Currently, the inappropriate disposal of plastic materials, such as polyethylene terephthalate (PET) wastes, is a major environmental problem since it can cause serious damage to the environment and contribute to the proliferation of pathogenic microorganisms. To reduce this accumulation, PET-type bottles have been recycled, and also explored in other applications such as the development of membranes. Thus, this research aims to develop electrospun microfiber membranes from PET wastes and evaluate their use as an air filter media. The solution concentrations varied from 20 to 12% wt% of PET wastes, which caused a reduction of the average fiber diameter by 60% (from 3.25 µm to 1.27 µm). The electrospun filter membranes showed high mechanical resistance (4 MPa), adequate permeability (4.4 × 10⁻⁸ m²), high porosity (96%), and provided a high collection efficiency (about 100%) and low-pressure drop (212 Pa, whose face velocity was 4.8 cm/s) for the removal of viable aerosol nanoparticles. It can include bacteria, fungi, and also viruses, mainly SARS-CoV-2 (about 100 nm). Therefore, the developed electrospun membranes can be applied as indoor air filters, where extremely clean air is needed (e.g., hospitals, clean zones of pharmaceutical and food industry, aircraft, among others).

Air pollution and solid pollution are considered global problems, and endanger human health mainly due to the emission of fine particulate matter released into the atmosphere and improper disposal of post-consumer plastic bottles. Therefore, it is urgent to develop filter media to effectively protect the public. The properties of plastics make them potential candidates for nanofiber mat formers due to their attractive structural and mechanical characteristics. This work aims to produce and evaluate novel PET electrospun fibers dispensed with the use of support materials to be used as filter media to remove nanoparticles from the air. The electrospinning process was carried out by changing the concentration of the polymer solution, the needle diameter, and the electrospinning processing time at two rotation speeds. The average diameters of the micro- and nanofibers of the filter media produced ranged from 3.25 μm to 0.65 μm and it was possible to conclude that, as the size of the fibers decreased, the mechanical strength increased from 3.2 to 4.5 MPa. In filtration tests, a collection efficiency of up to 99% with low-pressure drops (19.4 Pa) was obtained for nanoparticles, demonstrating high quality factor filter media, which could be applicable in gas filtration.

Although recycled poly(ethylene terephthalate) (rPET) is an attractive, sustainable feedstock for electrospinning, optimization of processing variables for filtration performance remains limited. This study quantifies how polymer concentration, flow rate, and applied voltage govern fiber morphology and key filtration metrics—collection efficiency (η), pressure drop (ΔP), quality factor (Q_f), and porosity—in rPET membranes. A fractional factorial design was employed to model interactions and identify trade-offs in filtration performance. The optimal condition was obtained at 16 wt.% PET, 1.2 mL·h⁻¹, and 22 kV, yielding uniform fibers with an average diameter of 328.6 nm and high filtration efficiencies (95.65–99.99%). The permeability constants were 1.07 × 10⁻¹² m² (20 wt.% PET) and 1.15 × 10⁻¹³ m² (8 wt.% PET), indicating an increase in permeability with increasing polymer concentration and fiber diameter. The 20 wt.% PET membrane delivered the highest Q_f of 0.0646 Pa⁻¹ with a low ΔP of 48.5 Pa at 4.8 cm·s⁻¹, reflecting a favorable balance between collection and airflow resistance. In summary, higher PET concentrations reduce flow resistance and improve Q_f, whereas lower concentrations yield finer fibers and high η at the expense of permeability. rPET nanofiber membranes, therefore, represent a sustainable and versatile route to high-efficiency, lower-pressure-drop air filters for residential, industrial, and commercial environments.