Virgin PET chip-spun uncarded staple fibre manufacture

1. Scope and Applicability

This method covers manufacture of virgin PET homopolymer, undyed monocomponent solid round-section cut staple from purchased fibre-grade chips, with spin-draw and final finish at declared as-released moisture. The connected route dries/conditions chips, melts/filters/spins them, air-quenches filaments to can tow, draws and crimps the tow, dries/finishes it, then cuts, bales and releases uncarded/uncombed staple [jrc-polymers-2007]. Tow in cans is a real internal intermediate, not filament yarn, monofilament/strip or another reference product. No use-specific new identity is created.

JRC supplies this particular chip-to-can-tow-to-staple sequence; EPA independently distinguishes melt spinning from solvent/reaction spinning and cut staple from tow/continuous-filament yarn [epa-synthetic-fibres]. The manufacturer brochure corroborates industrial conversion stages, not one common SKU or plant across all sources [neumag-staple-2023]. Numerical temperatures, draw ratios, finish recipes, yields, capacities, emissions and standard moisture/regain are not transferred. Factory records must establish actual quantities and conditions. Scientific review and classification mapping acceptance remain pending.

2. Product Category Identity

Field	Value
canonical_pcr_id	pcr.other-transportable-goods-except-metal-products-machinery-and-equipment.other-chemical-products-man-made-fibres.virgin-pet-chip-spun-uncarded-staple
classification_refs	CPC 3.0: 35510, narrower semantic subset; no mapping approval
covered_products	Virgin PET homopolymer, monocomponent undyed solid round-section drawn/crimped cut staple, not carded or combed, with declared spin-draw/final finish and as-released moisture
excluded_products	Continuous tow sold as such; filament yarn; monofilament/strip; carded/combed fibre; other polymers; recycled feed; bicomponent/hollow/dope-dyed fibre; PET chips as output; regenerated cellulose; direct-polymerisation melt feed
representative_product	Virgin PET chip-spun uncarded staple fibre manufacture
production_route	Purchased PET chips → crystallising/drying → extrusion/filtration/spinneret → air quench/spin-draw finish/can tow → creeling/drawing → crimping → drying/final finish → cutting/baling → production quality release
market_state	Baled textile staple at factory production-release gate, including measured residual moisture and retained finish in net fibre mass; wrapper and strap tare excluded

3. Reference Flow

Field	Value
What	Supply specified uncarded virgin PET staple as textile raw material
How much	1 kg newly accepted net fibre at the production-release gate
How well	Actual buyer acceptance for polymer/virgin identity, cut length, fineness, crimp, tenacity/elongation, finish and moisture; no default thresholds
How long or cycle	One matched actual production/reporting period with complete contributing runs and WIP burden carry-over; no use-life function claimed
reference_flow_link	pet_staple

Field	Value
Reference amount	1
Reference product flow	Polyester short fiber 03377e13-45a0-4774-9cc8-37c8c60523f2
Reference flow property	Mass 93a60a56-a3c8-11da-a746-0800200b9a66
Reference unit group	Units of mass 93a60a57-a4c8-11da-a746-0800200c9a66
Reference unit	kg
Required qualifiers	PET homopolymer / 100% virgin polymer and actual chip grade/additives; chip-fed extruder route with can-tow intermediate; uncarded/uncombed / solid round monocomponent undyed staple; actual cut-length distribution / dtex / tenacity/elongation and crimp acceptance methods; spin-draw/final finish identities / retained active content and supplied state; as-released moisture / oven-dry method / conditioning and regain convention; net fibre mass / packaging tare and unique first-release lot IDs; production-release Q gate / WIP and carried burdens / separate finished-goods ledger; actual site/supply geography / factory production mix and utility providers; full reporting period / failures/rework and included warehouse/dispatch service extent

Declare every qualifier in the concrete dataset. The reference is new production-release mass, not unconditional functional equivalence or actual net delivered quantity.

