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Recycled plastic bottles are becoming scarce. You can help.

As consumers’ appetite for recycled polyester products grows, the industry is facing an unintended consequence: There may not be enough recycled plastic bottles available to meet the demand. 

Campaigns such as the Recycled Polyester Challenge 2025 inspired brands to move away from virgin polyester and use recycled fibers. The challenge is to increase recycled polyester usage from the current 14 percent to 45 percent by 2025. As a result, Textile Exchange estimates we’ll need 17.1 million metric tonnes of recycled polyester to cover apparel industry demands.

Baled recycled plastic bottles ready for processing
Baled recycled plastic bottles ready for processing

In 2017, roughly 47 percent of all available recycled PET in the United States went to fiber products, according to the Association of Plastic Recyclers (APR) and NAPCOR’s “Report on Postconsumer PET Container Recycling Activity in 2017.” Food and beverage companies were the second largest users of rPET, at 21 percent. 

Meanwhile, the volume of PET bottles available for recycling in the U.S. declined for the first time since 2009. As Wood Mackenzie reports, most of the world’s bottle collection volume comes from a few key markets (in Western Europe and Asia, primarily), and collection rates are not rising enough to keep pace with demand. 

Recycled plastic bottles are becoming scarce. You can help.
Recycled Bottle Supply vs. Demand – 2020-2030 Forecast

If this trend continues, there simply won’t be enough bottles in recycling bins to cover the need for rPET. 

But, we can help change that. Here are some important ways consumers and businesses can help meet the demand. 

Raising Awareness About Recycled Plastic Bottles

Of course, we don’t want to resurrect virgin bottle usage. However, we can raise awareness to increase recycled plastic collection percentages, especially in the U.S. The problem is not a lack of bottles to recycle. It’s that not enough consumers are recycling.

The U.S. falls behind on recycling compared to other nations, while being the biggest consumer of them all. Add to that: The current recycling infrastructure and state policies governing recycling influence the amount of PET that enters the pipeline. Outdated technology in some states and municipalities, plus lack of public education means that consumers don’t know what kinds of plastics can be recycled. Or, they try to recycle contaminated plastic, which is rejected by older systems. 

The countries that lead the world in recycling, such as Germany and Taiwan, have robust nationwide support for recycling programs, government recycling goals, public awareness campaigns, incentive programs, and strict recycling policies for producers. 

If you want to see an increase in recycling rates near you, talk with your city or county officials or neighborhood association. Find out what’s stopping the flow of bottles to recycling centers. See if there are ways to lower those barriers or incentivize people to recycle more. 

Businesses As Influencers

A few things are happening on the corporate level that are influencing the supply of recycled plastic, for better or worse. First, many large corporations and travel companies have pledged to eliminate all single-use plastic. This is great news for the environment, but has an impact on rPET supply. Our hope is that they will continue to offer recycling for customers who bring plastic to their properties. 

Second, big beverage brands like PepsiCo and Coca-Cola are switching to rPET and asking customers to return empty plastic bottles to be remade into new bottles. In the U.S., the goal is that all Pepsi-branded products will be converted to 100 percent rPET bottles by 2030. Meanwhile, Coca-Cola has been rolling out bottles made from 100 percent recycled PET in North America since early 2021. To influence their customers to recycle, the beverage brands are offering bottle recovery programs. This ensures that they have a steady stream of PET to recycle into new bottles. 

What if more apparel companies and fiber brands offered bottle or fiber recovery programs too? Allowing customers to send in post-consumer PET or donate it at the point of purchase could help the supply problem. Brands could incentivize customers by offering them a discount on new products when they recycle their old plastic and polyester. Some brands are already doing this with success. 

By expanding this and creating a reliable pipeline, we could make the polyester industry more circular, capture bottles and fabrics before they make it to the landfill, and keep the supply flowing strong. To learn more about how you can join us, contact change@sayarenew.com

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Recycled Polyester vs Polyester, What’s their difference?

You’ve probably seen “recycled polyester” appear on product tags more often in recent years. Companies can use it in place of virgin polyester in clothing, luggage, outdoor gear, blankets, and so much more. But is it really different or better than virgin polyester? And how?

Plastic bottles are the most common ingredient in recycled polyester
Plastic bottles are the most common ingredient in recycled polyester

From rescuing plastic from the landfill to reducing greenhouse gas emissions, recycled polyester outshines virgin polyester in many ways. Here are just a few key differences:

Environmental Impact

As the saying goes, “one man’s trash is another man’s treasure.” In this case, the trash is tons of discarded plastic bottles. The treasure? A strong, sustainable, high-performance polyester fiber. 

