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Tokyo December 17, 2001
More information:
1. PET bottle recycling in Japan
(1) Demand
for PET bottles is rising quickly due to their utility and convenience.
Total demand in Japan rose from 332,000 tons in 1999 to 362,000 tons in
2000. Largely as a result of the introduction of large PET bottles for
Japanese teas, demand is projected to rise further in 2001, to over
389,000 tons (figures taken from a survey conducted by the Japan PET
Bottle Association).
(2) Since
the enactment of the Law for Promotion of Sorted Collection and
Recycling of Containers and Packaging in 1997, the amount of used PET
bottles has risen fast. In the year ended March 2002, around 173,000
tons of PET bottles were collected (equivalent to a recycling ratio of
42.6%). By fiscal 2004, the volume collected is projected to rise to
231,000 tons, for a corresponding recycling ratio of over 50% (Ministry
of the Environment, March 2001)
3) Teijin,
which is a corporate member of both the Japan PET Bottle Association and
The Council for PET Bottle Recycling, has therefore invested in
technical development programs to facilitate the establishment of a
total "bottle-to-bottle" recycling system for PET bottles that can
supply the required recycling capacity.
2. PET
"bottle-to-bottle" recycling technology
(1) The
process developed by Teijin involves the chemical dissolution of
collected used PET bottles to form DMT, which is then refined into TPA,
a raw material for the PET resin that is used to make PET bottles.
(2) The new
plant at the Tokuyama Factory will use recycled TPA to manufacture PET
resins with a variety of applications, including heat-resistant
bottles.
(3) Teijin
is currently in the process of validating the safety and hygiene
standards at the new plant. The company expects presently to receive the
approval of both the U.S. FDA (Food and Drug Administration) and the
relevant Japanese authorities. Products manufactured at the plant will
therefore be fully compliant with the standards laid down in Japan's
Food Sanitation Law. Teijin has also filed applications for 15 separate
patents related to its PET "bottle-to-bottle" recycling technology. (The
company has already received over 60 patents related to recycling
processes connected to the production of DMT raw materials.)
3. History
of PET bottle recycling at Teijin
1958:
Shortly after beginning production of polyester fiber, Teijin begins
chemical recycling of fiber scraps generated during manufacturing.
1995:
Teijin commences the manufacture and sale of ECOPET®, a recycled staple
fiber obtained from PET bottle recycling
1996:
Full-scale development of ECOPET® begins to produce a range of recycled
fiber products, including clothing, sundry goods, bedding and
interior-design items, kitchen products and sporting goods. As the range
of applications broadens, sales volumes increase, rising from 600 tons
in fiscal 1996 to 800 tons in fiscal 1997 and to 1,200 tons in fiscal
1998.
1999:
Teijin begins the manufacture and sale of a recycled filament yarn under
the umbrella of the ECOPET® brand; sales volumes continue to expand,
rising from 2,400 tons in fiscal 1999 to 3,000 tons in fiscal 2000 (and
a projected 5,000 tons in fiscal 2001).
2000:Teijin
develops raw material recycling technology to recover high-grade DMT
from polyester products that is of equal purity to DMT derived from
petroleum. The Company made a related announcement in December
2000.
April 2002:
DMT raw material recycling operations due to begin at the Tokuyama
Factory
October
2003: PET "bottle-to-bottle" recycling business is scheduled to become
fully operational.
4.
Facilities used in PET "bottle-to-bottle" recycling
(1)
Location: Tokuyama Factory, Teijin Ltd., 1, Yuka-cho, Tokuyama,
Yamaguchi Prefecture.
(2)
Representative: Shiho Iizuka
(3) Outline
of business and facilities
| |
Start of
operations in April 2002 |
Start of
operations in October 2003 |
|
Business |
Recovery of high-quality polyester raw
materials (DMT and ethylene glycol) from used polyester products,
mainly PET bottles. |
DMT sourced from chemical recycling will be
converted into TPA and used as a raw material in the manufacture of
PET resin for PET bottles. |
|
Facilities |
A
new recycling facility is being constructed, plus the existing DMT
production plant will be modified to accommodate chemical recycling.
Together, these will be able to produce about 24,000 tons of
high-grade DMT a year from 30,000 tons of used PET bottles
(equivalent to about 1 billion 500-ml PET bottles.) |
1.Total recycling capacity will be raised to produce about
50,000 tons of DMT a year from roughly 60,000 tons of used PET
bottles (equivalent to about 2 billion 500-ml PET bottles).
2.New facility will convert recovered DMT into suitable grades
of TPA, a raw material for PET resin for bottles.
3.TPA to be
entirely used to make PET resin for bottles at another newly
constructed plant. Annual production capacity for PET resin
projected to be 50,000 tons a year. |
5.
Production of PET resin for bottles
With the
increase in production capacity provided by the PET "bottle-to-bottle"
recycling operations detailed above, Teijin's projected production set-up
for PET resin from October 2003 onwards is as shown in the table below. As
demand for PET resin continues to rise, Teijin expects the market to
remain tight. The company is therefore aiming to raise its market share
following this increase in capacity.
|
|
Existing
facility
(Matsuyama Factory) |
New
facility
(Tokuyama Factory) |
Total |
|
Production capacity (tons/year) |
40,000 |
50,000 |
90,000 |
Contact:
|
Manabu
Mori
Teijin Public Relations & Investor Relations Office
(Tokyo)
Tel.: +81 3-3506-4055
Fax: +81 3-3506-4150
E-mail:
ma.mori@teijin.co.jp |
Hideko
Sugimoto
Teijin Public Relations & Investor Relations Office
(Osaka)
Tel.: +81 6-6268-2763
Fax: +81 6-6268-3010
E-mail: h.sugimoto@teijin.co.jp |
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Edited:
24.07.2003
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