4. Measurement and Unit Rules

rule_id	Applies to	Required property	Required unit	Rule
reference_mass	reference product	Mass 93a60a56-a3c8-11da-a746-0800200b9a66	kg	Q is positive newly accepted net fibre at first production release under cp_output; 1 kg includes measured retained finish and water. Exclude all packaging tare. Returns and repeat acceptance never create the same mass again.
moisture_basis	material and product mass	Mass	kg	Use actual as-released weighing as denominator. Record wet-basis water fraction w and dry nonwater mass D=m(1-w); assay retained finish separately to obtain polymer mass. Dry-basis regain R=m_water/D gives m=D(1+R). A contractual standard regain changes reported mass only through an explicit measured conversion, never silently changes Q.
linear_density	fibre fineness and length	Linear density	tex; dtex	tex and dtex are linear density, not volume density: 1 tex = 1 g/km and 1 dtex = 1 g/10000 m. A length conversion requires measured total relevant filament length and matching fineness; bale count, area and length alone never imply kg. Use actual mean net bale mass M measured by cp_output for count-to-mass, m=n*M, with configuration and spread retained.
formulations	finish and additive inputs	Mass	kg	Whole purchased wet formulation is the external input. Active fraction and carrier water are subledgers, not extra purchases; onsite blending uses actual individual ingredients, mixing energy and losses. Distinguish chip-borne additives from new additions.
raw_conversion	liquid/gas and energy measurements	Mass; energy	kg; MJ	Before normalize_period, convert actual integrated volumes using independently supported composition/density at stated conditions, or integrate rates over duration. An already integrated volume is never multiplied by time again. Electricity MJ = measured kWh * 3.6; count energy once. Steam mass/enthalpy and condensate are paired, not a second heat purchase.

5. System Boundary

Boundary Abstraction

Field	Value
declared_starting_condition	Purchased virgin fibre-grade PET chips and actual separately acquired finishes/utilities/packaging at plant receipt; no onsite polymer synthesis
starting_condition_role	Foreground gate-to-gate polymer-to-fibre conversion with separately linked upstream suppliers
product_classification_scope	Only the stated uncarded virgin PET cut-staple route within CPC 35510; not whole-leaf coverage
recursive_input_rule	Tow in cans and internal PET returns are tracked physical transfers with inherited burdens, not purchased fibre or additional Q. Purchased staple/tow changes this starting condition and requires review.
upstream_dataset_requirement	Compatible actual virgin fibre-grade chip, finish formulation, packaging and utility providers; a broad flow UUID establishes identity only, not a supplier or cradle-to-gate quantity
disclosure	Declare stages, can-tow residence, actual energy/finish systems, quality gate, full period, moisture/finish basis, WIP burdens, included warehouse/dispatch ledger scope, actual geography and upstream gaps

rule_id	applies_to	rule	source_ids
boundary_route	pet_staple	Include chip receipt/conditioning, extrusion/filtration/spinning, quench/finish/can handling, creeling/drawing/crimping/drying/final finish, cutting, baling and unique production release. Keep substage meters and internal tow transfers within the connected process.	jrc-polymers-2007; neumag-staple-2023
boundary_services	pet_staple	Retain all attributable actual utilities, start/stop/failed-run energy, cooling/air preparation, abatement, cleaning, packaging, handling and rework. Add a specific atomic card for every real fuel, cleaning chemical, replacement part, waste or measured emission not already listed. Conditional rows are absent only with recorded nonoccurrence, not presumed zero.	jrc-polymers-2007; epa-synthetic-fibres
boundary_release_and_storage	pet_staple	The terminal quantity gate is new production release, not net delivery. In the production ledger Q already contains every newly released bale, including bales still in closing finished-goods stock: never add that stock again as production output. Keep a separate finished-goods warehouse/dispatch mass and carried-burden ledger, including opening/closing stock, returns and actual included storage/packaging/handling/dispatch services. Reconcile release+opening FG+returns=dispatch+closing FG+documented withdrawals on one mass basis. Cancel internal release/receipt and their inherited burden on consolidation; do not cancel real service burdens. Attribute those services to the matching release cohort or retained stock, and disclose unobserved future services. A delivery dataset needs a separately declared delivery Q and full FG burden carry-over; no equality of release and delivery is assumed.
boundary_reaction_water	pet_staple	This chip-fed remelt route has no inherent polymerisation reaction-water output. Separate chip/finish water, bath water, condensate and physical evaporation from any independently evidenced hydrolysis/degradation species and water consumed/formed. Do not introduce PTA/MEG synthesis, polymerisation-water factors, COD species, or a pair of unknown reaction water and unknown outlet fitted to the same residual. A material change to an integrated synthesis route requires scope review.	jrc-polymers-2007; epa-synthetic-fibres
boundary_excluded	pet_staple	Foreground excludes virgin chip synthesis, recycled-flake preparation, melt-direct polycondensation, fibre carding/combing, yarn/monofilament/strip production, textile conversion, use and end of life. Declare transport legs and capital/infrastructure treatment explicitly; upstream coverage is required before any cradle-to-gate claim.	jrc-polymers-2007; epa-synthetic-fibres

