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ProductsPolymer PlantsPolyesterPolymer Plants - Polyester - Continuous

Continuous Polyester Plants


AQUAFIL Engineering has long experiences in building and designing continuous and batch polycondensation plants for textile, film and bottle grades. Some of our engineers are working in the business field already more than 40 years. The managing director of AQUAFIL Engineering was one of two inventors of the shaft less finisher (called disc-ring-cage reactor). The finisher design has been improved in the last years and is used for medium viscosities as well as for high viscosities up to IV 1.1.


2-Reactor Technology

The 2-Reactor plant technology can be used for capacities up to 600 tons/day. AQUAFIL Engineering analyzed carefully the market situation in the past. The result of this study was the request of the market and the customers to high efficient plants and low conversion costs. Even if all competitors were following the way of large production scales to reduce the operating costs, AQUAFIL Engineering was working on a different strategic approach.

Small is in, Large is out.

Following the idea of smaller, more flexible and simplified production AQUAFIL Engineering has designed a 2-Reactor process for which patents have been granted for the technology as well as for the equipment. The new concept of simplified and flexible polycondensation plants allow to compete with the production cost of large scale plants. All the advantages are possible to realize with the unique AQUAFIL UPR® (Universal Polymerisation Reactor). The 2-Reactor technology can be used for textile-, film- and bottle applications with IV 0.58-0.68 and technical yarns with IV up to 0.98. 


UPR advantages

  • Less equipment cost 
  • Less utility consumption 
  • Shorter hold-up and reaction time 
  • Lower AA-generation
  • Lower DEG formation due to large surfaces, low temperatures
  • Lower oligomer formation and losses
  • Reduced space and building cost
  • Shorter project realization time



3-Reactor Technology

The 3-Reactor plant technology has been built in the past but is still available.

AQUAFIL Engineering plants are designed for low utility consumptions and highest quality. The low consumptions can be reached by the advanced recycling / recovering system that are installed in all polyester plants. In this regard all EG and residues from the production are directly recycled to minimize the raw material consumptions.

The off-gases of the production are collected and used in a separate unit, so that all environmental aspects can be reached worldwide.

Polymer Plants - Polyester

Polyester Process and Reactor

The unique reactors of the polyester process are designed and patented by Aquafil Engineering. The reactors are fabricated by selected manufacturers with high quality standards in Europe.

Before the main reactors are shipped to the clients of AQUAFIL Engineering, each reactor is tested with a heat and vacuum test according to AE standards in the workshop.

Melt to Fiber/Resin/Preform/Film Process

AQUAFIL Engineering can supply polycondensation plants for direct spinning of fibre or filaments, direct film casting (DFC®) and high viscosity for resin.

Modifications needed for fiber, resin or film applications can be made with special AQUAFIL Engineering Melt Modifying Systems (MMS).