Asian Fibres is setting up what could be the biggest plant in the Middle East to manufacture regenerated polyester staple fibre (RPSF) from post-consumed PET bottles.

Construction of the $100 million ‘eco solution’ production facility is underway in Ras Al Khaimah and expected to be operational by year’s end.

Development of the facility along with the erection of machinery and utilities are ongoing at full swing and will help create an eco-friendly habitat for the UAE along with various opportunities for downstream industries in the textile sector of the GCC, the company says.

Construction work on the plant, located in Al Ghail Industrial Park, Ras Al Khaimah, began in November last year. Covering an area of 80,000 sq m, the plant will be able to produce 100 tonnes of polyester staple fibres each day. Asian Fibres will be able to maintain industries by generating raw materials for textile applications, technical textiles/non-wovens and fibre fills and will also create some 600 job opportunities when the production facility is completed.

The plant will integrate the latest innovations and modern technology in the recycling business to manufacture RPSF from virgin and waste PET bottles under stringent quality controls to ensure the finest quality.

Asian Fibres aims to conserve the environment by extending the life of PET bottles by reusing and converting PET bottles into RPSF, according to Suryamani Singh, director of technical operations at Asian Fibres.

“The RPSF can then be used as ring spinning of yarns for textile applications, technical textiles, carpets, filters and geotextiles as well as stuffing in toys, pillows, mattresses and quilts,” he said. Asian Fibres was established in 2014 as part of the Asian Investments Group.

The company has around 450-500 staff and the proposed turnover in the first financial year could touch Dh1 billion ($270 million).

“We can produce recycled polyester staple fibre from 1-10 Dtex for textile applications, non-wovens and filling applications in a variety of colours including white and grey. We will source raw materials locally as well as in neighbouring GCC countries.”

The company is building the facility in two phases. The first phase of 100 tonnes per day will be achieved in the current financial year. Phase two will begin in 2016 and will double production capacity by the end of 2016.

“This is a unique industry as it creates a greener ecosystem for our environment. The per capita plastic consumption in the Mena region is a third of the current level of First World countries. This will only increase in time to come; hence we are creating a greener future for ourselves in the UAE,” he said.

The main markets for the company include the Mena area as well as other parts of Africa, South America and South Asia. It will serve manufacturers of yarn, non-woven material and geotextiles.

Commenting on the company’s plans for the long term, he said: “We plan to aim for downstream captive consumption by setting up in-house non-woven and geotextile lines to serve the Mena region. We are also exploring the possibility of setting up additional similar plants in Egypt and Saudi Arabia.”