PET Recycling

Discarded PET bottles are collected, sorted, cleaned, shredded, and made into ‘washed flakes,’ which are then used to produce a variety of products, starting from polyester fiber, which is used for a variety of applications like filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. Recycled PET (a small percentage) is also used for the manufacture of PET straps, monoYarn, sheets etc.

Value Chain of PET Recycling

There are a large number of companies involved in the PET recycling business, starting from the waste collectors and kabadiwallahs to the small and medium traders, recyclers, and manufacturers who use recycled PET for various products. The chart above provides a simplistic illustration of the participants in the PET recycling business in Indian Continent.

It is intended to prepare a Feasibility Report to install a Recycled PET Flakes production facility with a capacity of 1200 MT per year as a Green Field Project.

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PET Recycling

Discarded PET bottles are collected, sorted, cleaned, shredded, and made into ‘washed flakes,’ which are then used to produce a variety of products, starting from polyester fiber, which is used for a variety of applications like filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. Recycled PET (a small percentage) is also used for the manufacture of PET straps, monoYarn, sheets etc.

Value Chain of PET Recycling

There are a large number of people involved in the PET recycling business, starting from the waste collectors and kabadiwallahs to the small and medium traders, recyclers, and manufacturers who use recycled PET for various products. The chart above provides a simplistic illustration of the participants in the PET recycling business in India.

Recycled PET (washed flakes from post-consumer PET bottles) are used for making any of the following products.

• Fiber fill denotes applications where short fibers are used to fill cushions, pillows etc.

• Polyester Staple Fiber (PSF) is further used in making a wide range of fabrics (clothing, upholstery etc.)

• POY (partially oriented yarn)/PTY is another type of polyester yarn that is used to produce texturized yarn that goes into making fabrics.

Polyester Texturized Yarn is one of the products from the scrap of PET bottles as value addition product.

Polyester fibre is one of the most used commercial fibres across the world. These are strong synthetic fibres made by blending the alcohol and acid and initiating a chain reaction. Strong and big molecules are generated in this reaction with repetitive structure. Yarns are commercially used interlocked fibres of continuous length majorly used for weaving and knitting. The Polyester Yarn is one of the finest and synthetic yarns that are used for various purposes like Embroidery, sewing, knitting, weaving and so forth. Such yarns are also called PY. Such yarns are created when MEG and PTA are spun directly. The Polyester yarns brought a revolution in the global textile industry.

There are basically three types of Polyester yarns:

Polyester Yarns – These are hugely demanded yarns in the global market made from PET Polyester. The PET Polyester is also called Polyethylene Terephthalate. These yarns are immensely used in the modern fibre manufacturing industries. PY is strong and compelling. These are used in both the multi yarn and mono yarn forms. PY has a selection of qualities, High tenacity PY are used for making light fabrics like organdie and voile while the regular tenacity PY is used to make lingerie while the low tenacity or duller version of PY are used to make blouse and shirts.

Spun Yarns – Created by using PCDT or cut PET, Spun yarns are a popular Polyester yarn type. The polyester fibres are spun together to create spun yarns. Such yarns are primarily used for the purposes like knitting and weaving. The use of spun yarn can also be seen in consumer fabrics, embroidery and home furnishings.

Textured Yarns – It is created by twisting and drawing of polyester POY. The PET multi yarn is used in its creation.

The global Polyester Yarn market size is expected to gain market growth in the forecast period of 2021 to 2025, with a CAGR of 7.4% in the forecast period of 2021 to 2025 and will expected to reach USD 110580 million by 2025, from USD 83210 million.

It is intended to prepare a Feasibility Report to install a Polyester Texturized Yarn production facility with a capacity of 6000 MT per year as a Green Field Project.

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PET is linear thermoplastic (long-chain molecule consists of repeating units shown as figure right), white but bluish resin made from terephthalic acid and ethylene glycol through poly-condensation. PET is supplied by the resin manufacturers in the form of small pellets, each about 0.05 grams. PET came into prominence in the 1950s as a textile material. Its strength, temperature tolerance and wear-resistance made it an ideal replacement for, or addition to natural fibres such as silk, cotton and wool.

