Manufacturing and Applications of Recycled Polyester Staple Fibre (RPSF)

September 15, 2023

Recycled Polyester Staple Fibre (RPSF) offers a dependable and eco-friendly alternative to synthetic man-made fibres.

By recycling post-consumer PET bottles and other PET/Polyester waste, sustainable RPSF is created for various applications like non-woven carpets, wadding, filtration materials, polyfill stuffing for cushions and quilts, geotextiles, and spinning yarns.

Substantial Gains of Using Recycled Polyester Staple Fibre (RPSF)

Recycled Polyester Staple Fibre (RPSF) eliminates the need for additional resources or energy consumption during manufacturing, making the entire process more environmentally friendly compared to outdated methods.

Additionally, recycling PET/Polyester trash and used PET bottles is essential for preserving the purity of the environment.

Many businesses are making money off of goods produced of recycled fibres in an effort to build a solid brand and draw in environmentally conscientious customers.

Recycled Polyester Staple Fiber (RPSF) Manufacturing and Production Process

The initial stage in making recycled polyester staple fiber (RPSF) is collecting post-consumer PET bottles. These bottles are examined and cleaned to get rid of any contaminants. To separate the color pigments, the bottles are then broken into flakes, cleaned in hot water, dried, and heated.

After melting the PET flakes, they are spun through a spinneret to create filaments, which are then quickly cooled in a liquid bath. These filaments can be mixed with other fibers to make skeins or cut into the necessary lengths. These yarns are spun into RPSF fabric as the last phase.

Recycled Polyester Staple Fibre (RPSF) production starts once the PET bottles have been cleaned. The hot-washed and dried flakes are melted at high temperatures, spun into yarn, and then used to make RPSF. In order to reduce landfill waste, this yarn is then utilized to make eco-friendly items like pillows and blankets.

Additionally, the product undergoes stringent quality control tests to ensure it meets specific criteria like color, composition, and fiber length. Recycled polyester staple fiber (RPSF) can be used in a variety of products if all conditions are met.

For an accurate manufacturing process, PET bottles are crushed into flakes measuring 12 to 15 mm. These flakes are then hot-washed in a chemical solution containing a 2 percent solution of Sodium Hydroxide. Moreover, the contamination level of PET flakes should not exceed 200 ppm.


Industrial Domains Enabling Recycled Polyester Staple Fiber (RPSF) Applications

Recycled Polyester Staple Fiber (RPSF) finds application in various industrial domains. Aside from clothing, industries across Gujarat, Punjab, and other states source recycled polyester from RPSF manufacturers. Here are some key applications of RPSF:

o Footwear products: Several brands create unique and lightweight footwear for both men and women. These shoes are comfortable, easy to maintain, and can be washed and dried, unlike leather or suede shoes.

o Comforters: Recycled polyester offers insulation properties, making it ideal for comforters and fleece. Those who venture to high altitudes often favour sleeping bags made from recycled polyester.

o Sewing threads: Top RPSF manufacturers in India supply sewing threads due to their superior tensile strength.

o Carpets: They are made with high-quality recycled polyester and are durable as well as visually appealing. Manufacturers in cities like Surat offer long-lasting fiber with an elegant aesthetic.

o Travel and luggage bags: RPSF manufacturers provide lightweight and tear-resistant fiber for luggage bags.

Key Takeaways

The usage of recycled polyester has gained momentum as people recognize its unique and sustainable properties. What was once seen as fabric derived from waste bottles is now sought after as a solution. There are still untapped opportunities waiting to be explored by using RPSF in different domains.

At JB Ecotex, we are one of the best Recycled Polyester Staple Fibre (RPSF) manufacturers in India. Our teams specialize in manufacturing recycled polyester staple fiber (RPSF) and PET flakes leveraging sustainable methodologies that are completely environmentally friendly.