(PSF, 3000T/Y-50000T/Y) Polyester Solid/Hollow Conjugated Staple Fiber Production Line

Recycled regenerated Polyester staple fiber is a synthetic man-made fiber made from PET/Polyester waste and post consumed PET bottles. Hollow Conjugate Siliconised Fiber, Hollow Non-Conjugate Siliconised Fiber, Solid Fiber Siliconised/non Siliconised, It is used in Non-Woven carpets, wadding, filtration industries, as a polyfill for stuffing cushions, pillows, soft toys, quilts. It’s 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.

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Process

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, it was very difficult to dispose them. New technology was developed in Europe, Korea and finally China which helped in recycling this post consumed PET bottles to make man-made fibers 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 chemical helps in taking out glue from bottles and also cleaning them. The overall contaminations in PET flakes should not be more than 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 become soft/crystallized & dried. Moisture held within the PET flakes it is known as inherent moisture. The Driers helps to reduce the inherent moisture to less than 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 (0.7Den  33Den). 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 fiber. These fibers are then dried and relaxed in a relaxer and cut in various cut length before bale packing.

Specifications

  • Denier Size: 1.5Den, 3Den, 6Den, 10Den, 15Den, 18Den, 22Den, 25Den, 33Den
  • Cut length: 44, 51, 64, 76, 102 (As per customer requirement) 
  • Feel: siliconised or non siliconised soft as well as harsh feel 
  • Tensile strength: 3.5 to 4.5 gm/Denier 
  • Elongation: 40 to 60% 
  • Oil Pickup: minimum 0.20% to 0.35% 
  • Crimps: 3 to 5 per cm 
  • Shades: All shades available 
  • Quality: Hollow Conjugate Siliconised Fiber, Hollow Non-Conjugate Siliconised Fiber, Solid Fiber Siliconised/non Siliconised

Application

Cushions – Pillows – Quilts – Toys – Jacket – Mattress – Non woven carpet – Automotive felts, speaker felts, geo textiles, polyfill wadding, filter fabrics and other acoustics as well.