Bottle Grade PET

Nowadays PET is still widely used for these purposes, but when, in the 1970s a marketing need was identified for larger light-weight, unbreakable bottles to contain carbonated drinks, PET fit the bill perfectly. Unlike simple polymers such as polyethylene, PET is not made by a single stage process, but by the reaction between two chemicals, purified terephthalic acid (PTA) and ethylene glycol (EG). The availability of the first of these has dictated the supply of PET resin in the past, but new capacity coming on stream this year will ensure more than adequate supplies to meet the growing uses of PET over the coming years. Related polyesters are polybutylene terephthalate (PBT) used mainly for engineering applications, and polyethylene naphthalate (PEN). The latter offers significant performance improvements over PET, particularly in terms of barrier properties and heat tolerance. Since PEN can be blended with PET a range of new 'alloys' is becoming available for special packaging applications.

As PET (bottle grade) is a kind of transparent, wear-resisting and corrosionresisting plastics with high strength and smooth finish, it is widely used for PET bottles of mineral water, juice, edible oil, pharmaceuticals, cosmetics, etc.

Melting Temperature: 254-256oC

Crystallinity: >=45%

PET products can be made crystallizable or non-crystallizable through controlling crystallization temperature and cooling speed. Usually it's crystallinity is 0~50%. The higher IV value, the slower crystallization speed.

The key factors that effect PET bottles' molding process and performance are crystallization and orientation. If PET’s moisture level is high, hydrolysis will happen while molding and it's IV value will drop which means products' quality be affected.

Most bottle grades of PET are copolymers, which means that a few percent of a modifier has been incorporated into the polymer chain. Copolymers are easier to injection mold because the crystallinity behaviour is improved.

A remarkable transformation takes place when injection molded PET is stretched at the right temperatures and to the right extent. The long chains undergo strain hardening and strain-induced crystallization, which gives the properly-made PET bottle exceptional clarity, resistance to internal pressure, uniform wall thickness, toughness, and a host of other features. To achieve these useful properties, however, care must be taken in choosing the right grade of resin, as well as the right preform and bottle designs, and good molding practices.

The world food markets are nowadays glutted by a high variety of plastic packaging materials for just as many varied sorts of food products. Only to name a few - Polyethylene, Polypropylene, Polystyrene and Polycarbonate are commonly used in form of foils, bags, boxes and containers. With the introduction of a 2 litre bottle in 1976 Polyethylene terephthalate (PET) steadily conquered the market and emerged as a material of choice for beverage bottles. The characteristic properties of PET like stability, transparency and lower weight have led to the fact that glass bottles are more and more replaced. Due to the stability of the material the multiuse system of PET bottles is common in many countries. The strength and ruggedness of the nearly indestructible PET material is one reason that beverage bottles can achieve high circulation rates between the bottler and the consumer. The use of a rugged material, however, cannot rule out the fact that material changes may occur during the life time of a bottle.

On the account of a direct contact between the PET bottle and the beverage interactions e.g. migration processes can occur during the often long storage time. Plastics have for example the ability to absorb organic compounds easily. For this reason the aspect that a number of refillable PET bottles may be misused by the consumer is very important for the quality assurance and safety-in-use of refillable bottles.

Consumer may "misuse" the bottles for example by filling them with beverages with strong flavour, household chemicals or even pesticides. Compounds absorbed in this way will not be fully removed during the washing and cleaning procedure of a refillable bottle. Therefore these substances may be able to remigrate into a refilled foodstuff or beverage which in turn can result in an off-flavour. Due to the intrinsic interactivity of a refillable plastic bottle with contacting chemicals the question of testing compliance with food regulations arises. To this day there is neither any specific national or EU regulation nor a standard test available which could be applied by industry and enforcement laboratories to cover this problem. One of the main purposes of the EU project SMT4-CT96-2129 was to establish a standardized and easy-to-apply method for general chemical inertness testing in conjunction with the production of a certified reference material of PET applicable not only for the industry but also suitable for enforcement laboratories and therefore having a systematical control possibility to check the food safety of refilled PET bottles taken from the market.

