Why Recycle Textiles?

The textile industry is a major contributor to global environmental pollution, affecting land, air, and marine ecosystems. The processes involved in apparel manufacturing chain significantly impact greenhouse gas (GHG) emissions in addition to water resources depletion. Of the 37.4 billion MT global CO₂ emissions in 2023, roughly 1.2 billion MT were attributed to the textile industry alone.

• Approximately 92 million tons of textile waste is generated globally each year, out of which just 0.6-0.8% is recycled currently
• The combined apparel and footwear industries account for approximately 8-10% of global GHG emissions
• It is estimated that 0.5 million tonnes of microfibres from washing synthetic textiles are released into the oceans every year [EEA 2019 & EPRS 2017], contributing to marine pollution
• Synthetic textiles like polyester, nylon, and aramids can take hundreds of years to degrade naturally, remaining in the environment for far too long. Further, the degradation residues of some fibers such as aramids, are toxic

In response, governments worldwide are implementing stricter waste management regulations and promoting sustainable practices, urging businesses to increase the proportion of recycled products in their offerings. As a result, there is a growing demand from users for more sustainable workwear, with heightened awareness and subsequently more frequent inquiries about eco-conscious options.

Upcycling and Downcycling are both considered types of recycling – specifically, they are subcategories of material reuse within the broader recycling process.

• What is Upcycling: Think of it as recycling “up” — you’re improving the material or making it more useful. It is a kind of value addition through creativity or better functionality i.e. turning old jeans into a stylish handbag, turn old clothes or vintage fabrics into modern, high-fashion pieces.
• What is Downcycling: This is recycling “down” — the material degrades a bit each time it’s reused. It is basically extending the life of the material, but often with a loss in performance or appearance, for instance, PET bottles turned into synthetic fibers for carpets or fleece clothing.

Routes of Textile Recycling

Textile waste falls into two categories: pre-consumer and post-consumer. The first step in textile recycling is waste collection, followed by preliminary sorting. Effective sorting by material composition is critical as it prevents contamination and improves the recovery of valuable fibers. After material sorting, textile waste is further categorized into 15–16 different colors, tailored to meet specific end-user requirements. Accessories such as buttons, zippers, and other attachments are then carefully removed.

After sorting of textile waste is completed, it will be recycled in the next step via chemical or mechanical techniques. The chemical recycling route can comprise of several types of degradation mechanisms, viz. glycolysis, hydrolysis, hydrothermal or ammonolysis, ultimately leading to polymer pellets or chips (in case of polyester) or to dried pulp sheet (in case of cellulosic fibers such as cotton or viscose). Both types of reclaimed materials can be then spun into fibers by a fiber manufacturer.

The mechanical recycling method essentially consists of shredding the pre- or post-consumer waste into usable fibers on dedicated recycling lines and comprises the key stages of: pre-cleaning to remove dye & finish contamination, followed by cutting & shredding (extraction of ‘reclaimed fibers’). Post-extraction process steps then use these reclaimed fibers to prepare yarn by mixing and blending (with virgin fibers), carding and drawing and yarn spinning. Lastly, this reclaimed yarn is converted to fabric (woven or knit) and ultimately the manufacturing of garments, made fully or partially from recycled fabric, is carried out.

Flame Retardant (FR) Workwear Recycling- Challenges & Solutions

Garments made from meta- and para-aramid fabrics are 100% non-biodegradable, making them a challenge for disposal. The best solution is to prevent them from ending up in landfills. However, these garments cannot be incinerated due to presence of benzene as well as other hazardous chemical finishes leading to toxic fumes & residues, hence they must be sent to a landfill. Mechanical recycling is the only viable option to re-introduce this type of textile waste back in to the mainstream. When aramid fiber based waste is taken up for mechanical recycling, due to their very high strength and abrasion resistance, it requires specialized equipment to be used on the recycling machine, such as carbon / alloy blade-based cutting systems, reinforced tearing drums, and twin carding systems.

As with regular textile waste, FR apparel waste too can come from pre- or post-consumer origins. Pre-consumer waste streams can include several industrial sources, like – garment manufacturers’ cutting room waste, rope waste, tyre cord and aramid hose waste, ballistic armour cutting room waste, yarn on bobbins, tangled filament, selvedge trims, etc.

For recycling with post-consumer waste, the first and most critical step is to gather the discarded garments. Used & clean FR garments must be collected from end-users such as companies and government institutions. It is also possible to designate pickup points at commercial laundries (where garment wash care programs are run) for collecting garments that have reached the end of their useful life.

Tarasafe’s Commitment to Sustainability

The TARAcare range by Tarasafe is a range of sustainable FR workwear offerings, based on cotton rich blends, delivering the same level of protection and comfort along with being gentle on the planet. In addition, we are exploring more ways to turn our cutting room waste into new protective garments. We’re partnering with specialists who can shred the waste into fiber form and turn it into new yarn and fabric. Stay tuned for updates and follow us on social media for more information!

Conclusion

Textile waste recycling creates a win-win for both industry and the environment. While reclaiming FR workwear is more tricky than regular textile recycling, it is gaining momentum with advancements in shredding technology.

By embracing circular economy principles, India is showing the world that large-scale textile recycling is not just possible, but also profitable, sustainable, and socially inclusive. From high-value recycled garments to grassroots job creation, the transformation of textile waste is becoming a story of innovation, empowerment, and environmental hope. The next time you look at an old t-shirt or a pile of scrap fabric, remember – it could be the start of something beautiful.