Recycled PET | Sustainable custom branded rPet products

Sustainable
rPET

rPET, short for Recycled PolyEthylene Terephthalate, is a relatively new man-made material that was only introduced to the textile industry in 1993. It has undergone a lot of research and innovation to get where it is today.
PET is part of the thermoplastic family and one of the most commonly used materials in the world with its biggest use being in plastic water bottles.

When these items are recycled, instead of ending up in landfill, they are taken to a recycling facility and converted into a strong, lightweight polyester yarn.
The end material made using this yarn is known as rPET and is all part of the circular economy which is one of the many reasons why we love it.

Types of rPET

From trash to treasure, rPET products from Bag Maverick

Types
of rPET

Polyester is an artificial fibre made from a chemical reaction involving petroleum and it is the most widely used fibre in the world. You can learn more about polyester here. When this gets recycled, it can be used to make brand new products which can then, in turn, also be recycled at the end of their useful life. Our RPET fabric is made from 100% recycled plastic bottles and is popular for making bags and home textiles.

This is a non-woven fabric that is held together by stitching or knitting in additional yarns and it that can be easily identified as the threads are visible. Unlike other methods used in the production of non-woven fabric will stiffen the material, stitch bonding allows the material to remain soft. It is also a stronger fabric because the threads run both vertically and horizontally which makes it tear-proof.

Another type of non-woven RPET by this one is when the fibres are bonded together using chemicals or heat and pressure. The result is a smooth and breathable fabric that has the feel of cloth but the stretch and durability of canvas.

This is a polyester fabric that looks and feels like cotton. It undergoes the same production process as conventional RPET with some added features. For example, this fibre has physical traceability through embedded tracers and digital traceability through blockchain. It also has superior dyeing performance so this would be a great option if you are creating products with bold and bright colours.

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From trash
to treasure

In the production of rPET products, recycled plastic is collected, cleaned and remade into something useful through a fairly simple process. The most popular recycled PET product that goes through this process, and the one that we use in our products, are plastic water bottles.

There are two types of recycling processes for rPET – mechanical, which is the most common, and chemical which is a better method as it doesn’t degrade the quality; however, it is rarely used because it’s very expensive.

The mechanical recycling process involves the PET being compressed into bales and transported to a recycling facility where the bales are broken apart and separated from other plastics. The PET is then ground up into small flakes, cleaned, dried and chopped down further into tiny pellets which are melted and stretched into string-like fibres.

These fibres are then tied together to create a polyester yarn that can be used to manufacture a wide range of products including bags and clothes.

Why we use rPET

Its CO2 emissions are 75% lower than that of regular polyester

It requires 1/10th of the water used in the production of virgin polyester

The production process uses 70% less energy than regular polyester

It can be continuously recycled with no degradation of quality

Our
rPET products

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Learn
a little more

rPET is a low maintenance fabric and when it does require cleaning, it’s a fairly simple process.

Most rPET fabrics can be machine washed but handwashing is always preferred.

Following this, it should be left to air dry as putting rPET in a tumble dryer could damage the fibres.

Non-woven rPET fabric is available in many different weights which is determined by the thickness of the yarn used to make the material. Non-woven rPET weights are measured in GSM (grams per square metre) and can range from 90gsm – 240gsm.

For other types of REPT, you can specify the fineness of the yarn being used which will determine how thick and opaque the end product will be. This is measured in denier (D) and the higher the denier the thicker the recycled polyester yarn.

The most common deniers that we use are 190D and 210D both of which are popular for tote bags.

70% Polyester and 30% RPET

This blend is a mix of virgin and recycled polyester that creates a high-end fashion fabric with a great look and feel. Out of all the blends this one uses the least amount of RPET making it the least sustainable. It’s mainly used when making fashion garments.

94% RPET and 6% Spandex

This is an RPET fabric with a small amount of the synthetic fibre, spandex, mixed in to create a lightweight sophisticated fabric which can be used for making travel suits. This is a highly sustainable fabric with the addition of spandex making it slightly more breathable and comfortable to wear.

65% RPET and 35% Cotton

This is one of the most optimum blends of RPET and cotton and is commonly used to make fashion garments. This fabric has moisture wicking properties and requires little maintenance. In this case, the 35% mix is conventional cotton only.

40% RPET, 30% Recycled Cotton and 30% Cotton

This is a blend of 70% recycled materials - polyester and cotton - with conventional cotton. This fabric has high moisture wicking properties and is very breathable which makes it a great option for active wear.

rPET can be dyed in any colour based on a coated Pantone – the universal colour guide used as a standardised colour matching system.

We use two different methods for dyeing rPET and we only work with REACH compliant dyes.

Yarn Dyeing

In this process, RPET is mixed and melted with colour pigments and then extruded through a nozzle. This extruded mass is then spun into coloured yarn and the yarns are knitted or woven into fabric. This process ensures uniform and accurate colours in the RPET fabric.

Piece Dyeing

The grey RPET fabric is dyed in hot water under high pressure mixed with liquid dye stuff to impart the desired colour. This is a faster dyeing process but the results aren’t as precise or vibrant as yarn dyeing.

Finishing, as the term implies, is the final step in fabric production. Hundreds of finishes can be applied to textiles, and the methods of application are as varied as the finishes.

rPET fabrics can be finished in a few different ways. Some finishes change the look and feel of the fabric, while others add special characteristics.

Laminated

Laminated fabrics have a very thin transparent layer of polyurethane film fused to them using hot melting process technology. The lamination helps make the RPET fabric even stronger and more rigid. This will enable it to hold its shape for longer and is ideal for products that need the additional sturdiness or durability.

PVC Coated

PVC stands for polyvinyl chloride which is a synthetic material that can be applied to RPET fabric to make it waterproof. This is ideal for creating bags, jackets and other outdoor items that are likely to be exposed to rain and water so will need the added protection.

rPET can easily be branded with your artwork using a variety of techniques. Learn more about each one here.
Choose from a range of print techniques :
• Screen Printing
• Sublimation
• Transfer Printing
• Gravure Printing
• Embroidery

We can provide rPET with various certifications. Learn more about each of them here