Recycled polyester reduces our reliance on petroleum as a raw material. That means less drilling for oil. Furthermore, it diverts used plastic bottles from landfills and the ocean. Several outdoor and athletic brands advocate for using recycled fiber or rPET because it saves energy throughout the production process — as much as 50%. Using rPET also reduces greenhouse gas emissions by as much as 70 percent, according to many estimates. 

Studies show that textiles composed of recycled PET can be recycled repeatedly without affecting the quality or properties of the fiber. The more brands that choose recycled polyester, the more opportunity to reuse the fiber. This creates a circular system at the industry level, which benefits business, the environment, and consumers.

Versatility

As recycled polyester becomes more widely available, brands are using it in a variety of products. The fiber is well suited for clothing and shoes, because of its durability and sweat-proof qualities. Also, some brands are using it in place of canvas in duffel bags, backpacks and luggage. 

Because of its antibacterial qualities and soft feel, manufacturers are using the fiber for high-performance athletic wear. You can also find recycled microfiber in high-quality bath towels, sheets, and blankets. 

Performance

Recycled polyester is a prime choice for active individuals who want high-performance fabrics. It is known for its moisture-wicking properties and its ability to withstand years of frequent wear and washings. All this without losing its shape, color, or soft feel. In addition, recycled polyester is breathable and lightweight, making it ideal for travel, athletics, or outdoor sports. 

Recycled polyester is a prime choice for active individuals who want high-performance fabrics with moisture-wicking properties and the ability to withstand frequent wear and washings.
Recycled polyester is a prime choice for active individuals who want high-performance fabrics with moisture-wicking properties and the ability to withstand frequent wear and washings.

Best of all, it resists fading over time. SAYA uses a patented technology called ChromShield™  to provide ultra-rich color and superior fade resistance. So our fibers withstand elements like UV from the sun, machine washing and general wear and tear. Our water-free, eco-colors stay brighter and more vibrant longer.
To learn more, contact change@sayarenew.com

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Are there disadvantages of recycled polyester?

The Disadvantages of Recycled Polyester and How to Solve It?

You probably already know the advantages of recycled polyester. In terms of quality, recycled polyester fiber performs just as well, if not better, than virgin polyester. It’s durable and sustainable. And, it typically requires less energy and carbon emissions to manufacture. But are there disadvantages of recycled polyester? The answer is: yes and no.  

Circularity of Polyester: Polyester fabric scraps become recycled PET pellets, which become recycled PET fiber, which is used to make apparel, which is recycled back into fabric scraps.
Circularity of Polyester: Polyester fabric scraps become recycled PET pellets, which become recycled PET fiber, which is used to make apparel, which is recycled back into fabric scraps.

Let’s take a look at a few of the common concerns people have about recycled fabric (and how to overcome them). 

Cost of recycled polyester

One possible disadvantage of recycled polyester is the advanced technologies manufacturers use to create recycled fabric can be more costly than virgin polyester, but not always. It depends on several variables. For example, if you compare the cost of recycling with the environmental cost of virgin plastic, the winner is recycled fabric. 

Virgin polyester production requires fossil fuels (petroleum). It strains our planet’s natural resources and biodiversity. On the other hand, recycled polyester reduces our dependency on these resources. A 2017 research study found that manufacturing rPET generates 79% less carbon emissions than producing virgin material. So, using recycled polyester can help corporations meet their climate targets — which benefits the environment, the business, and the consumer. 

But there are other costs to consider too. Some big cities are finding that the cost of recycling plastic is less than the cost of disposal. A study from the University of California estimated that cities like Los Angeles and San Francisco benefit economically from recycling instead of dumping. The savings are as much as $200 per ton. Recycling reduces the amount of land the city requires for waste management. Over time, those cost savings really add up. 

Availability of recycled polyester

Some companies and consumers are concerned about the lack of availability of recycled polyester fabric. In the past, it was much easier to find virgin polyester fibers and pellets. But that trend is shifting. As consumer demand for sustainable plastic grows, it has generated a shift in businesses and manufacturing practices. 

