Our Process
CYCLO® recycled fibers are mechanically recycled in a process that does not use any water, dyes or chemicals.
Sourcing
We use the cutting waste from garment manufacturers, as our raw material. We source the waste directly from manufacturers and dedicated traders. Since we do not dye our fibers or yarns, the color of the waste determines the color of the yarn. Our dedicated procurement team works closely with our network of manufacturers and traders to source the shades that our customers are looking for. If an exact match is not available, we blend different shades together later in the process.
STEP 1
Sorting
The sourced waste is delivered to our factory premises, where it is manually sorted, particularly to separate shades within the color family. At the same time it is checked for quality and any contaminants that may be there are removed.
STEP 2
Recycling
The sorted waste is then processed in the recycling machine, where the fabrics are opened and the yarns are shredded into recycled cotton fiber. The fiber is pressed into bales and transferred to the blending section. This mechanical process requires no chemical.
STEP 3
Blending
The recycling process shortens the cotton fiber, so we blend it with another fiber to ensure sufficient strength and quality. We always recommend other more sustainable fibers such as recycled polyester, viscose, acrylic, EcoVera™ or Tencel™. The final composition depends on the yarn: the coarser the yarn, the higher the percentage of recycled cotton. All our yarns are at least 50% recycled cotton. During this blending process we also blend for color, combining different shades of fiber to match the required shade as closely as possible.
STEP 4
Spinning
The blended fibers are spun into yarn using a specialised open-end spinning process. Open-end spinning allows for the maximal use of recycled fibers and uses less energy per kg (less CO2) s opposed to traditional ring spinning. First the fibers are loosened in the blow room, the fiber is carded to remove naps, impurities and fibers that are too short to be processed into finer yarns (not to worry – this waste is recycled again and used for coarser yarns!). The fibers come out in continuous bundles called sliver. In the drawing process, the fibers inside the sliver are aligned and the sliver thickness is equalized. Finally, the sliver is fed into the open-end spinning machine, in which it is rotated at high speed and spun into yarn.
STEP 5
Doubling/Twisting
Depending on the customer’s requirement, the yarns can be doubled or twisted together to create coarser yarns and to create different color combinations within the same yarn.
STEP 6
Delivery
The final product is the least environmentally taxing yarns available in the market. These brand new, colored yarns, produced without using water, dyes or chemicals are ready to be used by our customers to create a wide variety of products!
STEP 7
