Comparative Study of Virgin Polyester and Recycled Polyester Fiber Properties for a Feasible Alternative in Textile Applications

Use of recycled product is important as it conserves natural resources and energy, reduces waste and pollution, and helps combat climate change. Now, the textile industry is seeking for sustainable alternatives to virgin polyester, understanding the quality and limitations of recycled fibers becomes essential. This study investigates the comparative performance of virgin and recycled polyethylene terephthalate (PET) fibers in order to enable the substitution of virgin polyester. The primary objective was to evaluate how recycling affects fiber structure and performance by evaluating single-fiber characteristics. Recycled PET fibers exhibited about 26% reduction in tensile tenacity compared to virgin fibers, but showed higher elongation at break and greater crimp stability. Fourier transform infrared spectroscopy and scanning electron microscopy confirmed that both the fibers retained identical chemical structure suggesting minimal chemical degradation. However, SEM imaging revealed that recycled fibers had rougher surfaces, increased diameter (~15.7 μm vs. ~14.7 μm), and visible surface defects, likely due to thermo-mechanical damage. These structural changes contribute to the lower yarn strength, higher nep formation, and processing difficulties observed in textile mills utilizing 100% recycled PET.