Recycled Plastic PET pellets
Recycled Plastic PET pellets ready to be processed into recycled fiber

Availability is also related to cost. The cost of virgin PET plastic rises with the rise in global oil and petroleum prices. Trade magazines such as Plastics News have observed that the cost of virgin pellets is starting to climb higher than the cost of recycled pellets. This means fiber mills may have easier access to recycled materials. In turn, recycled polyester fiber will become more widely available to meet consumer demand.

Circularity of recycled polyester

Recycled polyester is very durable and sustainable. But, consumers still need to know what to do with their worn-out recycled clothing. They could donate it to someone else and extend its life, or find garment recycling centers so that it doesn’t end up in a landfill. Some clothing brands offer recycling or buy-back programs to increase circularity. 

Yet, one of the disadvantages of recycled polyester is most polyester fabric can only be recycled so many times before it reaches the end of its life cycle. 

The circularity of a garment largely depends on the recycling method. If the polyester undergoes mechanical recycling, machines wash and shred and turn the fabric into polyester chips. Factories then melt and transform the chips into new fibers. During this process, however, the fiber can lose its strength, especially if it’s a blend of other fabrics like cotton. As a result, recyclers will mix the recycled chips with virgin polyester. 

However, during chemical recycling or advanced recycling processes, manufacturers break down recycled polyester to the molecular level. This preserves the integrity of the original polyester monomer and makes it easier to create new fibers that are just as strong as the original. No need to mix in virgin materials. 

The total number of tons of textiles generated, recycled,  and land-filled between 1960 and 2018. Chart courtesy of epa. org
The total number of tons of textiles generated, recycled, and land-filled between 1960 and 2018. Chart courtesy of epa. org

So, the answer to the concern about circularity is simple: advanced recycling techniques will keep polyester fibers and garments in use much longer. In time, brands and consumers will find that this is the most cost effective and convenient option too. 

The bottom line? Soon, the perceived disadvantages of recycled polyester will fade away, thanks to technology and accessibility.

To learn more about our recycling methods, contact change@sayarenew.com

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How circularity can put an end to plastic waste

Surprising Products Made from Recycled Plastic Bottles – SAYA

In the face of climate change, pollution, and population growth, businesses are looking for more sustainable solutions. One of those solutions is circularity. Circularity disrupts the idea that items like plastic are disposable. Instead, it focuses on reuse and recycling. 

Can you imagine a world without trash? 

In a circular economy, however, post-consumer waste is recaptured, reused, or recycled and put back into the economy.
In a circular economy post-consumer waste is recaptured, reused, or recycled and put back into the economy.

In the old, linear model of economics, manufacturers take a natural resource and turn it into a product. A consumer then uses the product and throws it away. For example, a tree is cut down and turned into lumber, which is made into furniture. A customer buys the furniture and uses it until it breaks, then throws it away. The process is linear, as products travel from point A to point B to point C. The end of the line is usually a landfill or the ocean. 

In a circular economy, however, post-consumer waste is recaptured, reused, or recycled and put back into the economy. According to the Ellen MacArthur Foundation, a circular economy is restorative and regenerative by design. Circularity means we use resources sparingly and recycle over and over again, capturing as much utility as possible. 

Proponents of circularity say that growing the global economy requires this harmony with nature.

Applying Circularity to Plastics

For some materials, like metals, circularity is an easy choice. You just capture the used metal, melt it down and create new products. As the steel industry discovered, remanufacturing and reuse is less expensive and more sustainable than making new metal. 

A circular plastic economy is a bit more challenging. That’s because manufacturers need to design plastic products with recycling and reuse in mind. And companies use different techniques to renew plastic into products such as fibers, clothing, building materials or household items. 

A sea of plastic waste which could be renewed with plastic recycling and circularity
A sea of plastic waste which could be renewed with plastic recycling and circularity

According to The SustainAbility Institute, companies need more incentives to reuse and recycle. And, one of the biggest incentives is consumer demand. Understanding the value and usability of the recycled products is key. The private sector can lead the way, especially in Asia where many plastics originate. How? By showing the world the innovative products that we can make from recycled bottles and other plastics. 

Using advanced recycling techniques, companies are creating fibers and fabrics that perform better than their non-recycled counterparts. Some companies in Europe and Asia are even pioneering ways to renew hard-to-recycle plastics into food-grade plastic products. They’re finding ways to not only recycle plastic bottles and containers, but also recover plastic waste from the oceans. 

The hope is that in the coming years, virgin plastic will become obsolete. 

