Polyester is one of the world's most commonly used synthetic fibers

Polyester is one of the world's most commonly used synthetic fibers and produced using an innovative manufacturing process to yield its desirable properties of high tensile strength, dimensional stability and versatility. Thanks to this special processing, polyester can be found in apparel products as well as home furnishings and automobile interiors - ensuring its global demand remains steady over the forecast period.

Polyester production requires vast amounts of raw materials derived largely from fossil fuels - which are limited resources used for other things such as producing electricity and transporting goods. Therefore, polyester producers strive to reduce energy consumption through efficient systems, innovative solutions and by developing new technologies.

Polyethylene, composed of ethylene (E) and hydrogen (H), is a vital chemical in the production of polyester polyurethane foam (POY). Produced through an advanced process known as polymerization, where an ethylene molecule is separated into its constituent parts by applying heat and pressure; then they react with other chemicals present to form propylene or butylene polymers that will later be processed to form final POY products.

This process can be carried out in large processing units to create staple fiber or yarns as well as thousands of small plants worldwide, estimated to number over 10,000 plants totaling over 10,000 capacities for global polyester production. Each of these manufacturing facilities features state-of-the-art machines for melting, extrusion, and spinning; an estimate puts the total global capacity of polyester production at over 10,000 plants worldwide.

Barmag's directly spun system ensures excellent dyeing uniformity, yarn tension, and CV% values that remain constant, and outstanding further processing properties like yarn evenness and easy twisting. Furthermore, this yarn can be further processed into DTY, ITY and air texturized POY textures used in garment fabrics, wool-like products like hemp products as well as decorative items such as curtain fabric or car interior decoration cloth production.

The global polyester POY market is experiencing rapid expansion, driven by several key drivers. First, is the increasing global population and urbanization, driving demand for textiles; second is an expanding e-commerce industry driving increased packaging material demand. Polyester is an eco-friendly and long-term investment, making it an attractive option for the industry. This report presents a detailed cost analysis of polyester POY production through melting, filtering, and high-speed spinning processes. It includes processes, material flows, operating costs, financial expenses, and depreciation charges in its analysis of polyester POY production. As a result, this report offers a clear view of its cost structure, helping identify opportunities to reduce costs and enhance profitability. In addition, the report covers the impacts of various technologies on the production process as well as strategies that could optimize its production.