having 28 years experiance in Virgin as well as Recycled Polyester fibre production. I have set up 4 no. Korean & 2 no.Chinese Tech. plants in India including Technology selection, erection, commissioning and commercial production of Solid & Hollow Conjugate fibre production. Do me a favour by forwarding me contacts of interested persons in this field.
ciel s cantoria Aug 4, 2010 2:30 PM
Hello Pravin
There are some useful infos about textile fabrics and distributors here:

http://www.esources.co.uk/international-suppliers/22/1/2/
ciel s cantoria Aug 4, 2010 2:22 PM
Hi Hitesh
You can find the answers to your questions in this publication:
http://www.referenceforbusiness.com/industries/Rubber-Miscellaneous-Plastics/Plastics-Bottles.html
Pravin B Aug 4, 2010 2:05 PM
Wanted list of re-cycled Polyester Fabrics Manufacturer
I plan to start some project soon in india and was looking for list of Re-cycled Polyester Fabrics manufacturer in mumbai or anywhere in india.

Does any one have a list of contact ? it would be of great help.

thanks
Pravin
pravinmum@gmail.com
Hitesh Aug 4, 2010 8:31 AM
DATA Analysis
Hi, i am hitesh, i have writen u earlier regarding, my interest towards refering data analysis of this topic.
1, production rates against requirement of Recycling textile fabrics or yarn.
2, potential growth rate of this industry.
i am having some contact details of machine manufacturer towards this area. and i would like to invest in this area of industry.
Hitesh Aug 4, 2010 8:14 AM
Recycling Trends
I am Hitesh, i would like to get some data relevent to this topics.
1. what are present production rates.
2. what is the growth potential of this industry (PET recycling industry).
3. can you give me some graphical data year on year basis related to production vs demand of PET recycling yarn/fabric/textiles ?

this data will be very useful to me.
pl. do needful.

regards
Hitesh Bhatt
91-9879522842
ciel s cantoria Aug 3, 2010 3:21 AM
Hello Manu
Like others before you who have requested for the same information, I would like to thank you for your interest in this article. Again, I am flattered by your confidence in my ability to assist you with your recycling project but I'm afraid I do not have that kind of expertise.Nevertheless, let me refer you to this site where you can find names of entities that have the technology and expertise in handling different types of business.

The Sustainable Practices and Opportunities Plan
http://www.nps.gov/sustain/spop/bmp.html
Manu khurana Aug 3, 2010 3:13 AM
Polyster staple fibre plant
Dear ,
I am supplying raw materials to all the manufacturer of REGENRATED POLYSTER STAPLE FIBRE here in india including of RELIANCE INDUSTRIES . now as i am fully aware of this product i also want to set up my own polyster staple plant , please guide me how i can set up and which machniery will be the best china , korea or tiawan and please also let me know the costing of full plant .

Regards
Manu khurana
ciel s cantoria Jul 25, 2010 5:43 AM
RE: Polyester Fiber from Recycled Bottles Providing Cost Efficiency in Textile Manufacture
Hi Shva, as I've mentioned in the comments posted, I'm afraid I do not have the kind of expertise although I'm flattered that you think I do.
Nevertheless, please explore the answers previously posted here where I provided links that helped me learn about the process during my writing of the article. If they're not enough, you can always go to some legitimate government like the Natural Resources Conservation Services and from there seek for technological help.

Good luck with your studies and future undertakings.
s.shivaram Jul 25, 2010 3:14 AM
hi
ciel im shiva im a college student from india, can u please send me manufacturing process of recycled pet bottles into a fabric.
ciel s cantoria Jul 23, 2010 9:50 AM
RE: Polyester Fiber from Recycled Bottles Providing Cost Efficiency in Textile Manufacture
Hi Sandeep,

Thank you for your interest in this article. Truly, I am flattered by your confidence in my ability to assist you with your recycling project but I'm afraid I do not have that kind of expertise.Nevertheless, let me refer you to this site where you can find names of entities that have the technology and expertise in handling different types of business.

