The document details the process of recycling knit-fabric cutting waste into eco-friendly cotton/poly yarn called cyclo®. It describes how the waste is collected, sorted, processed into shoddy, blended with polyester staple fiber, and spun into yarn for various applications. The process is waterless and chemical-free, significantly reducing environmental impact while also ensuring that the yarn is predominantly made from recycled materials.

1. BY

2. 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

3. 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

4. • 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 Process
Blending / Color
Matching

5. • 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 Process
Blending / Color
Matching

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

7. • 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

8. • 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 Benefits
Reduce

9. • 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 Benefits
Reuse

10. • 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
The Benefits
Recycle

11. • 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!

12. • 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

13. Thank You
REDUCE – REUSE - RECYCLE