Over the last 30+ years, the Estal family has dedicated relentless efforts to building a unique expertise for delivering high-quality recycled polyester staple fibers which will contribute to a better, healthier environment. Backed by our employees’ experience, state-of-the-art machinery, and ISO 9001:2008 certified quality control methods, we are proud to give you a tour of our factory, which embodies our core values: performance, authenticity, reliability, and sustainability. Want to discover how to regenerate polyester fibers? Simply hover over each photo below to learn more about Estal’s production process.
We begin the manufacturing process by collecting scraps of PET bottles and other PET wastes. These scraps would have been dumped into landfills, but we give them another chance to serve a purpose, saving the environment.
Feeding and Mixing
We feed and mix PET bottle scraps and other PET wastes, which have been processed into chips, into our state-of-the-art machines to be transformed into a eco-friendly product.
PET bottle flakes and other PET processed chips are left out on the dryer to reach the high quality of PSF that we desire.
Extrusion allows us to create consistency in our product.
The semi-hard product is now cooled down and allowed to firm.
The cooled down product is now stretched and gathered.
The drawing process allows our product to be stretched and strengthened.
The crimping process allows us to achieve good crimp and bulkiness that our final product offers.
We finalize the product by low heat drying, high heat setting, and cooling down.
We cut the tow per individual client's request.
We finally package the product into PP bags with plastic banding.