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1. WHAT is Recycled POY?
Recycled POY, or Recycled Partially Oriented Yarn, is a type of yarn made from Recycled polyester. Its birth stems from the pursuit of environmental protection and resource recycling. Its raw materials mainly come from post-consumer or post-industrial polyester waste, such as discarded plastic bottles and polyester fiber fabrics. Through a series of advanced collection and reprocessing technologies, these waste materials are transformed into high-quality recycled polyester, which is then spun into POY yarn.
2. The production process of Recycled POY
(1) Raw material collection and pretreatment
Post-consumer waste collection: The main source is discarded plastic bottles in daily life. Through an extensive recycling network, various plastic bottles are collected from household and public place trash cans as well as specialized recycling stations. Afterwards, the collected plastic bottles are preliminarily classified to remove non-polyester bottles and other impurities, such as bottle caps and labels.
Post-industrial waste collection: Polyester waste such as scraps and defective products generated during the production process in textile factories, plastic product factories, etc. is also an important source. These wastes are usually relatively pure and the difficulty of recycling and processing them is relatively low. After collection, it is also necessary to sort and organize the waste materials to distinguish different types and qualities.
Pre-treatment: Whether it is post-consumer or post-industrial waste, it needs to go through pre-treatment steps such as cleaning and crushing. The purpose of cleaning is to remove dirt, impurities and residual chemical substances from the surface of waste materials. Crushing is the process of processing waste materials into smaller particles for subsequent processing.
(2) Manufacturing of recycled polyester
Physical method: Directly dry the pre-treated polyester waste (such as bottle chips) to remove the moisture within. Subsequently, the dried waste is melted at high temperatures, impurities are removed through a filtering device, and then recycled polyester fibers are produced through a spinning process. This method requires less equipment investment, has a relatively simple process, and has a smaller impact on the environment. However, the bottle-grade recycled polyester fibers produced by it have certain gaps in physical and chemical indicators compared with virgin polyester fibers, and complete recycling cannot be achieved.
Chemical method: Use appropriate chemical reagents to carry out depolymerization reactions on waste polyester, causing it to decompose into polyester monomers or oligomers. Next, high-purity polyester raw materials are obtained through a refining process, and then a polymerization reaction is carried out again to generate high-quality polyester chips, which are finally spun into fibers. The chemical method can achieve the complete recycling of waste polyester, and the performance indicators of the recycled polyester fibers are good. However, this method is technically complex, requires a large investment in equipment, and at the same time, the use of chemical reagents may cause certain environmental problems.
Physical-chemical method: The sources of recycled raw materials for this method are extensive, including recycled bottle flakes, recycled fabrics, as well as bubble materials made from friction materials, scraps, etc. After crystallization and drying, these raw materials are processed through a series of techniques such as screw melt extrusion, two-stage high-precision filtration technology, static high-efficiency mixing technology, melt liquid-phase conditioning and viscosity adjustment technology, computer-aided color matching technology, and vacuum impurity removal technology, and finally spun to prepare recycled polyester.
(3) Spinning of POY yarn
The manufactured recycled polyester chips are heated and melted through a screw extruder to form a melt with good fluidity. After filtration and metering, the melt is extruded through the spinneret to form a fine stream. In the spinning corridor, the fine stream is cooled by air and rapidly solidifies into filaments. At the same time, a certain tension is applied to the filament with the help of a winding device so that it is wound into a bobbin in the partially oriented state, thus obtaining Recycled POY yarn.
3. Recycled POY 's advantages
(1) The environmental protection benefits are remarkable
Reducing plastic pollution: A large amount of post-consumer and post-industrial polyester waste is recycled and reused, preventing these wastes from entering landfills or the natural environment, thereby reducing the pollution of plastic waste to soil, water sources and the ocean. Take discarded plastic bottles as an example. The vast amount of plastic bottles produced globally each year, if not effectively Recycled, will remain in the environment for hundreds or even thousands of years. Converting them into Recycled POY yarn greatly reduces the stock of plastic waste.
