Polyester Manufacturing

 Esterification is a reaction between Acid and Alcohol resulting in an Ester plus Water.

 Polyester is a chain molecule formed by many basic ester molecules through condensation
reaction.
 Monomer (single) > Oligomer (some) > Polymer (many)
Introduction

 Polyester is a category of polymers that contain the ester functional group in every
repeat unit of their main chain.
 As a specific material, it most commonly refers to a type called polyethylene
terephthalate (PET).
 Polyesters include naturally occurring chemicals, such as in plants and insects, as well as
synthetics such as polybutyrate.
 Natural polyesters and a few synthetic ones are biodegradable, but most synthetic polyesters
are not. Synthetic polyesters are used extensively in clothing.
 Polyester fibers are sometimes spun together with natural fibers to produce a cloth with
blended properties.
 Cotton-polyester blends can be strong, wrinkle- and tear-resistant, and reduce shrinking.
Synthetic fibers using polyester have high water, wind, and environmental resistance
compared to plant-derived fibers.
 They are less fire-resistant and can melt when ignited
 Liquid crystalline polyesters are among the first industrially used liquid crystal polymers.
 They are used for their mechanical properties and heat-resistance.
 These traits are also important in their application as an abradable seal in jet engines.
History of the development of Polyester Fibers

 1928-1932: Carothers laid the foundation for all processes used in the production of polyester,
polymaide using polycondensation process.
 The polycondensation of ethylene glycol and sebacic acid produced a melt from which
filaments can be drawn by contact with a glass rod.
 Early 1940s: the use of terephthalic acid for development of polyester fibers was
implemented almost at the same time in Germany by Schlack at a branch of Agfa Wolfen and
by Whinfield and Dickson in England in the laboratories of the Calico Printers Association.
 Whinfield and Dickson preferred using a combination of terephthalic acid and ethylene glycol
to produce polyester. Schlack used terephthalic acid and 1,4 butanediol.
 The combination chosen by Whinfield and Dickson was the most favorable from the point of
economy and application to textile usage and that is the reason it has succeeded over the
combination used by Schlack.
 1947: Mass production started in United Kingdom by I.C.I. and in USA by Dupont after both
companies acquired the patent rights from Calico Printers' Association Ltd. in Manchester.
The I.C.I. marketed their polyester fiber as 'Terylene' while Dupont marketed their product as
'Dacron’.
 All the procedures have one thing in common:
i. Preparation of the polymers;
ii. Spinning of the polymers into filaments;
 iii. Further processing of filaments into continuous filament or staple fiber

Polyester Manufacturing
PET - Polyethylene Terephthalate
• Raw materials: EG + PTA (Esterification process) or EG + DMT (Trans estrification process)
IMPORTANCE:
Production
 The polymer is made by heating teraphthalic acid with excess of ethylene glycol ( Both of
high priority) in an atmosphere of nitrogen initially at atmospheric pressure.
 A catalyst like hydrochloric acid speeds up the reaction.
 The resulting low molecular weight ethylene glycol teraphthalate is then heated at 280 °C
for 30 minutes at atmospheric pressure and then for 10 hours under vacuum.
 The excess of ethylene glycol is distilled off, the ester can polymerise now to form a
product of high molecular weight.
 The resulting polymer is hard and almost white substance, melting at 256 °C and has a
molecular weight of 8000-10000.
Unsaturated Polyester Manufacturing
Unsaturated Polyesters
• Raw materials: EG/PG + Phatic Acid/Anhydride/Maleic Acid/Anhydride
Unsaturated Polyester from PET (Upcycling of PET)
• Raw materials: PET, EG/DEG + Maleic Acid/Anhydride

• Curing of Unsaturated Polyester Resins

 • Raw materials: PET, EG/DEG + Maleic Acid/Anhydride

IMPORTANT POLYESTER
Pet Application:
1. Fibre applications
 Filament yarn
 Industrial yarn
 Staple fibre
 Nonwoven spunbond
 Special fibre products
2. Bottles and Containers
 Stretch blow molded bottles
 Extrusion blow molded bottles
3. Biaxial Oriented Films (BOPET)
 Electronic media Photo technique
 Electrical insulation
 Packaging
4. Cast films, A-PET
5. Food trays ovenable, C-PET
6. Engineering plastics
PET Characteristics:
 Because of higher melting (252 ~ 256 °C) and glass transition (about 80 °C) temperatures retains
good mechanical properties up to 150 ~ 175 °C .
 Its chemical and solvent resistance is good.
 It has good fibre forming properties, has outstanding crease resistance and work recovery and low
moisture absorption.
PBT - Polybutylene Terephthalate Characteristics:
 Its melting point is 232 °C, and mainly used in industrial plastics. Also
been used to manufacture carpet yarns and textile fibres.
 The base resin is widely used in compounding as it has good chemical and heat resistance and
outstanding electrical properties.
 It is easy to make flame retardant and master batches.
PBT Applications:
• Electrical/electric connectors
• Smart Network Interface Devices (SNID’s)
• Power plugs and electrical components
• Switches and controls
• Circuit breaker enclosures
• Outdoor telecommunications enclosures
• Automotive under-hood components
• Electrical appliance components
 • Fiber optic tubes Medical applications such as clamps, pump parts, plugs, etc.
PTT – Poly-tri-methylene Terephthalate
• Raw materials: PDO (1,3-Propanedio)+ PTA
PTT Characteristics:
 It can be spun into both fibers and yarns.
 Its Stain and wearability resistance, colour fastness, softness and stretchable. Its melting point is 233
°C and its easy to dye below 100 °C.
PTT Applications:
• It has extensive applications is in carpeting, textiles and apparel, engineering thermoplastics,
nonwovens, films and mono-filament.
SPECIAL PET PRODUCTS
 A-PET: processed into amorphous, non-drawn cast films
150 to 1000 microns, are used to manufacture all types of
rigid packaging, such as jars, meal trays & folded boxes,
etc.
 C-PET: a specially modified polyester obtained by adding
crystallization accelerators and is mainly used to
manufacture ovenproof meal trays for ready-to-serve
meals.
 G-PET: these are highly modified polyesters, whereby the
EG is replaced by other glycols, e.g., CHDM
(Cyclohexanedimethanol), are amorphous and uses
ranging from A-PET to injection and extrusion blow
moulding. Due to high modifier content are relatively
expensive.
 Bottle PET: are polyester feedstock for manufacturing
bottles produced by stretch-blow moulding, melting
temperature & crystallisation rate are reduced by use of
comonomers, e.g., IPA ( Isophthalic Acid), DEG &
CHDM.
 Co-PET: is a generic term for all copolyesters which
contain apart from PTA an additional acid e.g., IPA or an additional glycol e.g., CHDM. The
majority of bottle polyesters, A-PET and G-PET are copolyesters.
 BOPET: are biaxially oriented polyester films of 1 to 300 microns. Special anti-blocking additives
are used to improve winding characteristics.