FOR A COMPOSITE POLY FIBER MANUfACURING UNIT OF 90 TPD OF RECYCLED POLYESTER FIBER, WITH YARN SPG UNIT OF 30 tpd, and investment feasible and viable in 2 project phases

Based on Recycled PET bottles | to Pet Chips & Fiber | to Poly yarns

Project overview

The Project PROPOSAL, under reference of this Sustainability project for circular economy manufacturing route, is based on recycling of PET bottles via creation of polyester chips and onwards `value addition` into regenerated Polyester fiber and its spinning into textile Polyester yarn for knitting and weaving use. The fully integrated projecy proposal, is for setting up a  new greenfield globally competitive Textile manufacturing unit for regenerated PSF Polyester staple Fiber, of hollow and solid type for textile spun yarn grade, with installed capacity of 90 to 100 Ton/Day, and of this output 30 TPD of polyester fiber will be consumed for inhouse Yarn spinning [via  Ring and OE spinning systems]. Both the chosen products, are being increasingly supported in global markets by all major MNC textile brands like H & M, GAP, Adidas, Nike that are progressively switching over to such textile and apparels produced under `circular economy` mode. Both, the regen. PSF fiber and the spun polyester yarns, are in good demand for  productions of value added textile fabric and technical textiles, like knitting yarns, fabric and eventually apparels for use by consumers, as also technical textiles like felts, filters media. Polyester (PET) is the most widely used fibre in the apparel industry, accounting for around 52% of the total volume of fibres produced globally. The apparel industry accounts for around 32 million tons of such 57 million tons of polyester used each year, and is  now calling for increased use of recycled Poly. Such polyester fiber is also used widely in technical textiles and for hygience and PPE medical products.

Components for Proposed composite Project

The integrated pet bottle to textile yarn proj.to have 3 componets

[a] Production of approx. 90 to 100 Ton/Day of PET Chips [textile grade] from input of 100×1.3 Ton/day of recycled PET bottles, and followed by

[b] Production of approx. 90 Ton/Day of regenerated Polyster Fiber [PSF] for use in Textile Yarn spinning and for the use as hollow fiber as Filler for home textiles and for Technical textiles such as felts and Filter media etc.

[c] Production of last `value chain` item of Polyester Textiles yarns; total 30 Ton/day, of  both Ring spun and OE type for use in textile knitting and weaving.

The breakup of capacities for above 3 Basic and value-added products to be as per project configuration below:

Project Configuration

We advise to implement a 90 to 100 Tons per day Regenerated/ Recycled Polyester Staple Fiber manufacturing unit, to produce both solid and hollow type  Fibers, which will utilize recycled PET Bottles [at average yield of 70%] as the starting and basic raw material for manufacturing of textile grade PET and `value added` textile grade  regen PSF fiber which is to be of both solid and hollow type for textile end uses. The project can also produce `colored` fibers  by adding master batch into Pet polymer melt.

Of this PSF  fiber output, and for eventual and final `value addition ` about 31 Tons per Day of inhouse PSF fiber will be consumed for captive Yarn spinning unit to produce approx. 30 Tons per day of `value added`Ring and OE spun polyester yarns of textile grade for sale to fabric making knitting and weaving mills in the textile hubs like Egypt, Morocco, Ethiopia, Kenya and other markets like Iran and the CIS countries. Such yarns can be spun from the regen Poly fiber of both grey SD type and/or of colored type.

Notes: The Input/Output Norm of 1Kg of Regen PSF fiber till upto spun Yarn, consuming 1.3 Kg of PET input  bottles, are  assumed as per the industry norms. Here, it should be noted that the entire manufacturing process for RPSF can be divided into three processes, that is

1] Pet bottle washing and making of usable Pet chips,

2] Melting and drawing out of chips to make textile grade PSF or polyester fiber,and

3] Ultimate conversion of part of PSF fiber output into textile grade polyester spun yarns.

  • Bottle Crushing and Washing Line to produce flakes – the used/recycled PET Bottle waste is crushed, washed and converted into PET Flakes[100 TPD].This would require  2 nos.of PET washing lines,each of 2.5 Ton/Hour capacity.
  • Poly Spinning and Fiber Line – The PET Flakes are then fed into polymer spinning line and fiber line to manufacture the product i.e .regen PSF fiber for textile and Fiberfill enduses. Such fiber to be of type Solid and hollow for fiber fill uses.

Final Value addition to 30 ton/day of inhouse PSF  fiber, via captive yarn spinning on 15840 spindles, and 1000 OE spg. rotors, supported by 2 Blow room lines for fiber opening and balanced on 11 nos. Ring frame and 2 OE spg. frames for Yarn spinning in count range of 7s Ne to 24s Ne.

The USP of the plant configuration to be added is the induction of single line  [CPF] Homogenisaion and Polymer chemical regeneration unit for the PET flake melt, for creating pure and high strength quality of Pet chips and, PSF fiber and Yarn thereof.

Product Details

With the induction of  Annealer and Finisher or Homogeniser [in the Pet chip to fiber making line, for polymer melt] plants in the production line, the project will be  producing textile grade fiber of  high tenacity i.e 6.5 gpd plus. The end use for the output regenerated fibre will be 100% Textile Grade fiber of solid cross section, in popular 1.2 to 2.2 Deniers. The other PSF fiber will be for types hollow for Fiberfill, and for other uses as for nonwoven felts and technical textile uses.

