One-Step Recycling And Inline Spinning Of PET Waste Into Excessive-Finish Fibers

REMSCHEID, Germany — February 18, 2021 — German firm BB Engineering combines its VacuFil course of with the directly-connected VarioFil spinning system, therefore making a one-step course of for recycling and inline spinning of post-consumer and post-production PET waste into POY or FDY.

Manufacturing polyester fibers for demanding textile functions from rPET granulate – significantly utilizing the inline spinning course of – is an especially difficult activity. It requires recycling know-how and spinning plant experience. The beginning materials must be frequently processed into an homogeneous, spinnable soften.

All processing steps should make sure the required soften properties and hold these steady all through your entire course of runtime. For quite a few textile functions, parameters resembling viscosity and homogeneity are decisive and have to be topic to the one the minutest fluctuations. In different phrases: utilizing recycled polyester throughout the textile phase requires appropriate pretreatment processes along with exact course of administration.

BB Engineering, a subsidiary of Oerlikon Textile, has many years of expertise and know-how within the growth of spinning plant parts and techniques. And it was this spinning plant experience that was decisive for the profitable growth of the VacuFil PET recycling system. On this foundation, the corporate developed a Liquid-State Polycondensation recycling system for additional processing post-production spinning waste and post-consumer bottle flakes, optimally aligned to the textile additional processing of the recycled supplies within the spinning plant (patent presently pending).

The core part of this course of is the vacuum filter, with which the viscosity could be individually managed and monitored. To this finish, the required soften properties could be achieved inline in a dependable and reproducible method and managed throughout operation. In varied spinning trials, the rPET granulates manufactured on the Oerlikon Textile R&D Heart utilizing the VacuFil produced convincing outcomes.

Virgin PET reference Bottle flakes
Indian buyer
Bottle flakes
European origin
Fiber waste POY
Enter IV 0.66 dl/g 0.81 dl/g 0.80 dl/g 0.624 dl/g
Output IV VacuFil 0.646 dl/g 0.66 dl/g (±0.06) 0.643 dl/g (±0.05)
High quality No. 22.1 22.8 21.8 20.9
Frays / 10,000m 0.65 0 0.75 0.41
Yarn breaks / 1t 0 0 0 0
Dyeing uniformity

(1: finest – 6: worst)

1-2 1-2

>4.5 (grey scale) AA



The outcomes of the assorted spinning trials show that the brand new VacuFil know-how is so efficient that the rPET produced is of excellent high quality and similar to that of virgin materials.

The granulation step could be disbursed with for those who mix the VacuFil with BB Engineering’s rPET-compatible VarioFil* R+ compact spinning system (or different direct spinning techniques able to processing rPET). The waste materials is recycled and immediately spun in a single seamless course of – in superlative high quality due to optimum soften remedy. [Anm.: Den folgenden, englischen Part hat der Kunde so abgesegnet. Bitte nicht verändern.] Eco Spindles – a Sri Lanka-based buyer of BB Engineering – has been so satisfied by the VarioFil R+ spinning system with VacuFil extrusion that it’s investing in an extra rPET VarioFil system. Dr. Anush Amarasinghe, Managing Director of Eco Spindles, produces POY from bottle flake materials and explains: “Our shoppers are more and more asking for recycled fibers and we in fact want to fulfill their necessities and calls for. For that reason, increasing our portfolio to cater to this has been an necessary step for us. Bottle recycling continues to be a distinct segment market in Sri Lanka and we now have been decided to keep up our top quality requirements. We’ve got particular necessities and wanted a cutting-edge associate for this mission. A number of years in the past, we opted to buy a BBE VarioFil R+ compact spinning system to permit us to fabricate POY from bottle flakes. We needed to first check the set-up – additionally attributable to the truth that the bottles collected from seashores are partly problematic beginning supplies. Nevertheless, the extraordinarily good buyer suggestions and the truth that our product is worthwhile have prompted us to speculate additional. We’ve got determined to accumulate an extra VarioFil R+ line with VacuFil recycling system. What is especially nice is the truth that your entire course of is totally coherent. We’re capable of produce extraordinarily homogeneous, viscosity-stable rPET soften and spin it immediately into high-end fibers.”

Within the case of Eco Spindles, this can be a versatile VarioFil R+ compact spinning system with upstream VacuFil inline recycling unit with a direct feed. It has been designed to fabricate utilizing recycled bottle flakes, recycled chips and virgin chips. On the one hand, that is attainable on account of the drying system that’s appropriate for each flakes and chips. Alternatively, the vacuum extruder could be operated with out or with out vacuum and is due to this fact capable of soften recycled and virgin beginning supplies. The expertise acquired from >20,000 bought models has influenced the extruder design. Because of the mild melting, BBE extruders type the premise for absolutely-homogeneous soften, as required by the spinning plant. The only-screw know-how ensures the robustness obligatory in recycling. Final however not least, the particular metering system for a number of parts additionally gives producers with flexibility: both two components could be fed into the soften concurrently or the metering unit can be utilized for quick dye switches. With 6 positions, this VarioFil configuration achieves product throughputs of as much as 150kg/h and gives a broad finish product vary with last titers of between 50 and 150 den (DTY) with a DPF vary of between 0.7 and 4.0 dpf. In different set-ups, the VarioFil R+ covers a spread of 20-600 den POY or 30-500 den FDY with recycled PET.*

With this, the VarioFil isn’t solely a flexible spinning machine for probably the most numerous functions, it additionally caters to the constantly-rising demand for rPET fibers. Main textile-processing companies and companies – be these vogue manufacturers, sports activities attire and furnishings producers or these working throughout the car trade – are more and more specializing in sustainable merchandise and merchandise made out of recycled supplies. Right now, they’re already telling suppliers of filaments, fibers and nonwovens that they are going to be switching from completely virgin polyester to recycled polyester – in some instances as much as 100% – for the manufacture of their textile merchandise within the close to future.

*VarioFil is the identify given to BB Engineering’s compact spinning techniques product household. Generally, VarioFil techniques are capable of course of PET, PA6, PA6.6, PP, PLA, PBT, PTT and bi-components into POY, FDY or IDY. The VarioFil R+ system has been designed particularly for rPET and bottle flakes.

Posted February 18, 2021

Supply: BB Engineering GmbH

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