Looking into the future of production, some Bangladesh companies are now recycling plastic bottles into polyester staple fibers (PSF) for domestic production and exports.
The global man-made fibre market was at around $250-$300 billion in 2022, whereas Bangladesh held only 4%-5% of the market share.
According to a study, if Bangladesh invests $18 billion in the non-cotton fibre industry, then the country can export non-cotton readymade garment (RMG) items worth $42 billion by 2032.
These recycling companies are significantly contributing to sustainability and socioeconomic development through their pioneering efforts in PET recycling.
One recycling company, Mumanu Polyester Industries Ltd started in 2014 at its 138,200 square feet factory at Singair, Manikganj. They started full-fledged operations in 2017 and are currently producing 120 tons of fibres daily.
They employ 261 people in their factory unit. While about 15,000 workers are involved in their supply chains, which supply them with PET bottles. Around 70% of their workforce are women.
The company has helped create jobs for an estimated 365,000 workers in the waste management sector, ranging from bottle pickers to waste shop employees and distributors.
The recycling process involved collecting used PET bottles, extensive cleaning and sorting procedures, including manual sorting, label removal, multiple stages of washing, and final cold and hot washes.
After cleaning, the plastic is melted and passed through a spinneret to create fibres.
The finished fibre is then crimped, cut, and compressed into bales for shipment, meeting local and international market demands.
Currently, they have 14 clients who source from them. Most of the clients are the country’s prominent textile, geo-textile, and synthetic fibres manufacturers.
Bangladesh's PSF production gives it a cost advantage over major markets like China. The Chinese market sees prices around $1.45 per kg, while the cost of PSF in Bangladesh is approximately $1.15 per kg.
This $0.30 per kg cost difference is driven by lower raw material costs, affordable labour, and quicker shipping time.
Their yarn costs $0.27 per kg for the garments and textile sector, while the Chinese one costs $0.34.
In the financial year 2022-23, Mumanu has a turnover of $16.50 million.
Ruhul Hossain, deputy general manager and head of business development, told Dhaka Tribune that recycling PET bottles in their factory is essential in reducing plastic pollution and promoting sustainability.
“The company’s eco-friendly practices align with global environmental goals, turning waste into high-quality PSF that can be used in various industries, including the RMG sector,” he added.
According to industry insiders, about 200 factories in Bangladesh are currently involved in PET recycling; however, 10-12 factories produce textile-graded PSF.
The geotextile sector is also a major user of PSF, along with the textile industry.
They usually use geo bags on mega projects like river and sea embankments, road and highway protection activities, and others.
Gazipur-based Dhaka Geo Textile Ltd is one of the significant users of PET-recycled PSF. It produces geo bags for mega projects.
Ahsanullah, the company's director, told the Dhaka Tribune that PSF has increased significantly in the textile and geotextile sector for the last 20 years.
“PSF is being used for every fabric, so the demand for PSF is high. Moreover, PET recycling is also important for environmental safety and the government provides an incentive of 10% in exporting PET scraps, which was 20% initially,” he added.
Regarding rumours about banning PET bottles, he said that Bangladesh's supply of raw materials is lower than its demand. So, any ban on PET would make the country import-dependent.
According to a study by the Department of Environment, Bangladesh generates approximately 821,000 tons of plastic waste annually. Yet only 36% of it is recycled, and more than 527,000 tons are in landfills or dumped in open spaces.
In 2024, Mumanu alone collected 18,460.04 tons of PET bottles from districts around the country.