6. Process Inventory Structure

Process Map

process_id	process_name	inclusion	inclusion_condition	role	quantitative_reference
pet_staple	Connected chip-to-uncarded-staple manufacture	required	Declared virgin PET chip-fed can-tow route	Retain every substage record and internal tow mass/burden handover	per 1 kg reference flow

Process: Chip-to-uncarded-staple manufacture (pet_staple)

Retain physical records and accumulated burdens for every intermediate tow, bath and same-cohort rework; cancel internal handovers within the connected boundary. Conditional utility/packaging cards do not assert universal occurrence; real distinct formulations, fuels, packaging, controlled species and destinations require individual atomic rows.

Inputs

Product flows

Virgin fibre-grade PET chips (pet_chips)

Purchased virgin PET homopolymer chips, with actual supplier grade, IV, delustrant/additive content, crystallinity and moisture certified. The native identity is generic PET granulate: CAS, grade, virgin status, route, mix and supply geography are unspecified, not inferred. Bottle-grade and fixed-purity candidates are not substituted. All chip constituents enter once as supplied; no monomers or inherited additives are procured again.

• Selected flow: polyethylene terephthalate (PET) granulate 4f19f119-7b3b-11dd-ad8b-0800200c9a66
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_feed
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Metered purchased electricity (electricity)

Collect actual electricity for receipt, chip crystallising/drying, extrusion, filtration, spin manifold, quench-air conditioning, tow cans, drawing, crimping, drying, cutting, baling, controls, compressors, abatement and declared lot-linked handling/storage/dispatch. Record stage subledgers; no catalogue power or successful-run-only estimate. Specify voltage, supplier and geography before background matching.

• Selected flow: Electricity
• Flow property / unit: Energy / MJ
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_utilities
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Purchased process steam (steam)

Conditional on real imported steam for tow drawing/heating/drying. Meter supply mass and enthalpy conditions and returned condensate separately. Internally generated steam is an internal utility; count its actual external fuel and water and emissions instead of a second purchased steam burden.

• Selected flow: Steam
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_utilities
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Process make-up water (water)

Actual purchased deionised water for onsite finish dilution, drawing baths or cooling make-up, if used. Record each destination; recirculating volumes are not new intake. Carrier water already bought in either finish emulsion is a constituent subledger, not this second purchase. Other water qualities require their own atomic rows.

• Selected flow: Deionised water
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_utilities
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Purchased spin-draw finish formulation (spin_finish)

One actual commercial aqueous spin-draw finish supplied to the spinning/tow preparation stage. Record whole wet supplied formulation, supplier identifier, assayed active fraction and carrier water. No generic recipe, active-only procurement or duplicate water. If compounded onsite, replace this purchase with separately acquired actual ingredients and collect mixing energy and losses.

• Selected flow: Aqueous PET spin-draw finish emulsion
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_finish
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Purchased final-finish formulation (final_finish)

One actual customer-specified final-finish formulation applied after tow drying before cutting. Record the full commercial formulation independently of spin-draw finish. If one supplied formulation serves both points, split metered issues between stages and reconcile their sum to one procurement total.

• Selected flow: Aqueous PET final-finish emulsion
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_finish
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Purchased nitrogen (nitrogen)

Only where an actual inerting or blanketing circuit imports nitrogen. Record purity, gas state, meter pressure/temperature and normal-volume definition. Never assume a nitrogen demand from the general process diagram.

• Selected flow: Nitrogen gas
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_utilities
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Bale wrapper (bale_wrap)

Conditional actual PP woven bale wrapper, weighed separately from fibre Q. Measure waste and replacement wrapping as well as accepted-bale wrapping; another wrapper construction requires its own specific row.

