Introduction to rPETs

Around ten million tons of plastic make it to our oceans every year, and the need for sustainable alternatives to plastic have never been more critical. The textile and fashion industry are the largest consumers of Polyethylene Terephthalate (PET), and they are also spearheading the transition towards recycled polyethylene terephthalate (rPET).

At BIDBI, rPET embodies our green ethos and commitment to transforming the sustainable industry – becoming its own social movement. Finding green solutions to PET traditions is a legacy that businesses like ours will be proud to leave behind for future generations. They allow us to rethink traditional, use the natural resources we have available on this planet, and find a way to heal it – not hurt it.

Let us take a closer look at the world of rPET. We will start with how it is collected then turned into fabric, and how rPET is making a considerable difference. rPET does not end with simply recycling, but it enables us to redefine our idea of possible.

What is rPET?

Recycled Polyethylene Terephthalate, or rPET, is an absolute game changer. Made from recycled PET plastics, commonly found in food and drink packaging, rPET is positioned to stump the continued use of PET. Both oil and petrochemicals are used to created PET which is incredibly harmful to the environment, so utilising rPET conserves resources, helps reduce waste and harmful impacts on the environment, as well as divert plastics from the ocean.

Although PET and rPET could be mistaken for each other, they are significantly different. PET is made of non-renewable fossil fuels, while rPET is made from recycled materials – making it a cornerstone in sustainable textile practises and should be adopted by leading manufacturers.

How is rPET made?

1. Collection and sorting

Sourcing the materials:

The raw materials for rPET are strictly post-consumer PET products, like plastic bottles. These bottles are collected around the world by recycling programmes and initiatives. Ranging from bottle deposit points, specialised recycling centres, and even picking the up off the road.

Sorting them:

After the materials have been sourced and collection, they go through an extensive sorting process. Automated systems work to identify the PET bottles from other types of plastic bottles. Infrared sensors manually sort through each one to find the highest purity of raw materials in the collection of PET bottles, which determine the quality of the end rPET product.

2. Cleaning and preparation

The PET bottles are then cleaned and prepared before the next stages. All labels, adhesives, and remaining residual are also removed before the bottles cleaned:

2. Cleaning and preparation

The PET bottles are then cleaned and carefully prepared for the extrusion and polymerisation stages. All labels, adhesives, and any remaining residual content that remains on the bottles are also removed before being thoroughly cleaned:

1. Pre-washing – The bottles are given an initial rinse to remove any surface level dirt and contaminants.
2. Grinding – Once briskly cleaned, the bottles are ground into small flakes, which is done to increase the surface area for the subsequent cleaning stages.
3. Hot Washing – The ground up flakes are then washed in hot water, with added detergents to remove any further traces of adhesives, oils, and grease.
4. Rinsing – The ground up PET flakes are then given a final rinse to remove any cleaning agents and residues that have been used throughout this process.

After cleaning, the newly ground up and washed PET flakes then enter quality control to remove any impurities that remain, which are critical to remove to enhance the quality of the rPET at the end of this journey. Quality control scanners and manual checks are used to ensure only flakes of the highest quality proceed to the next stage.

3. Extrusion and polymerisation

Extrusion:

The cleaned PET flakes are fed into an extruder and melted at hot temperatures. The flakes melt at 260°C and put into a spinneret to form continuous filaments of polyester. These filaments are rapidly cooled so that they solidify and becomes fibres.

Polymerisation:

In the process of Extrusion, polymerisation reactions occur which connect the PET molecules into long chains. This is a key step during the rPET creation process for ensuring the fibres created are both strong and durable. This process can be manipulated down to molecular level to control the weight and viscosity of the polymer. All of which affects the physical properties of the final product produced.

4. Spinning and drawing

Spinning:

The solidified filaments are loaded onto a spool and spun. Steps can be added to the spinning process to enhance the elasticity or bulk.

Drawing:

The spun fibres are stretched to align the polymer molecules with the desired properties of the end product.

5. Weaving or knitting

Yarn formation:

The drawn fibres and then spun into yarn. The fibres are then twisted together into one continuous strand, making yarn. This can vary in thickness, strength, and even texture.

Fabric formation:

The yarn can either be woven or knitted into fabric. Depending on which is chosen, the flexibility, breathability, and durability of the end product are all impacted. Weaving involves interlacing two sets of yarns, while knitting is creating a series of interlocking loops.

 

6. Dyeing and finishing

Dyeing:

The fabric is then dyed using eco-friendly methods to minimise the environmental impact. The dyeing process can involve:

Batch dyeing – submersing the fabric in a dye bath.

Continuous dyeing – Passing the fabric through a series of dye applicators.

Finishing:

After the dyeing process is complete, the fabric goes through various finishing stages. This is key to enhancing the appearance and performance of the material. The stages can include:

Heat-setting: Stabilises the fabric dimensions and improves wrinkle resistance.

Coating or laminating: Adding properties like water resistance, flame retardancy, or UV protection.

Softening: Enhances the hand feel and drape of the fabric.[1] 

Safety and versatility of rPET

RPET has gained acceptance across Europe as a safe alternative for food and consumer packaging products. RPET's durability, chemical resistance, and ease of cleaning make it suitable for a wide range of products.

