Five lines,one specificationdiscipline

The route to PSF-R - how this line is made

1. 01

   Feedstock preparation & sorting

   Incoming post-consumer PET bottles and clean industrial polymer waste are sorted, hot-washed, and processed into decontaminated flake under GRS chain of custody.

2. 02

   Melt extrusion & spinning

   Clean flake is dried, melted in high-pressure extruders, and forced through precision spinnerets to form continuous filament bundles.

3. 03

   Multi-stage drafting & orientation

   Filaments pass through heated liquid draw-baths to develop molecular orientation, locking in target tensile tenacity and elongation characteristics.

4. 04

   Thermomechanical crimping & finish

   Tow is mechanically crimped to impart 3D elasticity and bulk cohesion, with tailored siliconized or non-siliconized finish chemistry applied.

5. 05

   Rotary cutting, baling & COA

   Tow is cut to the specified staple length (32–102 mm) and compressed into standard 200–300 kg moisture-sealed bales with laboratory COA verification.

Route assembled from the line’s verified construction and the published production sequence - per-grade parameters are order-specific and not published from a standing table.

The route to PSF-H - how this line is made

1. 01

   Decontaminated post-consumer feedstock

   Selected post-consumer PET flake is hot-washed, optical-sorted, and decontaminated under verified GRS chain of custody for high-purity spinning.

2. 02

   Hollow profile melt extrusion

   Molten polymer is extruded through specialized circular-aperture spinnerets to form continuous hollow filaments with internal thermal air channels.

3. 03

   Differential drafting & helical crimp

   Bicomponent drafting develops three-dimensional helical spiral crimp, imparting permanent spring-like resilience and high loft recovery.

4. 04

   Siliconization & thermal curing

   Tailored silicone micro-emulsion finish is applied and heat-cured in relaxing chambers to create an ultra-soft, slick, down-like hand-feel.

5. 05

   Precision cutting & moisture baling

   Cut to uniform staple length (32–64 mm) and packed into 200–300 kg moisture-sealed bales with full batch Certificate of Analysis.

Route assembled from the line’s verified construction and the published production sequence - per-grade parameters are order-specific and not published from a standing table.

The route to WAD - how this line is made

1. 01

   Fibre opening & precision blending

   Selected polyester staple fibres and low-melt bicomponent bonding fibres are pneumatically opened and metered in exact ratios.

2. 02

   Web formation & cross-lapping

   High-speed carding machines comb fibres into a fine web, layered by cross-lappers to reach the target GSM, thickness, and loft profile.

3. 03

   Thermal bonding oven (glue-free)

   The layered web passes through a multi-zone hot-air oven where low-melt fibres fuse contact points without chemical glues or volatile resins.

4. 04

   Calendering & loft stabilization

   Controlled cooling zones and smooth calender rolls stabilize loft recovery, structural density, and surface uniformity.

5. 05

   In-line slitting & protective roll packaging

   Continuous edge-slitting, roll winding, and heavy-duty poly-film wrapping with in-line caliper and density quality verification.

Route assembled from the line’s verified construction and the published production sequence - per-grade parameters are order-specific and not published from a standing table.

The route to FLT - how this line is made

1. 01

   Fibre selection & carding

   Selected GRS recycled or prime polyester fibres are opened and carded into a homogeneous multi-directional fibre batt.

2. 02

   Multi-layer cross-lapping

   The web is cross-lapped into heavy batts across the specified weight range to ensure isotropic tensile strength in both machine and cross directions.

3. 03

   Mechanical needle-punching

   Thousands of reciprocating barbed needles repeatedly penetrate the batt, mechanically interlocking fibres into a dense, binder-free cohesive mat.

4. 04

   Thermal consolidation & calendering

   Optional thermal calendering or surface singeing locks thickness tolerances, increases puncture resistance, and sets surface smoothness.

5. 05

   Caliper inspection, slitting & roll winding

   In-line density and thickness verification, precision edge-trimming, and protective roll wrapping for industrial dispatch.

Route assembled from the line’s verified construction and the published production sequence - per-grade parameters are order-specific and not published from a standing table.

The route to INT - how this line is made

1. 01

   Substrate web formation

   Non-woven polyester staple fibre webs are carded, or woven base lattices are formed according to the target garment rigidity and drape.

2. 02

   Matrix consolidation

   Substrates are consolidated via liquid resin binder thermal curing (chemical-bonded) or mechanical multi-thread stitching (stitch-bonded).

3. 03

   Thermoplastic adhesive dot coating

   Heat-activated low-melt thermoplastic adhesive is applied via precision rotary screen printing in computerized dot patterns (CP/double dot).

4. 04

   Thermal curing & drying tunnel

   Hot-air curing tunnels anchor adhesive dots securely to the substrate surface without strike-through or compromising fabric hand feel.

5. 05

   Optical inspection, slitting & roll packaging

   100% optical inspection for dot uniformity, roll slitting to width, and moisture-sealed packaging accompanied by fusing recommendations.

Route assembled from the line’s verified construction and the published production sequence - per-grade parameters are order-specific and not published from a standing table.