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Random freezes, missing sound and display glitches usually trace back to one bad driver. Find and replace yours safely.Free scan · under a minuteThere is no universal bottle count. Published studies report anywhere from 63 to 111 bottles for 1 kg of finished filament, because bottle weight, usable yield and conversion method differ. A 2025 measurement of 9.45 g of filament from each 35 g bottle implies about 106 bottles per kilogram, while the same paper separately gives an estimate of 63 bottles. Treat these as study-specific results, not a standard yield.
Why the answer changes
The calculation must use usable filament output, not simply the mass of bottles collected. The basic equation is:
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Estimated bottles per kilogram = 1,000 g ÷ usable filament grams per bottle.
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A bottle’s nominal capacity is not its mass. One 2024 study measured bottles averaging 14.55 g, while a separate 2025 study used 1.5 L bottles averaging about 35 g. Caps, rings, labels, glue and contaminated sections may also be removed before processing, so bottle mass and finished-filament mass are different denominators.
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Published bottle counts and what they actually measure
| Source and method | Reported bottle or yield data | What it implies for 1 kg of filament | Important qualification |
|---|---|---|---|
| Journal Online of Physics study (2026 search result), pultrusion | 63 PET bottles of 1.5 L; about 23 minutes’ conversion time per bottle; 205 °C and 45 RPM are reported operating conditions | 63 bottles, according to the study’s estimate | This is the paper’s estimate under its machine and operating conditions. |
| Jurnal Otomasi Kontrol dan Instrumentasi (2025) | Each 35 g bottle produced 7 m and 9.45 g of filament; 28 bottles were described as approximately 1 kg of plastic input | About 106 bottles by arithmetic: 1,000 ÷ 9.45 | The paper also gives an approximately 63-bottle estimate, which does not reconcile with its stated per-bottle yield. Do not combine the figures as if they were one measurement. |
| Semesta Teknika (2024) | 14.55 g bottle mass and 9.07 g filament output per bottle; reported 38% weight reduction | 111 bottles per kilogram, as reported | The article also says 1 kg of bottle waste contains 69 bottles. Its resulting filament is reported at 1.7 mm, with nozzle and quality improvements still needed. |
These numbers cannot be ranked as a universal “best” result. They use different equipment, feed preparation and definitions of usable output. The 2026 pultrusion estimate, the bottle-strip route and flake extrusion are not a controlled head-to-head comparison.
Feedstock kilograms are not filament kilograms
The distinction is easiest to see in the 2025 study: a 35 g bottle yielding 9.45 g of filament means the finished product is only part of the collected bottle mass. Applying that measured yield gives roughly 106 bottles for 1 kg of filament, while 1 kg of bottle input would contain roughly 28 such bottles. Those are answers to two different questions.
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The same issue appears in the 2024 result: 69 bottles per kilogram refers to bottle waste, whereas 111 bottles refers to the reported amount needed for 1 kg of filament. Never substitute the feedstock count for the finished-filament count.
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Bottle-strip processing
In a strip workflow, a clean bottle is cut into a continuous strip and pulled through a heated nozzle. An Indonesian laboratory design describes 10 mm strips and a 1.75 mm nozzle. A current Filament Maker V2 product page likewise describes cutting a clean strip and advertises 1.75 mm output, but its figures are manufacturer specifications rather than independent tests: up to 92 g/h, bottles of 1 L or larger and 48 W power draw. See the manufacturer’s details at Sustainable Design Studio.
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Shredded-flake extrusion
A flake route requires substantially more preparation. The 2025 Springer study removed labels, caps and rings, washed and air-dried the bottles, then shredded and sieved them. It dried the flakes at 140 °C for five hours before extrusion, explaining that residual moisture can cause hydrolytic degradation. This is that study’s laboratory protocol, not a guaranteed home recipe. The reported process is documented in Discover Mechanical Engineering.
Another batch result in the same research area converted 12 recycled 1.5 L bottles into 200 g of PET flakes and about 30 m of usable filament. That is a yield for the paper’s equipment and workflow, not enough information to establish a universal bottle-per-kilogram figure.
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A practical way to estimate your own count
- Weigh a representative bottle sample. Record empty-bottle mass after removing parts your process will reject.
- Run a measured batch. Weigh the actual filament that meets your diameter and quality requirements; do not count offcuts or failed sections as usable output.
- Calculate the yield. Divide 1,000 by your measured filament grams per bottle.
- Repeat the batch. Bottle designs, wall thickness, moisture and cutting losses can change the result, so use an average from several bottles.
- Record filament diameter. A nominal 1.75 mm or 1.7 mm result does not prove consistent diameter along the entire spool.
What the published workflows warn about
- Remove non-PET parts and wash away labels, glue and dirt before shredding.
- Dry PET thoroughly; moisture can damage the polymer during extrusion.
- Expect process-specific quality. The 2024 study notes nozzle and filament-quality limitations, and the Indonesian laboratory article says printer configurations should match PET.
- Do not assume recycled PET filament is automatically equivalent to commercial PETG or ready for every printer.
- Compare methods using the same questions: bottle mass, usable grams per bottle, strip versus flake feed, drying requirements, diameter control, processing time and energy.
Costs and throughput in context
An Indonesian Journal of Laboratory article compares commercial filament priced at Rp 200,000–275,000 per kilogram with an estimated production cost of about Rp 60,000 per kilogram for recycled PET filament. Those are source-specific Indonesian figures, not current worldwide prices or a guarantee of savings after labor, electricity, failed prints and equipment are included. The product-page throughput of up to 92 g/h is likewise a manufacturer claim, not an independent performance benchmark.
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So, how many bottles should you plan for?
For planning, use a range rather than one headline number: published results span 63 to 111 bottles per kilogram of finished filament. If your bottles resemble the 35 g bottles that yielded 9.45 g each, start with the arithmetic estimate of about 106 bottles and validate it with your own batch. If you are using a different bottle design or a strip and nozzle system, measure again; the published 63-bottle pultrusion estimate cannot be transferred automatically.
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