• Selected flow: Woven polypropylene bale wrapping cloth
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_pack
• Sources: jrc-polymers-2007

Bale strapping (bale_strap)

Conditional actual steel strap, net issued mass with cut-offs and re-strapping retained. Do not infer the strap composition from a bale count or omit packaging because Q excludes tare.

• Selected flow: Steel bale strapping
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_pack
• Sources: jrc-polymers-2007

Baler hydraulic-oil make-up (hydraulic_oil)

Conditional actual mineral hydraulic oil purchased for the bale press. Use measured make-up and oil-stock changes, distinguish retained oil, spills and exported spent oil, and add other real lubricants as separate rows.

• Selected flow: Mineral hydraulic oil
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_feed
• Sources:

Replacement melt filter (new_filter)

Actual consumed stainless-steel melt filter, matched to replacement and stock records; distinguish reusable cleaned filters from purchased replacements. Polymer retained in spent filters belongs to its measured waste subledger.

• Selected flow: Stainless-steel melt filter
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_feed
• Sources: jrc-polymers-2007

Waste flows

Elementary flows

Outputs

Product flows

Newly released uncarded PET staple (pet_staple)

Terminal Product output: virgin PET textile staple, industrial route, production mix at factory. It is uncarded and uncombed, monocomponent, undyed, solid round-section, drawn/crimped/cut and finished, newly released against the actual buyer specification, net of all wrapping/straps. The native record declares 100% virgin material and textile-fibre industrial production mix at factory; CAS and geography/locationOfSupply are not declared. It specifies no chip route, cut length, fineness, moisture or finish. Declare these independently; no CN/HK or universal provider is inferred. Native descriptive remarks are not recipes or numeric acceptance criteria.

• Selected flow: Polyester short fiber 03377e13-45a0-4774-9cc8-37c8c60523f2
• Flow property / unit: Mass / kg
• Amount rule: 1 kg
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_output
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Returned steam condensate (condensate)

Conditional actual condensate crossing back to the steam supplier, measured separately with temperature and quality. Do not count internal recirculation as export or apply a substitution credit without a compatible supplier boundary.

• Selected flow: Steam condensate
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_utilities
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Waste flows

Extruder purge (pet_purge)

PET melt purge and start-up strand material actually exported as waste; record composition, moisture and destination. Internal remelt returns are tracked loops and not this external waste a second time.

• Selected flow: PET extrusion purge waste
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Rejected fibre and captured PET dust (offspec_fibre)

One PET fibrous waste stream removed from the line, including captured same-polymer dust only if actually managed together. Distinct waste destinations/compositions need separate rows. Reworked fibre retains burden and does not become waste until it leaves the foreground.

• Selected flow: Off-specification PET staple fibre waste
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Exported finish-bearing wastewater (wastewater)

Conditional actual wastewater sent to external treatment after measured onsite handling. Record wet mass, dissolved/dispersed constituents and treatment destination; COD is a treatment indicator, not a chemical species or a reaction-water estimate. Onsite treatment needs its own real energy, chemicals, sludge and species rows.

• Selected flow: PET fibre spin-finish wastewater
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Spent melt filter (spent_filter)

Conditional discarded stainless-steel filter with its measured retained PET; count replacement filters as separate actual product inputs when consumed, including their composition and stock. Filter cleaning consumables and emissions are additional atomic exchanges if present.

• Selected flow: PET-contaminated stainless-steel melt filter
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Spent baler oil (spent_oil)

Conditional exported spent hydraulic oil, separated from fibre/finish wastewater. Reconcile equipment oil stocks and any measured spills; no arbitrary loss percentage.

• Selected flow: Spent mineral hydraulic oil
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources:

Elementary flows

Physical water evaporation (water_vapour)

Measured physical water release from chip drying, finish carrier water and any real drawing bath/dryer. Quantify independently of unidentified outlets; account product moisture and liquid discharge. Purchased-polymer remelting creates no inherent polymerisation reaction water.

• Selected flow: Water vapour to air
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources: jrc-polymers-2007; epa-synthetic-fibres

Residual PET dust after capture (pet_dust_air)

Only independently identified and measured PET particulate emissions after actual abatement, distinct from captured waste. Measure actual finish aerosols and volatile species separately where present; never assign unknown aerosol composition to PET or invent an emission factor.

