The CYCLO® System

Closing The Loop

We are closing the loop and creating a circular model.

We collect the buyer’s waste from the manufacturer, recycle it, spin it into yarn, and deliver that yarn back to the manufacturer.

The manufacturer then uses it to produce garments, ultimately recycling the buyer’s own waste.

What started almost 10 years ago with the production of coarse, lower quality yarn that was mostly used to produce cleaning materials and other home textiles, has evolved into CYCLO® recycled fibers: a high-quality, commercially applicable yarn that is internationally recognised as one of the most sustainable alternatives for apparel and other textile applications. CYCLO® recycled fibers is a member of the Sustainable Apparel Coalition (SAC) and is working with HIGG index.

We continue to invest in new technologies and developments to widen our range of applications, improve quality and bring innovation.

CYCLO® recycled fibers are mechanically recycled in a process that does not use any water, dyes or chemicals. How does that work? Scroll down and find out!

 

STEP 1

Sourcing

We use the cutting waste from garment manufacturers, as our raw material. We source the waste from manufacturers via a small group of dedicated traders that we have partnered with. 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 2

Sorting

The sourced waste is delivered to our factory premises, where it is manually sorted for color once again. At the same time it is checked for quality and any contaminants that may be there are removed.

STEP 3

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

STEP 4

Blending

The recycling process shortens the cotton fiber, so we blend it with another fiber to ensure sufficient strength and quality. We use a variation of blending fibers, such as recycled polyester, viscose, acrylic, EcoVera™ or Tencel™, depending on customer preference. 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 5

Spinning

The blended fibers are spun into yarn using a specialised open-end spinning process. 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 6

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 7

Testing

Every batch of sliver and yarn is tested for evenness, strength, thickness and composition in our in-house lab.

STEP 8

Delivery

The final product is brand new, colored yarn, produced without using water, dyes or chemicals – ready to be used by our customers to create a wide variety of products!

Interested to find out more about the CYCLO® system?

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