Closing the loop

Athletic apparel made out of performance recycled polyester
Athletic apparel made out of performance recycled polyester

SAYA is proud to help close the loop and make plastic circularity a reality. We partner with major consumer brands and like-minded manufacturers to bring innovative, high performance fibers and fabrics to consumers worldwide. 

To learn more, contact change@sayarenew.com

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The Journey To Circularity

TEXTILE INSIGHT MAGAZINE July/August 2021 – With the launch of the Rscuw Project, and Saya’s recognition of material waste as a valuable resource, the company continues to clear a pathway to more eco-conscious advancements. In fact, work is already underway creating pilot projects to renew pre-consumer cutting scraps and overstock with key strategic brands.

Worker carries roll of fabric made from recycled plastic
Worker carries roll of fabric made from recycled plastic

Saya is further elevating renewal efforts, and gathering data, to aid the next big breakthrough: textile-to-textile recycling. In addition, Saya is on track with renewal efforts designed to sort and clean finished garments. This action will facilitate garment recycling, considered the key to opening the door to total circularity.

These commitments to establishing a robust system of renewal will hasten the upcoming introduction of SAYA Garma, a project to recycle finished garments, projected for commercialization by Fall 2022.

Looking even further ahead, the company envisions new and different ways to produce polyester from ingredients other than petroleum. Ready To Renew “As one of the world’s largest producers of PET (both virgin and recycled), we understand that increasing the recycling rate is very important,” states Jack Chen, Saya director of R&D. (The current recycling rate in the United States is only 29 percent compared to 72 percent in Japan and 48 percent in Europe).

It is also important to note that Saya parent company Nan Ya Plastics has been producing recycled PET out of bottles for more than ten years in 13 facilities worldwide, producing an average of 72,000 tonnes (1 ton = 2000 lbs) of recycled fiber each year. This scale of operation allows R&D into more efficient manufacturing methods and superior and new performance options in fiber.

Also critical to the company’s efforts is Saya’s proprietary 5-step filtration process and 2-step purification process. What makes this technology stand out from others? And why is it needed? The answer is quality: The biggest challenge in post consumer recycling and renewing is the equality and purity of goods. In order to provide recycled fibers consistently with superior dyeability and strength that can cater to mass market demands, it’s not just a quick flush of bottle under a hose. Saya’s proprietary purification process becomes mission critical for global brands to rely on.

Charting a Sustainable Future: A Timeline of SAYA’s Strides in Renewal Technology

We strive to build upon our successes by finding innovative ways to improve the sustainability performance of our products.

2010-2015

Launch bottle-to-textile recycling

Draw and spin fibers with post-consumer recycling content PET (rPET) chips from Japan

Received certification from Global Recycled Standard (GRS) 2.0

2016-2018

Expanded to new streams of GRS certified rPET flake to include sources from Japan, Taiwan, China, Vietnam, Thailand, Philippine, Indonesia and USA

Launched antimony-free virgin PET (titanium-based catalyst)

Increased from recycling 32,000 tonnes/year of plastic bottles into rPET yarn in 2018 to 65,000 tonnes/year in 2019

2020

Expanded recycled processing capacity to 174,000 tonnes/year

GRS 4.0 certified

bluesign® certification for select manufacturing sites for yarns

Pilot SAC’s Higg Facility Environmental Module (FEM) and adoption of Higg Material Sustainability Index (MSI) to assess environmental impacts of materials and processes

Converting garment cutting scraps and overstock fabrics into new yarn – the SAYA Rscuw Project

2021

Expanded recycled processing capacity to 216,000 tonnes/year

bluesign® certification for additional manufacturing sites for yarns

Adopted SAC’s Higg Facility Environmental Module (FEM)

Pursue Fair Trade certification to ensure we make a positive difference for the workers that make our products

Commercialization of the SAYA Rscuw Project – converting cutting scraps and overstock fabric into new yarn

https://viewer.e-digitaledition.com/i/1395728-july-august-2021/18?

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Recycled Plastic: How Much of the World’s Plastic is Recycled Plastic?

Recycled plastic makes up a very small percentage of plastic produced

Since the 1970s, plastic has been one of the most popular materials in the world. Plastic is used for everything from packaging to fabric to textiles. According to the United Nations Environmental Program, “more than 8.3 billion tons of plastic has been produced since the early 1950s. About 60 percent of that plastic ended up in a landfill or the natural environment.” As a result, plastic pollution is widespread and harmful, leeching toxic chemicals into the environment and threatening wildlife and habitat. The need for recycling plastic has never been greater, yet estimates suggest that only 8% of the world’s plastic is recycled.

