How does Polygenta chemically recycle PET bottles into yarn and chips?

Polygenta — now operating as Revalyu Recycling (India) Limited — chemically recycles post-consumer PET bottles into 100% recycled PET chips and texturised filament yarn. The company says it currently recycles roughly 1 billion post-consumer PET bottles per year, with expansion plans targeting more than 6 billion bottles annually. It supplies more than 30 global brands and exports over 50% of its products, mainly to high-end sports and fashion brands.

Chemical recycling vs. mechanical recycling

The core difference is what happens to the polymer chain.

• Mechanical recycling sorts, washes, and melts PET flakes. The polymer chains are not rebuilt, so contaminants, colourants, and mixed inputs tend to degrade quality. Output is often limited to lower-end applications — the site notes that most recovered PET is recycled this way.
• Chemical recycling breaks PET down and rebuilds it. Because the material is purified at the molecular level, the resulting polymer can match virgin-quality specifications rather than being downgraded.

That distinction is why Polygenta can describe its output as 100% recycled content while still aiming at high-performance end uses — the recycled content is the feedstock, not a blend or a downgrade.

From bottles to chips and yarn

The site describes the process at a high level rather than as a step-by-step technical manual, so the sequence below reflects what the company states, not a published process flow.

1. Collection — post-consumer PET bottles are gathered. The site frames this as the starting point of the environmental case: billions of PET containers are discarded each year, and less than half are recovered or recycled.
2. Chemical recycling — using what the company calls a unique recycling process, the PET is chemically broken down and purified.
3. Output — the result is 100% chemically recycled PET chips and texturised filament yarn.

The two outputs serve different markets: chips are the raw polymer form, while texturised filament yarn is the finished textile input. Both are described as 100% recycled.

Why the output can be called 100% recycled

The claim rests on the feedstock and the process, not on blending. Because the input is post-consumer PET bottles and the polymer is chemically regenerated rather than simply re-melted, the recycled content is intrinsic to the material. The site presents this as the basis for the products' sustainability positioning — "breakthrough innovation" in its own words — and as the reason high-end sports and fashion brands have adopted them.

What it means for landfill and incineration

The site's environmental argument is straightforward: PET containers that are not recovered are either landfilled or incinerated, and it describes both outcomes as environmentally damaging. Chemical recycling widens what can be recovered by turning used bottles back into high-quality material instead of low-end products.

Scale is the other half of the argument. Recycling about 1 billion bottles a year, with a stated target of 6 billion-plus, is the company's measure of how much discarded PET it can divert.

Practical takeaways

• If you need recycled PET with virgin-comparable quality for yarn or chips, chemical recycling is the relevant route; mechanical recycling is the route for lower-grade applications.
• Polygenta's own numbers — 1 billion bottles/year today, 6 billion+ targeted, 30+ global brands, 50%+ exports — are the company's stated figures and are the ones to cite.
• The company identity matters for sourcing: Polygenta Technologies Limited is now Revalyu Recycling (India) Limited, so older references to "Polygenta" point to the same operation.

For current product specifications, certifications, or supply terms, the site lists a Certificates section and social channels but does not publish pricing or ordering details — those would need to be requested directly.