Recycled Polyester Staple Fibre (RPSF) is a reliable and sustainable alternative to synthetic man-made fibres. Manufacturing RPSF involves recycling post-consumer PET bottles and other PET/Polyester waste to create a new fibre that can be used in multiple applications.

These applications include non-woven carpets, wadding, filtration materials, polyfill stuffing for cushions and quilts, geotextile, and spinning yarns.

The advantages of using RPSF are that it does not require any additional resources or energy consumption when manufacturing, which means, the complete process is more environmentally friendly than traditional processes.

So, recycling PET/Polyester waste and used PET bottles is highly significant to sustain the cleanliness of the environment.

Manufacturing Process of Recycled Polyester Staple Fibre (RPSF)

The Manufacturing Process of Recycled Polyester Staple Fibre (RPSF) begins with collecting post-consumer PET bottles, which are then sorted and cleaned to remove contaminants. The bottles are then cut into flakes and rewashed in hot water before being dried and heated to separate color pigments.

The PET flakes are then melted down and passed through a spinneret to produce filaments that are cooled rapidly in a liquid bath. These filaments can be cut to the desired length or combined with other fibres to form yarns. Finally, these yarns are spun together into RPSF fabric.

Once the PET bottles have been cleansed, manufacturing of Recycled Polyester Staple Fibre (RPSF) can begin. RPSF is made when the hot-washed and dried flakes are melted under high temperatures before being spun into yarn. This yarn creates fabrics such as blankets and pillows, providing a sustainable option that reduces landfill waste.

The product must meet stringent requirements of quality control tests which measure color, composition, and length of the fibre, amongst other criteria. If all conditions are met, the recycled polyester staple fibre can be certified for use in various products.

For a precise process, PET bottles are crushed to make 12 to 15 mm flakes and are hot washed in a chemical solution encompassing a 2 percent solution of Sodium Hydroxide. Also, PET flakes’ contamination should not be more than 200 ppm.

Manufacturing RPSF requires the use of vacuum driers to reduce the inherent moisture in PET flakes. The driers help to eliminate surface moisture and reduce the internal moisture content.

By controlling and managing the moisture levels, RPSF can attain a soft/crystallized texture with optimal drying characteristics when spun into yarns or filaments.

Careful management of this process ensures that RPSF maintains consistent quality across every batch. As a result, RPSF provides superior performance characteristics compared to virgin polyester fibres.

Spinneret is accessible to make hollow or solid PSF of variable denier (1.5Den 50Den). Filaments coming out of spinning are gathered in bobbins or cans. These dried flakes are transferred to Extruder for spinning. This completes the process of spinning.

After the Hollow and Solid PSF are treated to create different types of fibres, they are ready for manufacturing RPSF. The process begins with several cans or bobbins combined in a Creel area.

The mixture of several cans is then stretched multiple times in a chemical hot bath, which produces the RPSF. Finally, this Recycled Polyester Staple Fibre (RPSF) is now complete and ready for use.

​Recycle Polyester Staple Fibre (RPSF) Manufacturing by JB Ecotex Limited

JB Ecotex Limited offers Recycle Polyester Staple Fibre (RPSF) with a world-class polyester fibre manufacturing process and technology.

JB Ecotex Limited is revolutionizing the industry with its accurate process of manufacturing Recycled Polyester Staple Fibre (RPSF). With state-of-the-art technology and processes, JB Ecotex Ltd provides an eco-friendly solution to plastic waste. ReNAYA from JB Ecotex is a fantastic way to create something new out of plastic waste while maintaining or surpassing the quality parameters of virgin fibre products.

The name itself brings across the core idea – ‘Re’ stands for Recycle, and ‘NAYA’ stands for New. JB Ecotex has developed a unique process to convert post-consumer plastic waste into RPSF that can be used in different applications.

Under the brand name “ReNAYA”, JB Ecotex Limited provides Recycle Polyester Staple Fibre with complete dyeing assurance under different variants such as Ivory White, Hansa White, and Feher White in diverse cuts and deniers.