The Sustainable Practices and Opportunities Plan
http://www.nps.gov/sustain/spop/bmp.html

Good luck and I wish you all the best in your undertakings.
Sandeep Sharma Jul 23, 2010 9:22 AM
Thanks
Hi Ciel,

At the very outset, I would like take this opportunity to greet you and thank you for the points shared on the subject. Further, I would like to request you kindly help me in setting a fully automatic setup for making a Polyester staple fibre from used pet bottles.

I am located in Mumbai, Maharashtra, India and wish to know the techno-commercial report on this subject to start the project at the earliest.

Hope to receive your support and co-operation.

Thanx & Regards

Sandeep Sharma
Proprietor
Mansha Packaging Products.
Mumbai - 400 082
91 9870504060
ciel s cantoria Jun 24, 2010 12:28 PM
Info about pet recycling machine
For further information about these machines, please use the search word "PET recycling machine" for your research, and you will find several companies who have more detailed information about them in their websites.
SOURABH Jun 24, 2010 11:03 AM
machinery line
dear sir,
f`rom where we can bye machine for pet yarn . and
ciel s cantoria May 30, 2010 5:53 AM
Pet recycling machine
Hi Amir, Thank you for your interest in this article.

The main equipments and units of the whole line wound be: debaler, sorting table, grinder, KIA, pre-wash system, separator, spinner, water treatment system, Automatic bagging etc. and with touch screen PLC control system, all the security protection also contained in our washing line .

For further information about these machines, please use the search word "PET recycling machine" for your research, and you will find several companies who have more detailed information about them in their websites.
amir May 30, 2010 5:32 AM
pet recycling
hi, I am thinking of starting a pet recycling into fibre. could you please send me the details of the equipment involved.
ciel s cantoria May 22, 2010 12:32 PM
Hi Cee,
Thank you for reading this article. Try this Thailand business portal: http://businesswiththailand.com/search/searchresults.asp?phrase=ALL&Srchstr=recycled+pet+rugs&filterby=SLR&Search=Search&domain=ALL&cid=&orderby=

you could probably post a message . However, it might take long before you can get some responses as it seems the country is currently in turmoil.
Cee May 22, 2010 9:06 AM
looking to import
Hi
I am looking to buy directly from Thailand from the factory that makes the recycled water bottle rugs, can you help us, we are direct importers, looking for OEM
Cee
ciel s cantoria Feb 14, 2010 6:36 AM
Greetings Sir Abdullah
Thank you for taking interest in this article about Pet recycled fibers. Below is an excerpt from a government owned website called The Sustainable Practices and Opportunities plan

advantages

PET fibers are naturally stain resistant and do not require the chemical treatments commonly used on nylon carpet. ScotchguardÓ coating increases the stain resistance properties. Fibers retain their color and resist fading due to sun or harsh cleaning. Shades can be richer and brighter than those found in nylon yarns. Because plastic beverage containers are made with top quality PET resins as required by the U.S. Food and Drug Administration, recycled PET is superior to lower grades of virgin synthetic fibers used in making other brands of polyester carpet yarns. PET has exceptional strength and durability and the value of these properties is not lost in their recycling process. Polyester has fewer emissions than nylon because it is made with fewer additives, and because it is inherently stain resistent. Easier maintenance reduces the use of cleaners which also emit VOCs.


disadvantage

Purchasing new carpet means you have to get rid of the old and keep it out of the landfill (unless you choose a leasing or maintenance program to prolong the life). Ensuring that your old carpet is recycled and made into new products is very important. Although recycled PET carpet uses plastic that otherwise might be destined for the landfill, once the carpet serves its useful life, it is presently very difficult to recycle the carpet. Find a company that will keep your old carpet out of the landfill.

For more information you can visit the site via this URL:
http://www.nps.gov/sustain/spop/carpet.html

I hope I was able to provide you some of the answers you needed and thanks once again.
Abdullah Feb 14, 2010 5:15 AM
recycled PET yarns
First, I would like to introduce myself, I am Abdullah Khalil, R&D staff, a reputable, well known company in the field of carpet production and which is considered as a leading company in the field of printed carpet worldwide.i hope if you support me with more information about the recycled PET yarns, e.g. its advantageous, disadvan. , suppliers, if it is usfull in carpet manufacturing,
 
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