From Plastic Waste to World Cup Flags: How Surat Recycled 2.2 Lakh Bottles into Giant National Flags
Plastic bottle recycling is becoming a major raw material source for the textile industry. As global manufacturers look for sustainable alternatives to virgin polyester, recycled PET (rPET) is emerging as a scalable solution. A recent large-scale production project in Surat demonstrates how approximately 2.2 lakh plastic bottles were processed and converted into oversized flags used at the ICC Men’s T20 World Cup.
The project highlights the industrial viability of recycled plastics in textile manufacturing and reflects the growing demand for sustainable production practices in large international events.
Project Overview: Large-Scale Flag Production from Recycled Plastic
A textile manufacturer(Praveen overseas) based in Surat undertook the production of 20 large-format flags for participating nations in the tournament. Each flag measured approximately 35 meters by 20 meters and weighed more than 150 kilograms.
Key production details:
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Around 11,000 plastic bottles were used per flag
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Total bottles recycled: approximately 2.2 lakh
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Production timeline: 3 months
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Each flag included 54 reinforced fabric handles for structural support
The project required continuous powerloom operations and coordinated yarn processing to meet strict size and durability specifications.
The Future of Recycled Plastics in Industrial Textiles
The successful conversion of 2.2 lakh plastic bottles into large-scale textile products signals a broader transition within the manufacturing sector. As regulatory pressure, consumer awareness, and corporate sustainability targets increase, recycled materials are expected to become standard inputs rather than niche alternatives.
For textile manufacturers, early adoption of recycled polyester systems can provide:
Competitive advantage
Export opportunities
Alignment with ESG standards
Long-term cost stability as raw material markets fluctuate
Plastic bottle recycling is no longer confined to small-scale consumer goods. It is now an industrial material stream capable of supporting large commercial production.
Recycled Cotton Solutions for Sustainable Manufacturing
In addition to recycled polyester applications, sustainable textile production also includes recycled cotton derived from post-industrial and post-consumer textile waste. Recycled cotton helps reduce landfill pressure, lower water consumption, and decrease dependence on virgin raw cotton.
We supply recycled cotton made from textile waste, suitable for various industrial and manufacturing applications.
Learn more here: https://ptgloves.com/product/jeans-industrial-jeans-hand-gloves-heat-resistant-recycled-fabric/