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The new Audi A3, from the vacuum to make the seats...
Surprise: 89 percent of the tissues with which they are clothed, the interior of the new Audi A3 is consisting of bottles in recycled PET (a thermoplastic resin) to be transformed into yarn by a process technically refined. The result? Tissues that, from the point of view of the visual and tactile, will ensure the same quality standards of the coatings classic.

In Germany and many european Countries, the empty bottles are inserted in the special automatic machines to receive, in exchange for an incentive of up to 25 cents a piece. But what happens after that? The disposable bottles are pressed and compacted to limit the overall length for transport. Once they arrived at the recycling plants, are divided according to the color, the size and quality of preservation. Separate the foreign materials, such as stoppers, a specific grinding tenderizes the bottles up to get “flakes” are intended to be washed, dried and melted.

Created a uniform mass, of the nozzles give rise to filaments without solution of continuity, after cooling, are chopped. The granulate produced in this way is transformed by extrusion into yarn, after being wound on spools, is intended for the production of the fabrics.
To make the upholstery of the seats of the new Audi A3 are required up to 45 in PET bottles of 1.5 liters. To these you add more 62 recycled bottles, destined to the carpet. The sustainability of the cockpit is further pointed out by many of the components produced making use of waste materials: for example, the inserts sound-deadening and vibration damping, floor mats and the side surfaces of the trunk.

today, however, the seat covers are not entirely of recycled materials. “The challenge is represented by the lower cloth, and attached to the upper material by means of an adhesive. We are working to replace the latter with a solution of polyester recyclable,” explains Ute Grönheim, responsible for the development of the textile materials of Audi AG. “The horizon is to produce coatings with a recycled pure, intended for further reuse so as to give life to a virtuous circle. We are not far from this goal.”

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