Procedure of Manufacturing Recycled Polyester Staple Fibre (RPSF)

February 01, 2023

Recycled Polyester Staple Fibre (RPSF) is a reliable and sustainable alternative to synthetic man-made fibres. Manufacturing RPSF involves recycling post-consumer PET bottles and other PET/Polyester waste to create a new fibre that can be used in multiple applications.

These applications include non-woven carpets, wadding, filtration materials, polyfill stuffing for cushions and quilts, geotextile, and spinning yarns.

The advantages of using RPSF are that it does not require any additional resources or energy consumption when manufacturing, which means, the complete process is more environmentally friendly than traditional processes.

So, recycling PET/Polyester waste and used PET bottles is highly significant to sustain the cleanliness of the environment.

Manufacturing Process of Recycled Polyester Staple Fibre (RPSF)

The Manufacturing Process of Recycled Polyester Staple Fibre (RPSF) begins with collecting post-consumer PET bottles, which are then sorted and cleaned to remove contaminants. The bottles are then cut into flakes and rewashed in hot water before being dried and heated to separate color pigments.

The PET flakes are then melted down and passed through a spinneret to produce filaments that are cooled rapidly in a liquid bath. These filaments can be cut to the desired length or combined with other fibres to form yarns. Finally, these yarns are spun together into RPSF fabric.

Once the PET bottles have been cleansed, manufacturing of Recycled Polyester Staple Fibre (RPSF) can begin. RPSF is made when the hot-washed and dried flakes are melted under high temperatures before being spun into yarn. This yarn creates fabrics such as blankets and pillows, providing a sustainable option that reduces landfill waste.

The product must meet stringent requirements of quality control tests which measure color, composition, and length of the fibre, amongst other criteria. If all conditions are met, the recycled polyester staple fibre can be certified for use in various products.

For a precise process, PET bottles are crushed to make 12 to 15 mm flakes and are hot washed in a chemical solution encompassing a 2 percent solution of Sodium Hydroxide. Also, PET flakes' contamination should not be more than 200 ppm.

Manufacturing RPSF requires the use of vacuum driers to reduce the inherent moisture in PET flakes. The driers help to eliminate surface moisture and reduce the internal moisture content.

By controlling and managing the moisture levels, RPSF can attain a soft/crystallized texture with optimal drying characteristics when spun into yarns or filaments.

Careful management of this process ensures that RPSF maintains consistent quality across every batch. As a result, RPSF provides superior performance characteristics compared to virgin polyester fibres.

Spinneret is accessible to make hollow or solid PSF of variable denier (1.5Den 50Den). Filaments coming out of spinning are gathered in bobbins or cans. These dried flakes are transferred to Extruder for spinning. This completes the process of spinning.

After the Hollow and Solid PSF are treated to create different types of fibres, they are ready for manufacturing RPSF. The process begins with several cans or bobbins combined in a Creel area.

The mixture of several cans is then stretched multiple times in a chemical hot bath, which produces the RPSF. Finally, this Recycled Polyester Staple Fibre (RPSF) is now complete and ready for use.

Recycle Polyester Staple Fibre (RPSF) Manufacturing by JB Ecotex Limited

JB Ecotex Limited offers Recycle Polyester Staple Fibre (RPSF) with a world-class polyester fibre manufacturing process and technology.

JB Ecotex Limited is revolutionizing the industry with its accurate process of manufacturing Recycled Polyester Staple Fibre (RPSF). With state-of-the-art technology and processes, JB Ecotex Ltd provides an eco-friendly solution to plastic waste. ReNAYA from JB Ecotex is a fantastic way to create something new out of plastic waste while maintaining or surpassing the quality parameters of virgin fibre products.

The name itself brings across the core idea - 'Re' stands for Recycle, and 'NAYA' stands for New. JB Ecotex has developed a unique process to convert post-consumer plastic waste into RPSF that can be used in different applications.

Under the brand name "ReNAYA", JB Ecotex Limited provides Recycle Polyester Staple Fibre with complete dyeing assurance under different variants such as Ivory White, Hansa White, and Feher White in diverse cuts and deniers.

Moving Forward

JB Ecotex is committed to providing the best quality recycled polyester staple fibre (RPSF). Manufacturing with RPSF produces a durable yet lightweight fabric, making it perfect for producing items like furniture and home textiles. Our "ReNAYA" brand focuses on creating highly environmentally friendly and sustainable products.

The properties of RPSF make it an ideal choice over natural fibres. It is stain-resistant, wrinkle-free, fire retardant, and has high elasticity, giving the product more durability than other fabrics made from natural fibres. RPSF also has good abrasion resistance and can be easily dyed or printed with various designs.

JB Ecotex Limited even provides RPSF in black colour, which is equivalent to virgin black polyester staple fibre matching the equal and higher quality parameters.