Production of Bulk Continuous Filament Yarn from Recycled PET

Recycling PET bottles A long and complex process chain is needed to turn a used bottle into usable raw material. It all starts with the collection of the bottles and pressing them into bales. Afterwards, the bales are opened, sorted out and grinded. The flakes obtained are washed (cold and hot) and separated from the polyolefin, which comes from caps and gaskets. After drying and metal separation, the flakes are practically ready to be filled into silos or big bags. A new cycle begins. One of the main processes for recycled polyester is spinning staple fibres, which can be used for spun yarns, textile fillings or nonwoven materials for instance. These applications are well established with fleece shirts and throws being prominent examples.

Spinning BCF yarn from PET and R-PET PET fibres offer a number advantages in carpet applications, including the high stain resistance, which is even higher than that of chemically treated PA BCF. Moreover, PET can be spun in undyed form, which is not the case for PP. Undyed yarns can be twisted, heat set, dyed and tufted or the finished carpet can be printed.

Compared to staple fibre production, using R-PET for manufacturing continuous filaments is also more challenging. In filament spinning, the quality of the yarn is determined by the homogeneity of the raw material. Recycled flakes are an instability factor, small deviations in quality can lead to an increased number of filament breaks or broken filaments. Further, the variance in the flakes quality could affect the yarn’s colour pick-up so the finished carpet shows streaks.   https://www.naraloca.com is a recycled plastic specialist that promotes the use of recycled PET flakes, recycled PET chips, recycled PP & HDPE granules to various plastic and polyester manufacturers.

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