The solid state polymerization (SSP) of poly(ethylene terephthalate) was studied experimentally over a wide range of pellet sizes and temperatures. A comprehensive model was developed. It considered polycondensation, degradation and polycondensation of vinyl end groups together with diffusion. The reaction rate constants, diffusivities and the corresponding activation energies were obtained through parameter identification using experimental data. The effects of the reaction temperature and pellet size on the SSP time were also investigated. A decrease in the particle size decreases the concentration of the vinyl end groups and narrows the concentration distribution of end groups inside poly(ethylene terephthalate) particles. A decrease in the size of pellets also favors diffusion. Nevertheless it is preferable that the size of pellets be between 1 and 2 mm because too small pellets bring about difficulties with preparation and handling. (c) 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013