Moving Forward

JB Ecotex is committed to providing the best quality recycled polyester staple fibre (RPSF). Manufacturing with RPSF produces a durable yet lightweight fabric, making it perfect for producing items like furniture and home textiles. Our “ReNAYA” brand focuses on creating highly environmentally friendly and sustainable products.

The properties of RPSF make it an ideal choice over natural fibres. It is stain-resistant, wrinkle-free, fire retardant, and has high elasticity, giving the product more durability than other fabrics made from natural fibres. RPSF also has good abrasion resistance and can be easily dyed or printed with various designs.

JB Ecotex Limited even provides RPSF in black colour, which is equivalent to virgin black polyester staple fibre matching the equal and higher quality parameters.

India generates a humongous amount of plastic waste per year, 3.3 million metric tonnes per year according to the Central pollution control board. Out of this 60 percent of waste is recycled and the remaining is dumped in landfills and has an impact on the environment. To solve this issue, the government introduced Extended Producer Responsibility (EPR) through Plastic Waste Management Rules, 2016 in India. EPR is a practice where Producers, Importers, and Brand Owners are given responsibility for the collection and scientific disposal of their post-consumer waste. Although EPR is relatively new in India, companies are coming forward and getting EPR compliance done. As the concept is new, there are many doubts and myths that come up surrounding it. This blog will debunk a few myths about EPR.

a) The most rumored myth regarding Extended Producer Responsibility Program is that the industry-funded EPR programs will drive up the cost of the products:-

Even if it is true that EPR shifts the responsibility for end-of-life management of products and packaging upstream to producers, the cost of the products does not go up due to this. The producer responsibility costs are generally determined by:-

1. Type of policy, its stringency, its enforcement, and the expected outcomes from the policy.

2. Plastic types in the EPR (Multilayer or Non-MLP).

3. Which products are actually in the EPR regime and which are exempted

Hence, the cost to be paid for the EPR is divided and less. Instead, this cost of EPR can create incentives for producers to incorporate environmental considerations into the design of their products and packaging.

b) EPR programs are cliche and require bureaucratic oversight.

While government oversight is necessary to ensure a level-playing field, producer responsibility legislation is designed to minimize the government’s role and provide flexibility to the industry in developing effective take-back programs.
Striking the right balance between government oversight and control of system outcomes on the one hand, and producer flexibility and control over system implementation on the other is key to the success of EPR programs.

c) EPR Programs do not really address the environmental issues

EPR fundamentally changes the landscape of Plastic reduction and recycling. Well-designed EPR systems increase the recovery and recycling of Plastic, reduce contamination, and develop markets for difficult-to-recycle materials. EPR not only provides sustainable financing for recycling by placing financial responsibility for the system on producers; it can also transition legal responsibility for recycling performance and the burden of day-to-day recycling management away from the public sector, allowing limited public resources to be directed toward other priorities. Producers are ready for a harmonized system that can help them achieve a circular economy and meet their sustainability goals — and EPR provides a path to building this system.

d) EPR is the only way to reduce pollution.

No, there are other ways to reduce pollution like reusing, making smart choices, etc.

e) EPR program will not make any significant changes.

It is better to start than to maintain the status quo. Changes are visible now as many of the big brands like l’oreal are working to change their product design to reduce plastic pollution. Hence, we can say that something is better than nothing.

f) Sorting my recycling is a hassle and isn’t really important.

On the contrary, sorting your recycling items and waste properly is fast, easy, and super-important! Not accepted—and potentially dangerous—materials (e.g., batteries, propane canisters, scrap metal, garbage) that should be collected through other programs, need to be disposed of properly. Items like batteries pose a huge fire risk to facilities and the people who work there. To keep everything moving safely and smoothly, take a few seconds to sort your recycling properly, please.

g) It doesn’t matter if I recycle. Everything just winds up in the landfill, anyway.

This pesky rumor has been around since the dawn of recycling, even though it’s patently false. The truth is: Every effort you and your family make to recycle properly has a positive impact! And the more residents understand about the recycling process, the less waste is sent to landfills, the fewer virgin materials are used in manufacturing, and the more your community can recycle.