Discarded plastic washed up on a beach can be prevented with advanced recycling methods
Recycled plastic using mechanical or advanced recycling processes can keep polymers out of our natural environment

This low rate is due to several factors. It is currently less expensive to produce virgin plastic using fossil fuels than to recycle it. Plastic is not uniform in its composition, and some plastic is easily recycled while other types are more resource and labor intensive. Estimates on recycling rates by country are difficult to find and vary. However, experts expect to see a significant increase in global plastic recycling rates in 2021 thanks to the addition of disposable plastic to the Basel Convention on the Control of Transboundary Movements of Hazardous Wastes and their Disposal.  This United Nations agreement regulates international transport of hazardous materials so that wealthy countries cannot dump garbage on less-developed ones.

According to an article in Science, the addition of plastics to the Basel Convention has the potential to deter the shipment of plastics from powerful countries like China and the United States to smaller and poorer countries, which could galvanize the plastic recycling industry.

While technology exists to recycle plastics, negative perceptions abound in regards to plastics recycling, according to the World Economic Forum.

However, regulatory, shareholder, and moral incentives are driving the discussion on how to increase global recycling rates in order to reduce current and prevent future plastic pollution. Specifically, world leaders are calling on financial institutions to develop new recycling markets that will have environmental and economic benefits.

Because it is cheaper and less complicated to develop new plastic instead of recycling it, The American Chemistry Council estimated that in 2018, less than 10 percent of American plastic was recycled. In that same year, American landfills received 27 million tons of plastic, representing 18.5 percent of all municipal solid waste. By contrast, both Europe and Asia have significantly higher plastic recycling rates, though specific rates vary by country.

Europe and Asia use more recycled plastic than other world regions.
Europe and Asia use more recycled plastic than other world regions.

In order to have a meaningful impact, some experts are calling for an international agreement that sets targets for “reducing plastic rubbish in the oceans,” which would galvanize worldwide plastics recycling.

Consultant John Richardson advocates for a global agreement akin to the Paris Climate Agreement for plastics that would, address the problem of plastic pollution—which results when plastics end up in landfills and the natural environment instead of being recycled and reused—“at the source.

He writes, “As the developing world gets richer, the content of plastic in the oceans can only increase unless we take urgent action. Many of the goods made from single-use plastics are lifesaving and so essential. Investments in chemicals and mechanical recycling won’t by themselves fix the problem. Waste collection and sorting systems need to be built from scratch with solutions region-specific. How do we start? With a Paris-type agreement on plastic waste, setting global binding targets for cutting plastic rubbish in the oceans. Then the regulations and incentives will follow.”

And it follows, countries will increase their recycling capability and will likely be more transparent in their plastic recycling achievements.

To share your thoughts on recycled plastic or to learn more about SAYA fiber, please contact us at change@sayarenew.com

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How Textile Recycling Companies Can Become More Sustainable

Textile recycling companies aim to reduce, reuse and recycle

Reduce, reuse, recycle. This mantra has also driven myriad sustainability efforts, including in textile recycling companies. Recycling textiles is important because the industry produces billions of pounds of unused materials each year, relies on fossil fuels to make virgin plastics, and has a mandate to recycle polyester and other materials to keep them from polluting the environment. Given the diverse imperatives, it makes sense that there are many ways to recycle textiles. As a leader in the textile recycling space, SAYA has programs that reduce, reuse, and recycle. More, we believe in highlighting other successful efforts undertaken by industry partners.

Rolls of overstock fabric available for recycling by textile recycling companies
Rolls of overstock fabric available for recycling

Reduce

Reducing may present some of the biggest challenges to sustainability efforts as manufacturers work to identify processes that reduce the amount of toxic chemicals in fiber and material production.

Another option for reduction in the manufacturing process: water. The textile industry uses billions of liters of water throughout all steps, from dyeing to chemical finishes. By developing ecologically friendly dyes and creating water-free finishing, textile recycling companies have established new approaches that benefit both the environment and environmentally-aware consumers.

SAYA RSCUW Raw is material made from recycled fabric cutting scrap and PET bottles that does not bleach or re-dye the material. The resulting knit has a unique heathered effect in shades of grey to nearly black. The process also significantly improves energy efficiency and reduces the carbon footprint of recycled polyester fabric.