• Selected flow: PET particulate matter to air
• Flow property / unit: Mass / kg
• Amount rule: A_j/Q as one reporting normalization; A_j is the raw actual-period numerator from this card protocol after physical conversion and burden roll-forward, still un-divided, and Q is unique new-release net mass.
• Value mode: foreground_record
• Specificity: site_specific
• Normalization basis: per 1 kg reference flow
• Basis kind: reference_flow
• Evidence kind: collected_record
• Collection protocol: cp_residual
• Sources: jrc-polymers-2007; epa-synthetic-fibres

7. Allocation and Co-product Handling

rule_id	applies_to	rule	source_ids
allocation_internal	pet_staple	Prevent allocation by treating tow, finish recirculation, reusable cans and same-lot rework as internal transfers. Track their masses and accumulated burdens. A returned released bale is not new production when inspected or repacked; retain original release identity and add actual incremental rework burden.
allocation_shared	pet_staple	Submeter or subdivide shared utilities and warehouse services first. If unavoidable, use a documented physical causal driver such as measured equipment time/load, actual processed mass or measured occupied bale-days, specific to the service. Retain complete site totals and allocation to other products/old FG, not just this successful output. Do not invent a universal yield, operating load or draw ratio.	jrc-ilcd-allocation-2010
allocation_waste	pet_staple	No automatic avoided-virgin credit for PET waste, captured dust, condensate or packaging. Determine actual waste/product status, destination and any genuine coproduct independently; apply a disclosed compatible allocation/treatment convention without omitting waste burdens or changing reference Q.