Renewable energy is energy derived from natural sources that are replenished at a higher rate than they are consumed. Sunlight and wind, for example, are such sources that are constantly being replenished. Renewable energy sources are plentiful and all around us.

Fossil fuels :- coal, oil and gas – on the other hand, are non-renewable resources that take hundreds of millions of years to form. Fossil fuels, when burned to produce energy, cause harmful greenhouse gas emissions, such as carbon dioxide.
Generating renewable energy creates far lower emissions than burning fossil fuels. Transitioning from fossil fuels, which currently account for the lion’s share of emissions, to renewable energy is key to addressing the climate crisis.

Here are a few common sources of renewable energy:

Solar Energy :- Solar energy is the most abundant of all energy resources and can even be harnessed in cloudy weather. The rate at which solar energy is intercepted by the Earth is about 10,000 times greater than the rate at which humankind consumes energy.
Solar technologies can deliver heat, cooling, natural lighting, electricity, and fuels for a host of applications. Solar technologies convert sunlight into electrical energy either through photovoltaic panels or through mirrors that concentrate solar radiation.
Although not all countries are equally endowed with solar energy, a significant contribution to the energy mix from direct solar energy is possible for every country.
The cost of manufacturing solar panels has plummeted dramatically in the last decade, making them not only affordable but often the cheapest form of electricity. Solar panels have a lifespan of roughly 30 years, and come in variety of shades depending on the type of material used in manufacturing.

Wind Energy :- Wind energy harnesses the kinetic energy of moving air by using large wind turbines located on land (onshore) or in sea- or freshwater (offshore). Wind energy has been used for millennia, but onshore and offshore wind energy technologies have evolved over the last few years to maximize the electricity produced – with taller turbines and larger rotor diameters.
Though average wind speeds vary considerably by location, the world’s technical potential for wind energy exceeds global electricity production, and ample potential exists in most regions of the world to enable significant wind energy deployment.
Many parts of the world have strong wind speeds, but the best locations for generating wind power are sometimes remote ones. Offshore wind power offers tremendous potential.

Here are five reasons why accelerating the transition to clean energy is the pathway to a healthy, livable planet today and for generations to come.

1. Renewable energy sources are all around us :- About 80 percent of the global population lives in countries that are net-importers of fossil fuels — that’s about 6 billion people who are dependent on fossil fuels from other countries, which makes them vulnerable to geopolitical shocks and crises.
In contrast, renewable energy sources are available in all countries, and their potential is yet to be fully harnessed. Renewables offer a way out of import dependency, allowing countries to diversify their economies and protect them from the unpredictable price swings of fossil fuels, while driving inclusive economic growth, new jobs, and poverty alleviation.

2. Renewable energy is cheaper :- Renewable energy actually is the cheapest power option in most parts of the world today. Prices for renewable energy technologies are dropping rapidly. The cost of electricity from solar power fell by 85 percent between 2010 and 2020. Costs of onshore and offshore wind energy fell by 56 percent and 48 percent respectively.
Falling prices make renewable energy more attractive all around – including to low- and middle-income countries, where most of the additional demand for new electricity will come from. With falling costs, there is a real opportunity for much of the new power supply over the coming years to be provided by low-carbon sources.
Cheap electricity from renewable sources could provide 65 percent of the world’s total electricity supply by 2030. It could decarbonize 90 percent of the power sector by 2050, massively cutting carbon emissions and helping to mitigate climate change.

3. Renewable energy is healthier :- According to the World Health Organization (WHO), about 99 percent of people in the world breathe air that exceeds air quality limits and threatens their health, and more than 13 million deaths around the world each year are due to avoidable environmental causes, including air pollution.
The unhealthy levels of fine particulate matter and nitrogen dioxide originate mainly from the burning of fossil fuels. Switching to clean sources of energy, such as wind and solar, thus helps address not only climate change but also air pollution and health.

4. Renewable energy creates jobs :- In addition, energy-related industries would require a further 16 million workers, for instance to take on new roles in manufacturing of electric vehicles and hyper-efficient appliances or in innovative technologies such as hydrogen. This means that a total of more than 30 million jobs could be created in clean energy, efficiency, and low-emissions technologies by 2030.
Ensuring a just transition, placing the needs and rights of people at the heart of the energy transition, will be paramount to make sure no one is left behind.