Reuse

Reusing clothing and cutting scraps from factory floors has grown popular within the textile industry. Zero Waste Daniel turns clothing scraps into fashion. Patagonia and The North Face have programs to recruit and refurbish used clothing and gear for resale. Eileen Fisher asks consumers to return clothing they would otherwise throw out; clothing that can be resold will be, and clothing that cannot is turned into “something entirely new” through the company’s circular by design program. Cotopaxi sews gear out of left over fabric yardage. And SAYA collects cutting room scrap and leftover yardage for our innovative recycling program.

Recycle

Recycling plastic, polyester, PET, and other man-made materials is a complex process. Recycling technical textiles relies on the use of chemicals and heat. For example, to transform plastic bottles into fabric, bottles are collected, separated into clear and colored bottles, and shredded. Next, the shredded plastic is heated and forced through tiny holes in an extruder to create long, continuous fibers. These fibers are then torn into shorter pieces. The fibers are balled (resembling wool). Next they are carded and spun into yarn.

Plastic recycling center preparing plastic for textile recycling companies
Plastic recycling center

By reducing, reusing, and recycling, the textile industry and SAYA can lower its carbon footprint, help safeguard the environment, and meet consumer demand.

To share your thoughts on how the textile industry can become more sustainable or to learn more about SAYA fiber, please contact us at change@sayarenew.com

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Types of Polyester Fabric: Their Feature and Uses

Polyester is a synthetic fiber containing petroleum, coal, air and water that was developed in 1941. Of the most common types of polyester fabric, PET (polyethylene terephthalate) is the most ubiquitous. PET is strong, dries quickly, is impervious to wrinkles and mildew, doesn’t shrink, and is able to change the nature of other fabrics with which it is used.

The second most used polyester variation, PCDT (poly-1, 4-cyclohexylene-dimethylene terephthalate), is more elastic, offers greater resilience, and is ideal for heavier textiles like curtains and furniture coverings. These synthetic polyesters are not biodegradable but can be recycled, which increases production efficiency and reduces the materials’ carbon footprint. By contrast, some lesser used polyester variations that contain naturally occurring chemicals—the cutin of plant cuticles, for instance—can be biodegradable. 

Illustration of molecular make of polyester fibers
Illustration of molecular make of polyester fibers


Polyester yarns

Manufacturers create three different types of yarn from polyester, and these yarns are used in everything from clothing to industrial materials to disposable water bottles, and more. The three yarns are monofilament, multifilament, and spun.

Industrial monofilament polyester mesh made of recycled PET bottles
Industrial monofilament polyester mesh made of recycled PET bottles

Monofilament polyester yarns consist of a single, untwisted strand of polyester and are commonly used to manufacture equipment for industrial uses such as conveyor belts, sieves and filters. 

Multifilaments are twisted monofilaments that produce a more flexible yarn with equivalent linear density and tenacity. By adding a twist to the monofilaments, polyester manufacturers enhance the strand’s  structural integrity. Multifilament yarns are commonly used for seat belts, industrial sewing threads, industrial webbing, flat or round slings and tie downs, ropes and hose and tire reinforcement. 

Multi-filament seat belts made of polyester fibers of recycled plastic
Multi-filament seat belts made of polyester fibers of recycled plastic

Spun polyester yarns refer to the process of blending polyester filaments with other fibers to create yarns that range from dull to bright with various tenacity. Polyester can be blended with both natural and synthetic fibers to to produce fabrics with blended properties.

Cotton-polyester blends are wrinkle, tear, and shrink resistant and can be remarkably strong. Synthetic-polyester blends have exceptional water and wind resistance and are ideal for outerwear.

Polyester fiber and fabric samples made of recycled plastic PET bottles
Polyester fiber and fabric samples made of recycled plastic PET bottles

To share your thoughts on polyester yarns and fabrics or to learn more about SAYA fiber, please contact us at change@sayarenew.com

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Stopping the Flow

TEXTILE INSIGHT | Emily Walzer – Coastal Efforts Escalate Scalable, Sustainable Solutions to Ocean-Bound Plastic Waste.

Stopping the Flow

Tons of plastic end up in the sea every year and hundreds of thousands of pieces of plastic waste now float in every area of the oceans. Coastal regions are major contributors to this problem; According to recent statistics, 80 percent of ocean plastics originate from these locales.