8. Foreground Data Collection, Calculation, and Quality Rules

Data Collection Protocols

protocol_id	process_id	flow_role	record_type	raw_fields	collection_method	unit	frequency	temporal_coverage	site_scope	aggregation_rule	quality_evidence
cp_output	pet_staple	Unique release and mass	release/weighing/test records	lot_id; first_release_id; prior_release_id; gross; tare; net; moisture_wet_basis; retained_finish; polymer_fraction; cut_length; dtex; crimp; tenacity; elongation; acceptance; time; M; bale_configuration	Owner: production quality manager. Calibrated weighing at first release after cutting/baling, with real moisture and retained-finish assays on matching lots; subtract wrappers/straps. Identify previously released returned mass so it cannot enter new Q. Collect M and distribution by configuration when counts are used. Retain raw masses and tests only, without division. Aggregation context: Sum unique positive newly released net mass as Q; final reporting uses normalize_period once per 1 kg reference flow. aggregation_rule labels the final report basis, not division during collection.	kg; kg/kg; dtex; mm	each lot/release	Matched full period; release cohort	Factory production release; buyer specification	per 1 kg reference flow	Calibration, tare tests, assay method, lot acceptance and duplicate-release audit
cp_feed	pet_staple	External solid materials and oil	issue/return/stock ledger	material_id; supplier_grade; lot; opening; receipts; unused_returns; closing; wet_mass; moisture; composition; stage; filter_replacement; oil_makeup	Owner: materials accountant. Weigh actual chip/filter/oil issues and unused returns, reconcile receipt and stock, link certificates and stage/lot. Include start-up, failure and rework issues, not only good runs; independently retain water/additive subledgers. No A/Q in collection. Aggregation context: Retain raw net external use and stage totals; carry into cp_burden, then normalize_period once per 1 kg reference flow. aggregation_rule labels the final report basis, not division during collection.	kg	each issue and stock close	Full period including zero-output runs	Receipt to connected fibre line	per 1 kg reference flow	Supplier certificate, scale, stock reconciliation, replacement log
cp_finish	pet_staple	Actual finish formulations	commercial formulation and dosing ledger	formulation_id; supply_lot; wet_issue; return; active_fraction; carrier_water; bath_opening; bath_closing; dilution_water; dosing_point; retain; discharge; mixing_energy	Owner: finish preparation supervisor. Meter each whole supplied emulsion and destinations at both application points; assay active and water, reconcile retained finish, bath stocks and effluent. Onsite mixing records each separately purchased ingredient and losses. Do not count carrier/active masses as new procurement. Retain raw records, no division. Aggregation context: Sum each actual external formulation once; route raw totals through cp_burden and normalize_period once per 1 kg reference flow. aggregation_rule labels the final report basis, not division during collection.	kg; kg/kg; MJ	each supply/dose and period close	Full matched period and bath carry-over	Spin-draw and final-finish circuits	per 1 kg reference flow	Supplier/SDS identity, assays, dosing/stock and wastewater reconciliation
cp_utilities	pet_staple	Stage utility burdens	meters and service records	stage; carrier; supplier; geography; voltage; opening_meter; closing_meter; time; rate; integrated_volume; temperature; pressure; density; purity; steam_enthalpy; condensate; runtime; other_product_share	Owner: utilities engineer. Capture complete measured stage and site totals including drying/air preparation, compressor, heating, abatement, failed batches, idle/changeover and rework. Distinguish utility import from internal generation/recirculation; document allocation. Convert raw units with convert_raw, but collect no normalized values. Aggregation context: Raw attributed totals with shared-service allocation retained; cp_burden then normalize_period once per 1 kg reference flow. aggregation_rule labels the final report basis, not division during collection.	kWh; MJ; kg; m3; h	continuous meters plus each batch	Entire matched period, shutdown and restarts included	Declared facility services and real providers	per 1 kg reference flow	Meter calibration, bill reconciliation, density/enthalpy basis and allocation evidence
cp_pack	pet_staple	Packaging and finished-goods services	issue/weighing and warehouse ledger	lot; wrapper; strap; net_issue; offcut; rewrap; first_release; opening_FG; closing_FG; dispatch; returns; withdrawal; inherited_burden; storage_days; handling_energy; dispatch_energy; service_cohort	Owner: packaging/warehouse manager. Weigh each packaging component and actual waste. Maintain a separate FG mass/burden ledger and meter real included storage, handling, dispatch and repacking by cohort; do not assume deliveries equal releases or add FG closing stock to production output. Preserve raw totals and opening-stock burden. Aggregation context: Retain raw cohort totals; eliminate internal handovers once on consolidation; cp_burden then normalize_period once per 1 kg reference flow. aggregation_rule labels the final report basis, not division during collection.	kg; MJ; bale-day	each pack/transfer and period close	Full period with explicit release and service cohorts	Pack-out and declared onsite FG services	per 1 kg reference flow	Tare/component measurements, FG reconciliation, service drivers and burden transfers
cp_residual	pet_staple	Atomic residuals and species	waste manifests/sampling	stream; species; medium; wet_mass; water; polymer; finish; filter_metal; concentration; sample_time; integrated_flow; dry_wet_basis; abatement; destination; internal_return; reaction_evidence	Owner: environmental engineer. Weigh waste streams and sample actual outlet species/compartments; preserve sampling coverage and outlet flows. Measure phase water independently; identify actual reaction species only with independent evidence. Record captured and residual emissions separately, with no COD-to-species or closure-residual fitting. No collection normalization. Aggregation context: Retain raw stream totals and uncertainty; cp_burden then normalize_period once per 1 kg reference flow. aggregation_rule labels the final report basis, not division during collection.	kg; m3; kg/m3	each event and representative sampling	Full period including starts, failures and cleaning	Every actual outlet after onsite control	per 1 kg reference flow	Weighbridge/manifests, assay/sampling plan, species evidence and treatment boundary
cp_burden	pet_staple	Period WIP, failure and stock burden reconciliation	linked mass and burden ledger	period; run_id; stage; lot; opening_WIP; closing_WIP; opening_carried_exchange; closing_carried_exchange; zero_output_runs; rework_transfer; FG_transfer; other_outputs; actual_period_exchange; released_cohort_services	Owner: LCI accountant, reconciled with production and warehouse owners. Preserve every raw numerator by stage and cohort, plus opening/closing WIP and FG carried burdens. Carry closing WIP forward and consume opening burden once when released. Failed/zero-output runs and rework remain assigned or transparently carried to the matching product; never dropped or double counted. Collect un-divided amounts only; do not execute A/Q here. Aggregation context: Preserve reconciled raw A_j and Q separately for normalize_period; final basis per 1 kg reference flow, no prior division. aggregation_rule labels the final report basis, not division during collection.	kg; MJ; exchange-specific units	each transfer/run and period close	Full campaign across relevant period boundaries	Connected line plus separately bounded FG services	per 1 kg reference flow	Mass/burden roll-forward, stage records, failure log, allocation and cohort reconciliation

