Industry Overview
Polyester filament yarn is distinguished by its high resistance to stretching, high elastic recovery, and high tensile strength. This combination of properties enables the manufacture of sheer and extremely lightweight fabrics. Polyester filament can provide high tensile strength while offering characteristics that make it suitable for applications where durability and dimensional stability are important.
The high tensile strength and resistance to stretching of polyester filament yarn also make it suitable for sewing threads used in wearing apparel and for certain V-belts where adjustment is not readily possible. Its resistance to abrasion, particularly under wet conditions, and resistance to bleaching solutions are useful in applications such as laundry nets. Its heat resistance is of interest in pressing fabrics, while sail fabrics can benefit from its tensile strength, resistance to stretching, resistance to mildew, and directional properties in both dry and wet conditions.
The report focuses on polyester yarn manufactured from waste, particularly through recycling PET bottles into polyester. It covers recycled PET types, applications, collection and sorting, cleaning, flaking, melt filtration, spinning technologies, manufacturing processes, plant layout, location factors, project implementation, and equipment and raw-material suppliers.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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:
- 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
- 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
Appendix
- 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)
Frequently Asked Questions
Recycled polyester yarn is yarn produced from recovered polyester materials, including post-consumer PET bottles and other suitable polyester waste. The material is collected, sorted, cleaned, processed into flakes or other intermediate forms, and converted into polyester suitable for fibre or yarn production. Recycling PET into polyester helps return a commonly used packaging material into textile and industrial applications. The quality of the resulting yarn depends on feedstock quality, contamination control, processing technology, and the required end-use specifications.
PET bottles are generally recycled into polyester yarn through collection, sorting, removal of non-PET components, cleaning, flaking, further treatment, melting, filtration, and spinning. Proper sorting is important because contaminants and incompatible materials can affect processing and final yarn quality. Depending on the manufacturing route, recycled PET may undergo additional treatment before being converted into polyester fibres or filaments. The report covers several process routes and flow diagrams describing the conversion of waste PET into polyester yarn.
Polyester filament yarn is used in textiles and several technical applications where strength and dimensional stability are required. Its properties can support lightweight fabrics, sewing threads for apparel, selected belt applications, laundry nets, pressing fabrics, and sail fabrics. Resistance to stretching, high tensile strength, abrasion resistance, and resistance to certain bleaching solutions contribute to its suitability for these uses. The precise yarn characteristics required depend on the intended product, manufacturing process, and applicable quality specifications.
Common fibre-spinning methods include melt spinning, solution spinning, dry spinning, and wet spinning. Melt spinning is particularly relevant to thermoplastic polymers such as polyester because the polymer can be melted and extruded through spinnerets before being cooled and drawn. Solution-based methods use a polymer solution and rely on solvent removal or coagulation. The selection of spinning technology depends on polymer characteristics, product requirements, plant configuration, and process economics. The report discusses these different spinning processes in relation to polyester fibre fabrication.
A PET recycling plant should be located after evaluating raw-material availability, market access, power and fuel supply, water availability, transportation, labour, waste disposal, regulatory requirements, taxes, site characteristics, community factors, and environmental or safety considerations. Reliable access to suitable PET waste is particularly important because feedstock quality and continuity can directly affect plant operations. Adequate infrastructure and logistics can also reduce material-handling difficulties and support efficient movement of raw materials, intermediate products, and finished polyester yarn.
Equipment requirements depend on the selected recycling and yarn-manufacturing process, but PET recycling facilities commonly require systems for sorting, size reduction, cleaning, drying, flaking, material handling, and further polymer processing. The report specifically identifies suppliers and equipment categories for grinders or shredders, hot air flaker dryers, material handling equipment, effluent treatment plants, D.G. sets, and laboratory equipment. Additional spinning and melt-processing equipment is required when the recycled PET is converted into polyester fibres or yarn.
Sorting is essential because clean and correctly identified PET feedstock supports consistent recycling and downstream polyester quality. Waste streams can contain non-PET plastics, labels, closures, metals, colours, dirt, and other contaminants that may interfere with processing. The recycling process therefore includes sorting at different stages, including collection and trader operations and further sorting at PET recycling facilities. Effective separation and cleaning help prepare the material for flaking, melting, filtration, and subsequent conversion into polyester fibre or yarn.
Why Choose Us
- More than 45 years of experience
- Managed by expert industrial consultants
- ISO 9001-2015 Certified
- Registered under MSME, UAM No: DL01E0012000
How We Work
- 24/5 Research Support Get your queries resolved from an industry expert. Ask before you purchase.
- Custom Research Service Speak to our consultants to design an exclusive study for your needs.
- Quality Assurance All reports are prepared by qualified consultants & verified by experts.
- Information Security Your personal & confidential information is always safe and secure.
Detailed Project Report (DPR) includes Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.
Each report include Plant Capacity, requirement of Land & Building, Plant & Machinery, Flow Sheet Diagram, Raw Materials detail with suppliers list, Total Capital Investment along with detailed calculation on Rate of Return, Break-Even Analysis and Profitability Analysis. The report also provides a birds eye view of the global industry with details on projected market size and then progresses to evaluate the industry in detail.
We can prepare detailed project report on any industry as per your requirement.
We can also modify the project capacity and project cost as per your requirement. If you are planning to start a business, contact us today.
- Market growth drivers
- Factors limiting market growth
- Current market trends
- Market structure
- Key highlights
- Up-to-date analyses of market trends and technological improvements
- Pin-point analyses of market competition dynamics to offer you a competitive edge over major competitors
- An array of graphics, BEP analysis of major industry segments
- Detailed analyses of industry trends
- A well-defined technological growth with an impact-analysis
- A clear understanding of the competitive landscape and key product segments
- Ask for FREE project related details with our consultant/industry expert.
- Share your specific research requirements for customized project report.
- Request for due diligence and consumer centric studies.
- Still haven't found what you're looking for? Speak to our Custom Research Team.
EIRI Board is a single destination for all the industry, company and country reports. We feature a large repository of latest industry reports, leading and niche company profiles, and market statistics prepared by highly qualified consultants and verified by a panel of experts.
Note: We can also prepare project report on any subject based on your requirement and country. If you need, we can modify the project capacity and project cost based on your requirement.
Our reports provide an expansive market analysis of the sector by covering areas like growth drivers, trends prevailing in the industry as well as comprehensive SWOT analysis of the sector.
Our Clients
- Our research reports comprehensively cover Indian markets (can be modified as per your country), present investigation, standpoint and gauge for a time of five years*.
- The market conjectures are produced on the premise of optional research and are cross-accepted through associations with the business players.
- We use dependable wellsprings of data and databases, and data from such sources is handled by us and incorporated into the report.
- Our project reports include detailed analysis that helps get the industry's Present Market Position and Expected Future Demand.
- Offer real analysis driving variables for the business and the most recent business sector patterns in the industry.
- This report comprehends the present status of the business by clarifying a complete SWOT examination and investigation of the interest-supply circumstance.
- Report gives analysis and in-depth financial comparison of real players/competitors.
- The report gives estimates of key parameters which forecast business execution.