Textile suppliers are stepping up efforts around this environmental issue with programs focused on infrastructure investment and collaborative initiatives along shorelines. The latest developments focus on creating supply chains that can support eco-responsible production of high-performing textiles made from ocean-bound plastic waste. Increasingly comprehensive in scope, new initiatives involve coordinating with established grassroots organizations to move the needle in terms of demand, quality and transparency around manufacture of recycled ocean plastics captured in high-risk coastal locations.

“Our focus for this enterprise-level project is something sustainable, a business that allows our mission to grow and grow and grow and do good,” explains Ed Rubin, Gore project champion, regarding Gore’s equity investment in Bionic to help streamline its fiber supply chain and grow its Costa Rica operation.

Similarly, Nan Ya Plastics, with its SAYA Coastal offering under the SAYA brand, and Unifi through its REPREVE Our Ocean program, are committed to stopping the flow of plastics into the sea. Launched in June 2019, Repreve Our Ocean is seeing really strong interest, according to Unifi, while Nan Ya reports large scale investment with plans to expand its global network.

While ocean plastics recycling is certainly a compelling story, textile firms are creating compelling solutions. Here’s how Saya, Gore and Unifi are leading the way.


Saya Coastal – Turning microplastics into microfibers

Currently, SAYA collects PET bottles from four zones in Thailand: Zone 1: Pattaya Beach; Zone 2: Pattaya Central Beach; Zone 3: Chanthaburi and Trat; Zone 4: South of Thailand. SAYA works with OceanCycle’s network of certified coastal recyclers, to collect the bottles from these zones with a collecting range that is 20 kilometers from the coastline. Cooperation with local partners includes collecting, washing and making PET flakes. SAYA has provided each partner with Nan Ya’s  proprietary technology and equipment to convert the flakes into chips for streamlined efficiency. Then SAYA collects the chips or flakes and redistributes them to mill partners to produce SAYA Coastal fibers.

According to the company, each SAYA chip converting system costs about $3M USD, for a total of  $12M USD.  

SAYA holds the key technology in converting collected PET bottles to performance chips and fiber and is currently seeking partnerships around the world to implement these technologies and facilities in strategic coastal cities and beaches to join the SAYA recycling network.

“We believe there will be increased demand for recycled fiber from the U.S. and we are looking into adding the technology to our South Carolina factory which could also incorporate coastal recycling,” company SVP, S.Y Huang.

Read article at: https://www.formula4media.com/articles/stopping-the-flow

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Chemical Recycling of Plastics

Chemical Recycling of plastics in a laboratory
Chemical Recycling of plastics

Chemical Recycling of Plastics: Advanced Recycling Technology

Chemical recycling of plastics, also called advanced recycling, is taking plastic waste and reducing it back to its original molecular form, which is raw petroleum. This PET can then go back into manufacturing system and eventually be processed into entirely new polyester fiber or plastic items.

Although chemical recycling is more expensive than mechanical recycling of plastic, the raw petroleum is not degraded and could be used and recycled again and again feeding an “infinite” recycling system.

Chemical Recycling Process

Chemical recycling is accomplished by dissolving the plastic with enzymes or chemicals or using heat to break down plastics into their original components.

Chemical recycling is used with plastics which are difficult to sort and process mechanically. It is also used to recycle plastics in food contact applications and packaging. The processes used in advanced recycling of used plastics either using chemicals or thermal processes takes place in the absence of oxygen so emissions from advanced recycling are generally considered very low.

New Technologies in Chemical Recycling

Currently, there are a number of ongoing projects in the plastics and recycling industries to make advanced recycling more widespread. Two processes which are being refined for wider use are Pyrolysis and Gasification.

Pyrolysis, turns plastics which are recovered from solid waste (garbage) into a synthetic crude oil that can be refined into diesel fuel, gasoline, heating oil or waxes. Using pyrolysis to convert plastics into fuel reduces greenhouse gas emissions by 14% and water consumption by 58%, and it saves up to 96% in traditional energy use as opposed to refining conventional crude oil.

Gasification turns materials recovered from solid waste (garbage) into a synthesis gas, or “syngas,” which can be used for electric power generation or converted into fuel or ethanol and methanol. It can also also be used to make new plastics that go into consumer products.

To share your thoughts on recycled plastic or to learn more about SAYA fiber, please contact us at change@sayarenew.com