Polyester Staple Fibre

Recycled Polyester staple fibre is a synthetic man made fibre made from PET/Polyester waste and post consumed PET bottles. It is used in Non-Woven carpets, wadding, filtration industries, as a polyfill for stuffing cushions, pillows, soft toys, quilts. Its also used for spinning yarns and making geotextiles. Hollow Polyester staple fiber gives good resilience properties and is used to make premium pillows, cushions and quilts. 
Recycling of PET/Polyester waste and used PET bottles is essential to maintain cleanliness of environment.

Worldwide millions of PET bottle are consumed daily and thrown to trash. PET is also called polyester. Polyester is a synthetic polymer made of purified terephthalic acid (PTA) or its dimethyl ester dimethyl terephthalate (DMT) and monoethylene glycol (MEG). 
Since PET bottles are practically non bio-degradable, its was very difficult to dispose them. New technology was developed in Europe, Korea and finally China which helped in recycling these post consumed PET bottles to make man made fibres like Recycled Polyester Staple Fiber. These fibers are then used to make non woven carpet for auto-mobiles, making quilts, yarns, pillows etc 
First bottles arrived in a factory, collected from trash, in bale form. These bales are opened and manually sorted to take out contaminations like iron, PVC, stones etc. Once cleared these PET bottles are crushed to make 12-15 mm flakes and are hot washed in chemical solution containing 2% solution of Sodium Hydroxide. This chemicals helps in taking out glue from bottles and also cleaning them. The overall contaminations in PET flakes should not be more then 200 ppm. 
These flakes are then dried and taken to vacuum driers where surface moisture as well as inherent moisture is taken out and flakes becomes soft/crystallized & dried. Moisture held within the PET flakes itself is known as inherent moisture. The Driers helps to reduce the inherent moisture to less then 200 PPM. 
These dried flakes are then taken to Extruder for spinning. Spinneret are available to make either hollow or solid PSF of varying denier (1.5Den 50Den). Filaments coming out of spinning are collected in cans or bobbins. This completes the spinning. Hollow and Solid PSF can be treated to make Siliconized, conjugated, polyfill, harsh, bouncy, anti static, anti fungal. In second step these cans are taken to Creel area where many cans or bobbins are combined to make tow and stretched several times in a chemical hot bath to make fibre. These fibres are then dried and relaxed in a relaxer and cut in various cut length before bale packing.