Reducing energy consumption: Much less energy is needed to produce Recycled POY than to produce virgin polyester fiber from petroleum. Because the regeneration process utilizes existing polyester materials, there is no need for a series of complex and energy-consuming procedures starting from crude oil extraction, thereby reducing the reliance on energy and minimizing carbon emissions caused by energy production.
Promoting the recycling of resources: It has achieved a circular model of polyester materials from "production - use - recycling - reproduction", enabling limited resources to be utilized more fully. This is in line with the concept of sustainable development and helps to build a circular economy system.
(2) Excellent performance
Strength and Durability: While being a Recycled product, Recycled POY yarn performs well in terms of strength and durability to meet the requirements of most textile products. Whether it is used for making daily clothing or industrial textiles with high strength requirements, such as tents and ropes, it can ensure that the products have a long service life.
Stability: Its physical properties are stable. Under different environmental conditions, such as changes in temperature and humidity, it has good dimensional stability and is less likely to deform or shrink, providing a reliable guarantee for subsequent textile processing and product quality.
Workability: Similar to virgin POY yarn, Recycled POY has good workability and can adapt to various textile processing techniques such as twisting, weaving, dyeing, etc., making it convenient for textile enterprises to produce a variety of products.
(3) Meet market demands
The improvement of consumers' environmental awareness: With the global popularization of environmental awareness, more and more consumers tend to choose environmentally friendly and sustainable products when purchasing. Textile products containing Recycled POY can appeal to this environmentally conscious consumer group and win market share and a good reputation for the brand.
The demand for brand sustainable development: Many brands, in order to enhance their corporate image and fulfill their social responsibilities, actively seek to use environmentally friendly materials. Recycled POY provides a way for brands to achieve sustainability goals and helps them stand out in the market competition, especially in industries such as fashion and sports where environmental image is highly valued.
4. Application fields of Recycled POY
(1) Clothing industry
Everyday clothing: Widely used in various daily wear such as T-shirts, shirts, trousers, dresses, etc. When consumers wear these clothes, they can not only enjoy a comfortable wearing experience, but also contribute to environmental protection. Fast fashion brands are launching collections containing Recycled POY to meet consumers' dual demands for fashion and environmental protection.
Sportswear: Due to its excellent strength, moisture absorption and breathability, it is also highly favored in the field of sportswear. Such as sports jackets, sports shorts, yoga wear, etc., can provide the wearer with a comfortable feeling during exercise, and at the same time have excellent durability, being able to withstand frequent friction and washing during exercise.
Functional clothing: Some functional clothing, such as windbreakers, waterproof suits, thermal suits, etc., also began to use Recycled POY yarn. Through special textile and post-treatment processes, it is endowed with corresponding functionality while meeting environmental protection requirements.
(2) Home textile industry
Bedding: Bed sheets, duvet covers, pillowcases and other bedding are also gradually being made from Recycled POY. Its soft touch and good comfort provide people with an excellent sleep experience, while adding an environmentally friendly element to the bedroom.
Curtains: As an essential part of home decoration, curtains made from Recycled POY not only look good, but also block ultraviolet rays effectively, adjust indoor light, and are excellent for environmental protection.
Carpet: Some carpet makers began to produce carpets using Recycled POY yarn. This kind of carpet has excellent wear resistance and stain resistance, while reducing the impact on the environment. It is suitable for various places such as homes, hotels and offices.
(3) Industrial field
Packaging material: In some packaging fields such as woven bags, plastic film, etc., Recycled POY can be used as a raw material. Its high strength and durability can ensure that the packaging materials protect the products during transportation and storage, while reducing the use of virgin plastics and lowering the environmental pressure of packaging waste.
Geotextiles: Geotextiles used in civil engineering, such as roads, DAMS, water conservancy projects, etc., need to have good strength and anti-aging performance. The geotextiles made from Recycled POY can meet these requirements, and through the recycling of waste, they achieve efficient resource utilization and environmental protection.
Car interiors: Recycled POY is also being used in car seat covers and interior fabrics. Not only does it add an environmentally friendly atmosphere to the in-car environment, but its performance can also meet the requirements of automotive interiors for wear resistance, comfort and aesthetics.