We believe in sustainable development; it means we fulfill our present needs without compromising with the needs of future generations. At JB Ecotex Limited we have installed 2.1 MW of Wind Turbine and 1.2 MW of solar power plant. Further, we are having a power purchase agreement with a third party generating renewable power. In total, around 25% of our power requirement is being fulfilled by renewable resources which further reduces our carbon footprint. Therefore, along with being the major rPet flakes producer, we try our best to contribute to a better planet.

Zero liquid discharge (ZLD) is an engineering approach to water treatment where all water is recovered and contaminants are reduced to solid waste. While many water treatment processes attempt to maximize recovery of fresh water and minimize waste, ZLD is the most demanding target since the cost and challenges of recovery increase as the waste water gets more concentrated. Salinity, scaling compounds, and organics all increase in concentration, which adds costs associated with managing these increases. ZLD is achieved by stringing together water treatment technology that can treat waste water as the contaminants are concentrated.

There are a number of benefits to targeting zero liquid discharge for an industrial process or facility:

1. Lowered waste volumes decrease the cost associated with waste management.

2. Recycle water on site, lowering water acquisition costs and risk. Recycling on-site can also result in less treatment needs versus treating to meet stringent environmental discharge standards.

3. Reduce trucks associated with off-site wastewater disposal, and their associated greenhouse gas impact and community road incident risk.

4. Improved environmental performance, and regulatory risk profile for future permitting.

5. Some processes may recover valuable resources, for an example, ammonium sulfate fertilizer or sodium chloride salt for ice melting.

Several methods of waste management are classified as zero liquid discharge, despite using different boundaries to define the point where discharge occurs. Usually, a facility or site property line that houses the industrial process is considered the border or ‘boundary condition’ where waste water must be treated, recycled, and converted to solids for disposal to achieve zero liquid discharge. Certain facilities send their liquid waste off-site for treatment, deep well disposal, or incineration and they consider this to qualify as zero liquid discharge. This approach to zero liquid discharge eliminates continuous discharge of liquids to surface waters or sewers, but can significantly increase cost.

Some engineers describe their designs as near-zero liquid discharge or minimal liquid discharge to highlight that they discharge low levels of wastewater, but do not eliminate liquid in their waste. For some facilities, it may be more economic to approach but not achieve complete ZLD by concentrating brine to lower volumes. Furthermore, it may be possible to avoid the creation of liquid waste on-site through careful water conservation or by treating contaminants at their source before they can enter the main flow of water.

What are the benefits of using Zero Liquid Discharge?

A zero liquid discharge system can assist with rising water costs and droughts. ZLD contributes to water conservation, reducing intake of fresh water, and avoids the environmental impacts of wastewater discharge. Although it is not possible to completely recover all of the influent water, the process maximizes the treatment and recycling of wastewater.

Why is Zero Liquid Waste Important?

In a world where freshwater is an increasingly valuable resource, industrial processes threaten its availability on two fronts, unless the water is treated. Many industrial processes require water, and then reduce the availability of water for the environment or other processes, or alternately contaminate and release water that damages the local environment. India has been leading the drive for zero liquid discharge regulations in the last decade. Due to heavy contamination of numerous important rivers by industrial wastewater, India has created regulations that require zero liquid discharge. They identified that the best means to ensure safe water supplies for the future is to protect rivers and lakes from pollution. By operating an in-house ZLD plant, disposal costs can be reduced, more water is reused, and fewer greenhouse gasses are produced by off-site trucking, which minimizes impact on local ecosystems and the climate.

All of us are aware of the fact that water is life, but still gallons of water are being wasted on a daily basis by industries as well as by people in their houses. We, at JB Ecotex Limited, are working with the Go Green concept as a responsible and sustainable RPSF manufacturer. We are a recycled polyester staple fiber supplier across India. At JB Ecotex Limited, we have installed an effluent treatment plant with all the latest available technology which enables us to process and reuse all the waste-water generated by us during the process. Thus, there is no liquid discharge from the recycling process which certifies us as a ZERO LIQUID DISCHARGE unit with the adoption of zero water discharge methodology. JB Ecotex Limited impressively decreases the requirements of water which helps to keep environmental resources intact for the future generations, an endeavor to being an efficient EPR services agency in India.