The European Food Safety Authority (EFSA) has assessed the safety of rPET and how effective the InWaste recycling process is. The assessment proved to be effective in removing contaminants, and remaining residual food stayed below safety standards. RPET's decontamination efficiency ranges between 96.5% to 99.9%, deeming it safe for direct contact with all food products. This proves rPET as a reliable choice for manufacturing food containers and storage solutions.

RPET is a versatile material and can manipulate into a range of products. Reusable bags, clothing, and even home furnishings can all come from rPET. Recognised for its versatility, its eco-friendly nature makes rPET are leading green-alternative solution. Choosing rPET choice reduces plastic waste, promotes recycling, and supports a circular economy.[2] 

Economic considerations of using rPET

Using rPET in manufacturing offers significant economic advantages. One of the most compelling benefits in using rPET is the reduction in raw material costs. Using post-consumer PET bottles means manufacturers reduce their dependence on virgin PET, derived from pricey petroleum. This approach is cost-saving for businesses and offers stability to the wider economy. By reducing the demand for fossil fuels and its volatile market, this is beneficial for all.

The investment in recycling and technologies infrastructure creates jobs and boost local community economy. The collection, sorting, and processing of recyclable materials requires a full-time workforce, and can do so for years. As recycling programs expand, they can stimulate economic activity and innovation in key sectors. Proving to be beneficial for the economic landscape.[3] 

Environmental impact of rPET

The impact of using rPET is not to be understated, just as the impact of not choosing rPET is also not to be understated. By making the conscious choice to use rPET, we are all contributing to a cleaner, greener planet. Recycled PET has already proven itself by offering environmental benefits compared virgin PET. The production of rPET flake leads to an average decrease of 79% in environmental impacts when compared to PET, and a 44% reduction compared to rPET pellets. This reduction is a result of reduced energy consumption and lower greenhouse gasses during the recycling process. Additionally, the use of rPET helps conserve non-renewable resources, reducing raw material consumption, and further reduces the overall environmental footprint.

Studies also highlight that using rPET in the manufacturing of products not only diminishes the demand for virgin plastics but also the total environmental burden. Water bottles made with rPET have shown lower global warming potential, photochemical oxidation, and abiotic depletion compared to those made from virgin PET. This means that integrating rPET into production processes can play a crucial role in mitigating climate change, conserving natural resources, and promoting sustainable manufacturing practices. [4] 

Future trends and innovations in rPET

The future of recycled PET is positioned for global adoption and remarkable advancements, all driven by technological innovations. As our collective understanding of rPET improves over time, so does our environmental awareness of this brilliant product and so the capabilities of what we can use rPET for grows. Starting with the recycling process, this is a key stage in the rPET development journey that can be endlessly refined and reviewed to achieve a higher quality and purity end product.

Innovations in chemical recycling can also significantly revolutionise the rPET creation. Chemical recycling can break down PET into monomers, then re-polymerise them to produce new PET properties that are identical to traditional PET. This would significantly expand the range of PET products that can be recycled.

Furthermore, the integration of rPET in various industries is expected to grow, spurred by regulatory incentives and consumer demand for sustainable products. For instance, the European Green Deal aims to increase the use of recycled plastics in packaging, which will accelerate the development and adoption of rPET. Additionally, the fashion industry is increasingly utilising rPET to create eco-friendly textiles, promoting circular economy practices.

Partnerships between PET manufacturers, recycling companies, and brands are fostering innovation in product design and recycling infrastructure, ensuring that rPET remains a cornerstone of sustainable development. As these trends continue to evolve, rPET will play a crucial role in reducing plastic waste and minimising the environmental footprint of plastic products.

[5]

Why choose BIDBI’s rPET bags?

Our rPET bags offer a sustainable choice without compromising on quality or style. Made from recycled plastic bottles, these bags help reduce landfill waste and decrease the demand for new plastic production. By choosing rPET, you are part of a global movement towards a more sustainable and responsible consumer culture.

Join the thousands of brands from around the world who have worked with BIDBI, and give us a call today. Do you have a daunting rebrand coming up, or have a future event where everything needs to be excellent?

Get in touch today and we will collaborate with you to fulfil your branding and sustainable needs.

VISIT OUR WEBSITE

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 [1]https://waste2wear.com/

 [2]EFSA CEP Panel (EFSA Panel on Food Contact Materials, Enzymes, and Processing Aids), 2022. Scientific Opinion on the safety assessment of the process rPET InWaste, based on the NGR technology, used to recycle post-consumer PET into food contact materials. EFSA Journal 2022;20(5):7273. https://doi.org/10.2903/j.efsa.2022.7273

 [HP3]https://www.recycletheone.com/recycle-now/how-does-pet-plastic-recycling-work/#:~:text=These%20PET%20preforms%20are%20heated,and%20governments%20across%20the%20world.

 [4]Silva, B., Costa, I., Santana, P., Zacarias, M. E., Machado, B., Silva, P., Carvalho, S., Faria, F., & Basto-Silva, C. (2024). Environmental performance of different water bottles with different compositions: A cradle to gate approach. Cleaner Production Letters, 6, 100061. https://doi.org/10.1016/j.clpl.2024.100061

 [5]Silva, B., Costa, I., Santana, P., Zacarias, M. E., Machado, B., Silva, P., Carvalho, S., Faria, F., & Basto-Silva, C. (2024). Environmental performance of different water bottles with different compositions: A cradle to gate approach. Cleaner Production Letters, 6, 100061. https://doi.org/10.1016/j.clpl.2024.100061