Recycled YARNBY

The Process• A dedicated team of professionals collect knit-fabric cutting waste (clips or jhoot) from the market, as per customer specific color requirements.•When exact color matches are not available, the team is trained in acquiring the closest available colors.*• These clips are then further sorted in the factory premises for quality control.

Raw Material Acquisition

*In these cases further color matching is achieved by our expert blending department

The Process•The sorted clips are then processed through our recycling machine, which tears the fabric waste back into useable fiber that we call shoddy.

•This shoddy is then bailed and either sent to the blending department, or stored in the fiber warehouse for future color matching purposes.

Recycling

• The bails of shoddy are then brought to the blending department where they are opened and mixed with polyester staple fiber (PSF).• Due to the shortened fiber length of the recycled cotton, PSF is

needed to add strength to the yarn. • Total Polyester composition varies from 15-30% depending on

final count and use for yarn.• Sweater and knit yarn is usually between 25 and 30% because

of the strength requirement of finer counts (NE 16s-20s)• In socks and glove yarn less PSF is required, usually15-20%

(NE 5s-14s)• There can be +/- <5% variation in final composition due to

some clips being 100% cotton and some being CVC.

The ProcessBlending / Color Matching

• Black and White colored PSF is always in stock and is used for solid Black, White, Navy, Off-White and colored yarns with a slight melange effect.• Lead time for these regular items is 60 days or less.

• When deep solid colors (Deep Red, Maroon, Orange, Yellow, Green, Blue, Rose, Mustard etc.,) are required, colored PSF will need to be imported to mix with the colored shoddy.• This extends the lead time to at least 75 days.

The ProcessBlending / Color Matching

• After the cotton shoddy and PSF are mixed, the normal open-end spinning process proceeds:• Blowing• Carding• Drawing• Spinning• Doubling/Twisting (required for multiple ply and

molene yarns)

The ProcessSpinning

• The final product is a colored, recycled, eco-friendly cotton/poly yarn!

• CYCLO ® is best used for sweaters, heavy knits, twill pants, socks, gloves, scarves, and home textiles.• For sweaters the best gauges are

3GG/5GG/7GG/9GG/12GG • For knits (single jersey, fleece, terry fleece) 22 and 24

gauge machines are best.• the GSM will be between 190-280 GSM, depending on required

yarn count and final product use:• Silicone wash of the garment can be applied later for extra

softness.

The Applications

• The process of making CYCLO® Recycled yarn is a completely DRY process. • Eliminates chemical and water consumption in giving

color, since no dyeing is required.• Reduces the requirement of cotton-growing land.• Avoids the CO2 emissions from the cotton-growing

and yarn-dyeing processes.• By the way- this also reduces the cost of the yarn!!

The BenefitsReduce

• Bangladesh is the 2nd largest producer of Ready-Made-Garments in the world and will soon become the largest exporter of knitwear.• Therefore, the amount of knit-fabric waste produced daily in Bangladesh is MASSIVE! Recycling these clips with SIMCO greatly reduces the stress on our limited land by making sure this waste doesn’t end up in a landfill.

The BenefitsReuse

• SIMCO Spinning is the only cotton recycling mill in Bangladesh that is certified by RCS (Recycled Claim Standard) and GRS (Global Recycled Standard).• The final composition of CYCLO® yarn is always majority recycled cotton, as opposed to other “eco-friendly” yarns whose final recycled content is usually very small.• The recycled content of CYCLO® yarn is also pre-consumer, meaning that the end customer doesn't have to worry about old dirty clothes being used to make their new sweater.

The BenefitsRecycle

• Because of the shortening of the cotton fiber in the recycling process, CYCLO® yarn is confined to courser counts Ne 5s-20s

• Because the yarn is made of the waste from the knit cutting industry, seasonal specific colors only become available late into the production cycle of the season. For these colors, we do our best to match from blending available colors.

• The blending and color matching is a physical and not a chemical process!• EXACT pantone matching becomes difficult, however we always come close.• Slight shade variations are to be expected for repeat orders, but NEVER in the

same lot.• The yarn is also not to be compared normal ring-spun yarn when it comes to the

testing and approval process. • There will be a slight increase in pilling, though final garment quality and hand

feel is always EXCELLENT!• We are using garment waste and no dyes, the final report of chemical content

can vary, however we have never failed a test!• There are rare occasions when a color might not be available in the market, so

speedy approval of samples as per closest possible match is required.

The Limitations

No Dyeing = No Lab-Dips!

• Daily current capacity is 8,000-12,000kgs of yarn a day, depending on count.• We are currently running 8 Schlafhorst Autocoro machines,

which will be increased to 10 by end 2016.• Minimum Order Quantity is normally 3,000kg for a

unique colors.• We can accommodate smaller requests based on

running production colors and counts for “tag-along” orders.

General info

Recycled YARN

Thank You

REDUCE – REUSE - RECYCLE