Textile Waste to Fiber Pellets
The fashion industry is dealing with considerable waste and recycling issues, and we are pursuing an initiative to promote circular strategies that convert textile waste into valuable new materials in harmony with new EU regulations.
A New Approach To A Major Problem
The fashion industry is well-known for generating significant waste due to its short product lifecycles and complex material blends, which hinder recycling efforts. In Sweden alone, each year, between 42,000 and 55,000 tons of textile waste could be reused, and 39,050 to 50,050 tons could be recycled, yet most currently end up incinerated. We believe this waste results from a lack of knowledge, inadequate strategies, and insufficient technology. We dedicate a large amount of our efforts to circular strategies focusing on the fashion sector, aiming to repurpose discarded garments into unique and valuable materials and products.
The Challenge
Transforming Mixed Textiles
Engaging with key stakeholders in the fashion and textile industry, now constrained by new EU regulations on mixed textile waste disposal, has fueled our ambition to transcend basic recycling practices. We always aim for fiber-to-fiber solutions whenever possible, but it requires a consistent stream of mono-materials, which is rarely the case. We are therefore often being challenged finding alternative processes where mixed fibers can be incorporated, both organic and synthetic sources. In collaboration with forward-thinking fashion brands, we have explored the capabilities of post-consumer textile fibers, and one particular process is standing out.
The Approach
Enhance Value From Textile
Our aim is to identify a scalable, commercial process which could solve the fashion crisis in scale. It is expected that this process is more costly than other non-viable solutions the industry is used to today. Therefore, it was also important we were able to provide additional value, making this process stand out. Thanks to our partners at Circular Materials, we are able to transform these fibers into new injection-grade composites, we've successfully crafted high-quality, circular products that solves large volume mixed textile waste, while also creating unique looking products and strengthen brand identity. This process is already confirmed feasible for large volume production.
Collection and Sorting
The success of any reuse and recycling initiative is grounded in effective collection strategies. For many fashion brands, managing post-consumer clothing involves significant logistical challenges, from motivating returns to handling the collection, transportation, and sorting of garments. We typically collaborate with our collection service partners to efficiently manage this phase for our clients. An automated sorting system is also being used in this process, removing all contaminants, including metals, to ensure a smooth and efficient workflow.
Fiber Opening
Textiles need to be processed and broken down into individual fibers, which are then transformed into pellets. This processing is efficiently scaled across various sites in collaboration with our EU partners. By setting up local value chains proximate to the source of waste, we enhance the sustainability and efficiency of our operations, making sure we minimize environmental footprint from logistics.
Pelletizing
This is the transformative stage of the process. We are able to provide our fashion brand clients with a distinctive, patented technology that converts fibers into pellets. These pellets are then integrated into the part manufacturing process right at the production site. This integration allows manufacturers to easily incorporate the material directly into their current operations without major modifications to their machines or tools.
Compounding
The fiber pellets are highly versatile, suitable for use in any injection-molded part crafted from polyolefins or TPE. Depending on the binder, the fiber based material will be tailored to various properties. Our goal is to offer brands a complete circular solution, which includes a take-back strategy where brands can return discarded products for recycling and reuse, and this material can be recycled at a number similar to standard plastic.
Customization
Storytelling and communication are important when driving the circular transformation, offering brands not only a circular solutions, but also added value in finishing and brand communication. During the compounding process, we incorporate any chosen color masterbatch. Often, we select a contrasting color to enhance the visibility of the fiber content, attracting greater customer interest. By using the brands' own fibers, we bring their signature colors into the products, strengthening their own identity.
The Outcome
Circular Fiber Pellets
Through our scalable recycling process for mixed textiles with our trusted partners, we've proven the capability to assist brands in aligning to new regulations and advancing their sustainability initiatives. This process shows that recycling is no longer about sacrifice—it enhances product value by improving performance, storytelling and unique aesthetics.
From Textile Waste to Hangers
The industry's first Circular Hanger, made entirely from 100% recycled materials and completely recyclable. These hangers are designed for circularity, meaning that at the end of their lifecycle, they are collected, reground, and reinjected into the manufacturing process to create new hangers, being a true closed-loop solution.
From Textile Waste to Flower Pots
The fiber pellets has also been used for production of flower pots made entirely from 100% recycled materials. By blending recycled fiber pellets with recycled polypropylene, each pot has a unique surface finish, making every piece a one-of-a-kind!
The transformation of complex textile waste into a customizable, circular material suitable for injection molding enables companies to comply with EU regulations and respond to market demands. By converting discarded textiles into economically viable products, we are introducing new sustainability standards in the fashion industry.
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