Calculation Rules

rule_id	Applies to	Formula or rule	Inputs	Output	source_ids
convert_raw	all inventory rows	Convert raw physical quantities to each row unit before normalization: electricity MJ=3.6kWh; liquid mass=integrated_volumemeasured_density; gas mass uses actual composition and stated pressure/temperature basis; rate totals=sum(rate*duration). Never multiply integrated volume by duration.	raw_quantity; density; composition; temperature; pressure; duration; cp_utilities	converted raw quantities
release_q	pet_staple	Q=sum(unique first-release accepted net fibre kg), with measured residual water/finish included and packaging tare excluded. Count released material once even if later returned, reworked, repacked or reaccepted. Q>0 is required for reporting; zero-output periods retain all raw burdens for explicit matched-cohort carry-over.	accepted_net_mass; first_release_id; prior_release_id; cp_output	Q
burden_rollforward	all inventory rows	For each exchange j, assemble raw A_j=actual attributed period exchange+opening WIP carried exchange-closing WIP carried exchange, with documented attribution to other real outputs where needed. Internal transfers/rework cancel, not their incremental burdens. Add only matched-cohort FG service increments from the separate ledger; do not import old FG production burdens into new-release Q. Every closing burden has one next-period receiver.	actual_period_exchange; opening_carried_exchange; closing_carried_exchange; FG_service_increment; cp_burden; cp_pack	A_j
normalize_period	all inventory rows	q_j=A_j/Q is the sole reporting normalization to per 1 kg reference flow. All protocols supply un-divided raw numerators, after convert_raw and burden_rollforward. Card amount formulas and aggregation references describe this same operation, not successive divisions. Terminal pet_staple=Q/Q=1 kg.	A_j; Q; cp_burden; cp_output	q_j
physical_reconciliation	all inventory rows	For each constituent separately, opening process stocks+external inputs=Q constituent+other measured external Product outputs+external wastes/emissions+closing WIP/process stocks, after cancelling internal transfers. Include returned condensate in the non-reference Product-output subledger. Record measured packaging carried with released bales as a separate physical output/subledger excluded from net fibre Q; count that packaging once without creating extra fibre output. Q already contains newly released FG stock, so do not add closing FG in this production equation. Use a separate FG equation under boundary_release_and_storage. Reconcile PET, finish active, water, filter metal and packaging separately, and relevant elements from actual species assays; disclose measurement uncertainty and unexplained difference rather than fit unknown reaction water or outlet.	raw_materials; Q; waste; emissions; opening_stocks; closing_stocks; cp_residual; cp_burden; other_outputs; released_packaging; cp_utilities; cp_pack	constituent and elemental reconciliation
moisture_and_regain	pet_staple	For the same weighed lot, D=m*(1-w); m_water=mw; polymer=D-measured_nonwater_finish-other_measured_nonpolymer_constituents. R=m_water/D. Any contractual mass D(1+R_standard) is separately labelled and cannot silently replace as-released Q; no universal w, finish fraction or R_standard is supplied.	net_mass; w; finish_nonwater; nonpolymer_constituents; cp_output	D; m_water; polymer; R

Data Quality Requirements

requirement_id	Applies to	Requirement	Evidence
identity	all inputs and reference	Verify actual polymer, virgin chip route, full supplied formulations and finished uncarded form against certificates. UUID broad identity never supplies absent geography, grade, water, oil or quantities.	Supplier certificates; native fields; lot acceptance
period	all inventory rows	One complete matched period/cohort; failed starts, zero output, rework, WIP and FG burden transfers are explicit. No successful-batch-only denominator or omitted negative balance.	cp_output; cp_burden; cp_pack
measurement	all measured quantities	Retain raw units, calibration, tare, assays, density/state, substage utility totals, uncertainty and any shared-service driver. Missing measurement remains a concrete-data gap, never an invented default.	Raw meter and lab records
completeness	all physical outlets	Identify every actual stream and species; distinguish physical water from reaction chemistry, purchased formulations from constituent subledgers, capture from release and internal circulation from external supply.	Mass/element balance and outlet evidence

