PET BOTTLE RECYCLED INTO POLYESTER

[EIRI/EDPR/3652] J.C.: 1736XL

INTRODUCTION

The polyster filament yarn unique in regard to its high resistance to its high
resistance to stretching, high elastic recovery and high tensile strength. This
combinaton of properties permits the manufacture of sheer extremly light weight
fabrics.

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.

Polyesters, Avlin, Daron, Encron, Fortrel, Kodel, Trevira, Vycran, Quintess of all
the polyesters, polythene terephthalate is the most important textile fibre. These
are manufactured under different names such as Terylene (ICI), Terene (CAFI.
Indies), Dacron (du Pant), Lavsan (USSR), Tergal (socite Rhodiacets, France),
Terital (societ Rhodiatoce, Italy), Tetoron (Teijin Ltd.) Trevira (Hoechst) etc. Certain
modified polyesters are also manufactured. These include kodel (derived from
isophthalic acid) or Govdyear. Beaunit mills (U.S.A.).

"Polyster" - a manufactured fibre in which the fibre-forming substance is any long-

chain synthetic polymer composed of least 85 percent by weight of an ester of a
dihydric alcohal and terephthobic acid (P-HOOC-C6H4 - COOH).

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The longchain polymer work which was begun by Dr. Wallace Carothers is still
bearing which fruit using it as a starting point Dr. J.T. Dickson and Mr. J.K.
whinfield working in the laboratories of the calio printers Association in
manchester, England, in 1941, discovered a new long chain polymer fibre. After
World-war II this fibre was developed further.

Imperial chemicals Industries bought the world right to produce thin fibre under
the name of Terylene. E.I. du pant purchased the right in the United States and
produced the fibre under the name Dacron.

However in Textile Industry nearly all yarns are twisted, as this protects the
filaments from damage untwisted yarn is almost, impossible to wear or without
damage. The twist is expressed in turns per inch (t.p.i.) Direction of twist is
described as "S" and "Z".

Sometimes, too, yarns are douled or folded and then the doubling or folding twist
shared be such that the yarn is balanced.

The addition of twist always increases the denier of any fibre, for fairly low twist
(up to say 30 t.p.i. for 70 dennier the increase in dennier is not great, out at one
point secondly twist develop (the already twisted fibre starts to "corkscrew"), and
then the dennier rises quickly. This effect may be seen in the following table of
figures for Dacron polyester yarn.

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Initial Dennier of Denier with twist (t.p.i.) of
Dacron
----------------------------------------------------------------------------------------------------
1 8 14 24 36 48 70 100

40 (34 fils) 40 40 40 40.5 41 42 44 49

70 (34 fils) 70 70 71 72 74 77 83 ---
210(34 fils) 210 213 216 226 246 271 --- ---

As twist rises strength falls & elongation at break roses as shown by the following
figures for 210 denier 34 files Dacron.

Twist Tenacity Elongation at

(t.p.i.) (gm/denier) break (percent)

1 7.1 11
23 6.6 15
36 5.3 16
47 3.9 17

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Types:-

Continuous Filament Yarn

40 denier 34 filament

Semi dull ----------- type 5600

70 denier 34 filament

Semi dull ----------- type 5600

75 denier 34 filament

Bright ----------- Type 5500

Staple:-

3 denier 1 1/2" & 2 1/2"

Semi dull --------- Type 5400

6 denier 2 1/2",

Semi-dull --------- Type 5400

Tows:-

3 denier, semi dull

---------- Type 5400

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 CONTENTS

INTRODUCTION
TYPES
STAPLE
TOWS
USES & APPLICATION OF RECYCLED PET
RPET IS EMPLOYED FOR NEW PRODUCTS SUCH AS:
USES AND APPLICATION OF POLYESTER YARN
B.I.S. SPECIFICATION
MARKET POTENTIAL OF PET RECYCLING
FIGURE: BOTTLE-TO-FIBER RECYCLING
FIGURE: GLOBAL ANNUAL R-PET MARKET VOLUME BY END-USE IN 2016
COMPANIES USING RECYCLED PET
RECYCLING PET BOTTLES INTO POLYESTER
THE STEPS INVOLVED IN THE PRODUCTION PROCESS ARE AS FOLLOWS
PROCESS OF RECYCLED POLYESTER
SORTING
BALES OF CRUSHED PET BOTTLES.
FURTHER TREATMENT
MELT FILTRATION
TECHNOLOGY
MANUFACTURING PROCESS OF PET BOTTLE RECYCLING INTO POLYESTER
SORTING
PET COLLECTION SORTING AND RECYCLING
PET COLLECTION AND SORTING
PET RECYCLING PROCESS
PROCESS FLOW DIAGRAM FOR PET BOTTLE RECYCLED INTO POLYESTER

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DETAILS OF PET BOTTLE RECYCLING
STEP 1: REACHING THE WASTE STREAM, GETTING COLLECTED
STEP 2. SORTING
STEP 3: REMOVING NON-PET COMPONENTS, SORTING, BALING AT
THE TRADERS
STEP 4: AT THE PET RECYCLERS—SORTING (ONCE AGAIN),
CLEANING, FLAKING
STEP 5: AT THE MANUFACTURERS – TURNED INTO POLYESTER FIBERS
MANUFACTURING PROCESS OF POLYESTER YARN FROM WASTE
(ACCORDING TO STEVENSON)
OTHER METHODS OF MAKING POLYESTER YARN FROM WASTE
(ACCORDING TO MAC DOVELL)
POLYESTER YARN FROM WASTE
(ACCORDING TO GRUSCHKE ET.AL)
FABRICATION OF POLYESTER FIBRES
WET SPINNING
OTHER PROCESS OF SPINNING
MELT SPINNING
SOLUTION SPINNING
DRY SPINNING
FLOW DIAGRAM OF MANUFACTURE OF POLYESTER YARN FROM WASTE
FLOW DIAGRAM OF MANUFACTURE OF POLYESTER YARN FROM WASTE
FLOW DIAGRAM OF MANUFACTURE OF POLYESTER YARN FROM WASTE
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:

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5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF PET WASTE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF GRINDER/SHREDDER

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SUPPLIERS OF HOT AIR FLAKER DRYER
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF D.G. SETS
SUPPLIERS OF LABORATORY EQUIPMENTS

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APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 2000 Kg/Day

Land & Building (3000 sq.mt.) Rs. 3.75 Cr
Plant & Machinery Rs. 1.30 Cr
Working Capital for 2 Months Rs. 55 Lac
Total Capital Investment Rs. 5.77 Cr
Rate of Return 26%
Break Even Point 53%

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