The rationale for product price, for  Regen. PSF fiber, for textile grade.

With the induction of Finisher unit in the  main production plant, the  project would produce  high strength HT fiber in range 1.2 to 2.2 denier, for  textile  yarn spinning end uses. This fiber can be spun on both Ring  spun and Open end spg systems, and competes `virgin`fiber due to  its quality and strength.

At present   day and period, the  price for such  regen. PSF fiber is  ruling between 100-105 Rs./kg for the Grey fiber and Rs.110-115 /Kg for the dope Dyed [ before GST, Vat etc] and matches the industry  norm of Rs. 45 to 55 /Kg  over and above the landed price of the recycled PET bottles, used as basic raw material. Overall, such recycled Poly. fiber yet remains lower by Rs 10 to virgin.

Project Cost Estimate

The Fixed capital project cost of the fully Integrated Greenfield  project comprising of  90 TPD regen Polyester Fiber manufacturing  with inhouse polyester spun Yarn spinning project of 15840 spindles and 1000 OE rotors , has been estimated at INR 2250 Million; and that is equivalent of USD 20.5 Million,per todays FE exchange rate.

The Summary of the project cost has been provided in INR Million,as per tablet below –

All Figures in INR Million
Description Total,INR Mln
Land and Land Development, for 22 Acres plot —–
Buildings and Civil Works for Pet Bottle washing to Chips, PSF Fiber spinning, and 2 nos. Yarn spinning units. 400
Plant and Machinery, all Imported CIF only, [before Duty, & installed at site] and incl Pet bottle wash & Fiber manufacturing and Yarn Spinning units 1000
Plant and Machinery, all Imported CIF only, [before Duty & installed at site] and incl 20 TPD Ring Spg plantand, 10 TPD OE Yarn spg.plant 750
Pre-Operative exp, and Misc-Excluding Working capital marginetc 100
Total Fixed Capital based, Project Cost 2250 INR Million
Notes: Fixed Cost above excludes Cost of any Land and Working Capital funds.

Total Fixed Capital based, Project Cost, as above, in USD Million $ 30 Million

Each of the sub-heads of the overall project cost to be broken-up and to be detailed in the subsequent Project Feasibility Report, alongwith Project Financial Viability model etc. The proposed  Means of Financing such projects under Indian Banking norms is based on the standard Debt-equity ratio of approx. 30% that is, Promoters share of $ 10 Million, and balance as Debt or banks Term Loan of abt. $ 2o million.

Project Utilities and Manpower

Other than  the prime  Raw material  and input of  recycle PET bottles, of all types/sizes. colors etc the integrated  PSF fiber and poleyster yarn spining project will be requiring consumables materials as Chemicals, colored master batch chips and packing materials for fiber and yarn packing etc.

The other Key utiltiies and services required for the Inegrated project are:

1]  Manpower, for 3  shift working, Total of 450 Nos./Day; and incl.Yarn SPG

2]  Electrical Power: total 5 MW, incl. both PSF fiber and 2 Yarn Spg. lines

3]  Steam  requirement is about 2.5 Ton/Hour, peferably from 1 Steam boiler.

4]  Water requirement is rather large mainly due to per bottle and at 400 Mln Ltr/Year, of which 80% recycled.

5] Project would also require a modern Zero Discharge type ETP plant.


Rationale & Recommendations

The consultants have rationalized the overall project configuration and its cost by selecting an optimum mix of imported Technology, its  plant and machineries. The main Fiber manufacturing plant will be imported from best of high tech and cost effective suppliers in China, while the spun Yarn spinning plants will be sourced from globally reputed Rieter in Switzerland  that has  advanced process technology for recycling  and spinning of regen Fiber into almost vurgin quality spun yarns.

Taking these aspects into consideration and based on the project plan to include a 15840 Ring spdl spun Yarn spinning and 100 rotor OE Spg. Unit of  Rieter Switz. to produce total of 30 Tons of  polyester yarns from own In-house produced regenerated PSF fiber for inhouse `value addition’, the overall project cost is at par with current standards and  reasonable vis a vis  towards long-term sustainability and viability of future profitable business operations.

It is recommended to implement the project on time bound target with Phase 1 from recycled Pet bottles to regen PSF manufacturing ,and followed by Phase 2 over next 1 year for setting up 2 In-house Yarn Spg units to produce 30 to 40 tons of recycled yarns. However, all Buildings to be done in Phase1, and Mcy induction is advised in  2 Phases.

Turnkey Project Planning from Pre-Project consultancy, till `On-Site` Execution Services, over both Phases of 18-20 Months, are  available  from Nuovatex Projects Co, based at New Delhi, India. Having successfully planned  and delivered a no. of such recycled fiber to spinning Textile projects, with foot print in India and 5 countries including the CIS, Mid East., NE Africa and others.

To begin with, the first initial step advised is to commission a 45-60 day duration, Project Pre-feasibility Report to guide the managements on all  aspects of the discussed and integrated Project based on recycled PET bottles, and for location closer to a seaport/ ICD.

Author: MUNISH TYAGI, NUOVATEX PROJECTS CO.