Packaging is everywhere, in your shopping trolley, your cupboards, your deliveries and so much more. This amount of plastic and other non-natural materials can cause environmental problems such as pollution. But there is an alternative: eco-friendly packaging. In this blog, we’ll cover all the benefits of eco-friendly packaging that you can gain from.

What’s the Issue with Normal Packaging?

The primary purpose of packaging is to contain and protect products. Today, packaging is usually an issue of convenience, especially when it comes to food and disposable items. The packaging we find is usually made of a type of plastic: polyethylene. It can come in various types:

1. Polyethylene terephthalate: commonly used to make liquid bottles. It’s the most common and most widely-recycled of all plastic resins.

2. High-density polyethylene: this is used to make containers for heavier items and liquids such as laundry detergent, shampoo or even crude oil.

3. Low-density polyethylene: used to manufacture plastic bags and flexible plastic films. This type of plastic is not widely recycled.

These types of plastic can even cover the clothes we buy, either given to us in a plastic bag or delivered in plastic packaging. Another issue caused by non-environmentally friendly packaging is their manufacturing process. Not only is the majority of plastic created by refining crude oil, but the degradation process is similarly harmful. As plastic degrades over hundreds of years, they can also release toxic substances such as bisphenol A, which can disrupt the hormonal systems of animals.

To fight these issues, let’s get to grips with the alternative: eco-friendly packaging.

What is Eco-Friendly Packaging?

The Sustainable Packaging Coalition has set up a number of rules when it comes to what can be called eco-friendly or sustainable packaging:

1. Beneficial, safe and healthy for individuals and communities throughout its life cycle.

2. Meets market criteria for performance and cost.

3. Sourced, manufactured, transported and recycled using renewable energy.

4. Optimizes the use of renewable or recycled source materials.

5. It is manufactured using clean production technologies and best practices.

6. It is made from materials that remain non-toxic throughout the life cycle.

7. Is designed to optimize materials and energy.

8. Effectively recovered and utilized in biological and/or industrial closed-loop cycles.

Essentially, it needs to be made from eco-friendly materials, biodegradable and able to be either reused or recycled.

The Environmental Benefits of Eco-Friendly Packaging !

Reduces Carbon Footprints:- If it’s made from recycled products, the carbon footprint of your packaging will be greatly reduced. Similarly, if the packaging is made from natural materials such as bamboo or cardboard, the growth of such products actually draws carbon out of the environment. If you’re looking to make your business carbon neutral, eco-friendly packaging is the way to go.

Biodegradable:- If the packaging is made from natural materials, this means it will be biodegradable. Plastic is not easily biodegraded, taking hundreds if not thousands of years to break down, releasing harmful chemicals on its way. Some eco-friendly packaging, such as sustainable paper products, will even be compostable.

No Harmful Toxins:- Non-sustainable petrochemical resources such as crude oil, which is used to make most plastics, is incredibly harmful to the environment in terms of both extraction, refinement, distribution, use and disposal. Eco-friendly packaging has none of these issues over its lifespan. As it degrades, harmful chemicals such as the ones produced by plastic are not present.

Easily Reused or Recycled:- Part of what makes packaging eco-friendly is its ability to be reused or recycled. Encouraging the reuse of packaging means that its lifespan is extended, which reduces the need for new materials, further lowering its carbon footprint. If the packaging is of good enough quality, it should be able to be reused for things like further packaging, storage and even arts and crafts.

It Can Reduce Transportation Costs:- If you source good quality, eco-friendly packaging, it can mean you need to use less of it. This means an overall reduction in transportation costs.

Easily Disposable:- Using packaging materials which are easily disposable helps to reduce plastic waste from this planet. This also creates a huge impact on your brand image.

Thus, using eco-friendly packaging helps us to remove waste from this planet and makes our home a better place to live on.

Why do we need plastic packaging?