9. Validation Rules

rule_id	applies_to	rule	source_ids
validate_identity	pet_staple	Reject filament yarn, monofilament/strip, sold tow, carded/combed fibre, recycled or non-PET feed, hollow/bicomponent/dope-dyed fibre and integrated-polymerisation substitution within this route. Check actual cut staple and reference row pet_staple against the reference UUID in both languages.	jrc-polymers-2007; epa-synthetic-fibres
validate_denominator	all inventory rows	Require unique positive new-release Q, actual as-released wet/finish basis, tare exclusion and once-only normalization. Reject use of delivery mass, added closing FG production, repeat returns/reacceptance output, or count/area/length conversions without measured mass evidence.
validate_burden	all inventory rows	Require full period, failed/zero-output burdens, WIP/FG carry-over and independent protocols with raw undivided numerators. Closing burden must roll forward once, opening burden must be consumed once, and real included warehouse/dispatch/packaging/rework burdens must survive internal elimination.
validate_physical	all material rows	Check complete wet/dry/finish and relevant elemental closure with independently evidenced outlet species; no inherent remelt polymerisation water, COD species, duplicated formulation/carrier procurement or residual-fitting. Distinguish linear from volume density and integrated volume from a rate.
validate_native	all UUID-bearing rows	Preserve complete native identity restrictions in consumable card descriptions. Supplier, grade, geography, route and measurement compatibility require actual evidence. Blank auxiliary UUIDs require later matching, not fabricated certainty or a replacement final reference.

10. Published Dataset Profile

Field	Value
dataset_role	secondary_dataset; background_dataset
downstream_use	Qualified input to fibre preparation, yarn or nonwoven models after provider/basis matching
allowed_use	Declared 1 kg production-release uncarded virgin PET staple for this chip-fed route
excluded_use	Whole CPC coverage, use-life equivalence, delivery-Q equivalence, other polymers/routes and scientific-approval claims
required_metadata	All required qualifiers; exact boundary/services; Q and period; upstream providers; units; allocation; WIP/FG burden ledger; moisture/finish; geography
required_quality_disclosure	Raw-data completeness, uncertainty, unobserved future services, provider gaps and independent scientific review pending
update_trigger	Polymer/grade/virgin status, route, finish, moisture/reference gate, site/services, supplier or measurement change

11. Data Sources

source_id	type	reference	used_for
jrc-polymers-2007	official_guidance	https://bureau-industrial-transformation.jrc.ec.europa.eu/sites/default/files/2019-11/pol_bref_0807.pdf	August 2007, §§10.2.6–10.2.7, printed pp.167–168 (PDF193–194), Figures10.7–10.9: chip conditioning and can-tow spinning/finishing/cut/bale sequence. No temperature, recipe, yield, moisture or performance values adopted.
epa-synthetic-fibres	official_guidance	https://www.epa.gov/sites/default/files/2020-10/documents/c06s09_0.pdf	AP-42 §6.9, 9/90 reformatted1/95, §6.9.2.1 and Figure6.9-2, PDF2–3: independent melt-versus-solvent route and staple-versus-tow/yarn distinction; actual oil/aerosol controls require collection. No generic emission factors, fixed filament counts or plant recipe adopted.
neumag-staple-2023	handbook	https://www.oerlikon.com/ecoma/files/DL_ONE_Staple_Fiber_Technology_2023_en.pdf?download=true	2023 manufacturer brochure, printed p.2 “The idea” on PDF2 spread: industrial extrusion/spinning/drawing/crimping/cutting/baling steps only. Other one/two-step and integrated-polycondensation systems, marketing savings and capacities are not the selected factory/SKU or numeric defaults.
jrc-ilcd-allocation-2010	official_guidance	European Commission JRC, ILCD Handbook: General guide for Life Cycle Assessment — Detailed guidance, First edition March2010, section7.9.3, printed pp.257–258 (PDF277–278); https://eplca.jrc.ec.europa.eu/uploads/ILCD-Handbook-General-guide-for-LCA-DETAILED-GUIDANCE-12March2010-ISBN-fin-v1.0-EN.pdf	Method support for attributional cases where allocation rather than substitution is selected: virtual subdivision and flow-specific determining physical causality support the measured shared-utility and warehouse-service allocation rule. The process literature supplies manufacturing context, not this LCA method. No generic mass/time share, economic coefficient, production/yield/utility factor, substitution credit or PEF/CFF conformity is established; actual service-specific drivers, site totals and cohort attribution remain required.