We aspire to solve world’s waste problem by being socially responsible and without increasing the environmental footprints.
Our Journey So Far
Polygenta Technologies Ltd (‘Polygenta’) entered into business in 1981. Polygenta is a professionally managed company with parent company based out of Germany.
Initially, Polygenta has been engaged in production of conventional yarn. From 2012, Polygenta has started with the full-fledged production of 100% chemically recycled polyester yarn. With support from its parent company, Polygenta has been successful in achieving a unique process to recycle post-consumer PET waste for making cost effectively high-quality virgin equivalent recycled filament yarns. Polygenta is the only such fully integrated plant in South Asia and currently processes more than 3 million plastic bottles a day to make 40 tonnes per day of 100% recycled yarn and rPET chips.
Our sustainable yarn offers unparalleled comfort, performance, and tenacity. Our yarns have been used in various applications including circular knitting, warp knitting, seamless knitting, weaving, mesh, fleece, denim, apparel work-wear, automotive, furnishings, and technical textiles to name a few.
Polygenta’s products achieve more than 66% reduction in Global Warming Potential (GWP) and more than 90% reduction in Primary Energy Demand (Source: ThinkStep LCA Study, 2019).
Our Expansion Plans – ‘The Chips Project’
Due to growing customer demand and need for sustainable products, Polygenta is in the process of expanding the capacity at the Nashik site from present 40 tonnes per day to 240 tonnes per day by setting up a two 100 tpd plant. The Project will focus on making 100% recycled textile grade rPET chips. Chips are a first stage product which can be sold to various customers who wish to convert into recycled partially oriented yarn (POY)/ fully drawn yarn (FDY).
Our Manufacturing Process
The PET recycling process uses a unique way to break down (depolymerize) used plastic PET bottles (i.e. multi-ester molecules) into sustainable esters (monomers). These monomers can be used to directly replace conventional oil derived monomers and used as the base building chemical to manufacture all PET based products such as polyester textiles, PET bottles, film, sustainable PET packaging etc.
To minimize undesirable side effects of the traditional depolymerization processes which operate at much higher temperature, we use a low temperature glycolysis process. For the chemical solvent, we conveniently use mono-ethylene glycol (“MEG”), which is one of the two components of polyester. So, there are no chemicals that are ‘foreign’ or toxic to polyester to be concerned about.
Over the last decade, the global consumption of polyester has grown. The apparel and home textile segments account for more than 79% of the total fibre consumption. Polyester is the fabric of choice for sportswear where its ability to “wick” away sweat is highly beneficial. Polyester is also much more durable than cotton and its elastic nature is used widely within a range of textile products including bags, denim and furnishings. Our yarns are used in thousands of products worldwide.