Production line and factory setup overview
A large strategic plant converting qualified, washed PET flakes into one polyester staple-fibre grade through flake receipt and contamination control, crystallisation and vacuum drying, extrusion, melt filtration, metering and spinning, quenching, spin finish, tow collection, drawing, crimping, heat setting, cutting, baling and fibre laboratory release. It is not a bottle-washing line and cannot accept mixed or poorly washed PET feed.
Recommended lowest-entry line configuration Start only after a bankable feedstock study and downstream customer qualification. The entry strategic screen is one nonwoven or filling grade at roughly 15-20 t/day, supplied by a defined washed-flake specification. Include flake laboratory, crystalliser/vacuum dryer, one extrusion-spinning line, filtration, quench and finish system, drawing/crimp/cutting, baler, water/thermal-oil systems, dust control and a fibre laboratory. Do not promise textile-grade fibre before customer trials.
Production process and implementation sequence
- Washed-flake receipt, laboratory and contamination release
- Crystallisation and vacuum drying
- Extrusion and melt filtration
- Metering, spinning and quenching
- Spin finish and tow collection
- Drawing, crimping and heat setting
- Staple cutting, baling and traceability
- Fibre laboratory release and dispatch
Products, capacity and market fit
- Afghan PET recovery can feed higher-value fibre only after rigorous sorting and washing.
- Nonwoven and filling grades are more realistic at launch than fine textile fibre.
- Moisture, PVC, polyolefin, colour and intrinsic viscosity govern spinning stability.
- The project needs continuous utility supply, water control, fire protection and committed fibre buyers.
- Recycled polyester staple fibre for nonwoven or filling use - Denier, cut length, tensile properties, elongation, crimp, moisture, colour, contamination, intrinsic-viscosity window and bale mass - Qualified Afghan or regional nonwoven, filling and insulation buyers
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Flake laboratory, crystalliser and vacuum dryer | Qualifies and dries PET before melting | Defined IV and moisture window |
| Extruder and continuous melt-filtration train | Melts and cleans qualified recycled polymer | 15-20 t/day strategic screen |
| Spin beam, quench and finish system | Creates controlled filament tow | One denier/grade family |
| Drawing, crimping, heat-setting and cutter | Builds staple-fibre properties and cut length | Buyer-approved specification |
| Baler, fibre laboratory and utilities | Releases traceable fibre bales | Downstream trial approved |
Raw materials, utilities and factory requirements
- Washed PET flakes to a written contaminant, moisture, colour and IV specification
- Spin finish, filters, quench water-treatment chemicals and packaging bales
- Critical spinneret, filter, cutter and drive spares
- Stable three-phase electricity with verified connected load
- Guarded machinery, lockout, ventilation and fire protection
- Covered segregated raw-material and finished-goods storage
- Maintenance tools, safe lifting and critical spare parts
- Continuous cooling water, thermal oil, compressed air and high-capacity drying vacuum
- Fire protection, polymer fume extraction and flake/fibre dust control
- Secure flake warehouse, wastewater control and qualified maintenance team
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Flake preparation, laboratory and drying | US$1.2m-3m | 15-20 t/day basis |
| Extrusion, filtration, spinning and quench | US$3m-8m | Core polymer conversion |
| Draw, crimp, cutting, baling and testing | US$1.5m-4m | One staple grade |
| Utilities, civil works, freight and commissioning | US$2m-6m | Continuous strategic plant |
| Indicative strategic project total | US$7.7m-21m | Land, finance and working capital excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.