The basic technical and financial parameters of a project on the manufacture PET preforms by injection moulding PET bottle grade resin are described in this profile. This is the first stage in the two stage PET bottle manufacturing process suitable for large scale production and here the pet preform is molded on an injection moulding machine, then in the second stage the preform is reheated and blown on a blow moulding machine. The advantages of PET bottles include exceptional clarity, pure, safe, good barrier to oxygen, carbon dioxide and water, lightweight and therefore less shipping costs, no leakage, design flexibility, recyclable, long shelf life, good chemical resistance etc.

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The gentle treatment of resources and economical use of materials are a must when it comes to sustainable production. Valuable raw materials such as PET must be processed as efficiently as possible while still tapping into every way of saving costs. The PET manufacturing and production process allows for the application of a sustainable approach which can optimally combine environmental awareness and cost effectiveness: the bottle-to-bottle recycling concept.

Bottle-to-bottle recycling plant efficiently recycles used PET bottles and the recyclate is then reused in the food and beverage industry as recycled PET (rPET). The complete process comprises the cleaning of the used PET bottles and the treatment of the recyclate so that the end product - which could come in the form of flakes, pellets or preforms - can meet the highest quality requirements after the recycling process. European and American certificates (e.g. FDA) and a number of different corporate approvals, all confirm the high quality of the recyclate for direct use in containers which come into direct contact with foodstuffs.

Polyethylene terephthalate (PET) is one of the most widely used plastics today. PET bottles are ubiquitous in our day-to-day lives–one has to just look around to spot a PET bottle containing mineral water or soft drink or used for other applications. With such wide usage (in 2015-16, ~ 900 KT of PET was used in India), comes the question, what happens to the PET bottles after use. Are they recyclable? If so, how can they be recycled? What can be made out of recycled PET? How much of PET consumed in India ends up being recycled, in a given year?

PET bottles, post use, still carry a lot of value, and recycled PET (r-PET) can be used in a wide variety of applications. This makes post-consumer PET bottles a very sought after item by waste collectors. Discarded PET bottles fetch waste collectors Rs 14-15/kg. These bottles are bought by kabadiwallahs or waste traders, who employ people to segregate, sort and further sell it to large vendors or recyclers. The caps, neck rings, labels (non-PET components) are removed, and the bottles are shredded, washed, and sold as what is called ‘washed flakes’. These washed flakes are then used to make (predominantly) polyester fiber, which is used as filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. These end products sell at anywhere between Rs 50-110/kg; the market for r-PET products is quite large. There are 40+ large manufacturers across India who use r-PET as raw material. The PET recycling business can be estimated (roughly) to be around Rs 3,000- 4,000 crore in a given year in India.

Worldwide, PET-bottles more and more replace glass bottles in the beverage and food sector. The success of PET in comparison to glass is based on several economic (and environmental) advantages.

On the one hand, the production of PET is less expensive and energy consuming than the production of glass. Secondly, the light weight of the PET-bottle makes it easier for merchants and consumers to handle the bottles and crates. It saves energy during transport, particularly on long distance haulage. Finally, PET offers more or less the same material properties as glass regarding hygiene, taste and gas impermeability.

The negative impacts of PET-bottles in recent years result from their use as nonreturnable beverage containers leading to a dramatic increase of beverage container waste. But even here, changes are on the move, particularly in industrialized countries, where PET-bottles enter more and more the existing returning and refilling schemes. Apart from returning and refilling, recycling of used PET-bottles is also possible, and will be an interesting option especially for developing countries, where refilling schemes are not in place or economically unfavourable.

PET is the abbreviation for polyethylene terephthalate. It is polyester (chain of individual “ester”) which is formed by polycondensation of two types of monomers called ethylene glycol and purified terephthalic acid.

Principle of polycondensation

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This filament can be made which has a tensile strength lighter than silk and linen. The high tensile strength and resistance to stretching possessed by filament yarn caused it to be an interesting possibility for sewing thread in wearing apparel, in certain v-belt which cannot be adjusted readily, and as a smaller bulk of host is desired.

Excellant resistance to abrasion in the wet condition and to bleaching solutions, are properties utilised in laundary nets. The high resistance to heat is of interest in pressing fabrics sail fabrics utilise the favourable properties-high tensile strength, resistance to stretching mildew and directional capability in the dry and wet states.

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