WECYCLED®
Cotton from the textile cycle.
Simply binning unused cotton yarn and fabric offcuts? We didn’t think that was a particularly good idea even years ago – especially as textile companies also have to pay disposal costs for them. That’s why, with WECYCLED®, we’ve developed an innovative process that feeds these scraps back into the textile cycle. They are collected, processed and broken down into individual fibres. Combined with virgin cotton, these fibres are used to create new WECYCLED® yarns – which in turn are used to make new textile products.
What the ‘WE’ in WECYCLED® stands for.
WECYCLED® turns supply chains into circular systems.
Our customers collect their leftover yarn and fabric offcuts and return them to us. Staff at an inclusive workshop in our region take care of the preparation: they remove the yarn remnants from the cardboard spools. And here in Velen, we turn these leftover yarn and fabric offcuts back into new textile raw materials.
A well-rounded process, then – and the ‘WE’ stands for everyone who plays a part in it.
This is how the WECYCLED® cycle works.
Experience has shown that, for technical reasons, between 10 and 30 per cent of yarn remains on the bobbins at our weaving mill and those of our customers: flawless material that nevertheless cannot be processed further. The same applies to offcuts from woven fabrics. This results not only in a loss of material value, but also in the waste of raw materials and resources that have already been invested in the cultivation, transport and processing of the cotton.
WECYCLED® turns these offcuts back into raw material – whilst also saving on disposal costs. Here’s how:
„Textile manufacturers collect their yarn and garment scraps for the WECYCLED® process.“
„At a regional inclusive workshop, leftover yarn and cardboard spools are sorted into single-type recyclable raw materials.“
„The yarn and fabric scraps are then broken down into individual fibers.“
„In the spinning mill, we mix in raw cotton from African partner companies.“
„The blend of WECYCLED® and virgin cotton is processed into yarn or fabric.“
„The WECYCLED® production returns to the textile cycle.“
Why we add virgin cotton.
In the mechanical recycling process, cotton fibres inevitably become shorter. For this reason alone, recycled cotton is often not sufficient to produce a strong, consistent yarn. That is why we at Velener specifically blend long-staple virgin cotton into the recovered fibres. During spinning, its longer fibres interlock over a greater distance, thereby ensuring greater tear resistance, consistency and good drape.
This is precisely why, for WECYCLED®, we only accept yarn and fabric offcuts that originally came from our own production. Only then do we know the quality of the cotton used and can ensure that the new recycled yarn also meets our quality requirements.
Recycling, yes – but not at the expense of quality.
Using more cotton instead of disposing of it.
Today, consumers increasingly expect products not only to work well, but also to make responsible use of raw materials. WECYCLED® offers a principle that is both sensible and cost-effective: existing material is reused, disposal costs are eliminated – and a waste material is transformed into a tangible added value for the product.
This means that cotton that has already been used remains in the production cycle for longer and replaces some of the new raw materials required. At the same time, this creates tangible added value for your products: technically, economically and as a transparent story for your customers.
The benefits of WECYCLED®:
- Free collection of cotton offcuts
- No more need for expensive disposal
- No waste of unused raw materials
- Sustainable, contemporary added value for your textiles
- Manufactured to your individual specifications
- Excellent processing properties
- A sustainable approach, a compelling product story
New textiles are created from the recycling loop.
At Velener, the recovered cotton fibres are used to produce new WECYCLED® yarns – and, on request, bespoke WECYCLED® fabrics. We tailor the fibre blend, yarn quality and fabric construction to the specific application and our customers’ requirements.
You can find out more about the specific qualities on our product pages for WECYCLED® yarns and WECYCLED® fabrics.
What is WECYCLED® cotton?
WECYCLED® cotton is recycled from unused yarn and fabric offcuts from Velen, which are left over from our clients’ weaving or cutting processes. We break these scraps down to individual fibres and spin them together with long-staple virgin cotton to produce high-quality yarns that meet your specifications. On request, we can also weave these directly into WECYCLED® cotton fabrics for you in our weaving mill.
How is WECYCLED® produced?
WECYCLED® is produced as part of a textile circular economy. We regularly collect yarn and fabric offcuts from participating businesses. Staff at a regional workshop for people with disabilities then remove the yarn offcuts from their cardboard spools so that both materials can be recycled separately by type. The yarn and fabric scraps are then broken down into individual fibres. We blend these recycled fibres with virgin cotton at our spinning mill – and spin WECYCLED® yarn to the required specifications.
What are the benefits of WECYCLED®?
WECYCLED® reintroduces suitable cotton offcuts into textile production, thereby reusing material that would otherwise be disposed of. This allows some of the new cotton required to be replaced, whilst at the same time eliminating the disposal costs for the reclaimed offcuts. The sorting and preparation of the materials is carried out in collaboration with an inclusive workshop in the region, creating meaningful employment opportunities there. For our customers, this also creates tangible added value for their own product communication: WECYCLED® combines resource conservation, reuse and a clearly explainable product story.
Are there any restrictions on the further processing of WECYCLED®?
No, not generally speaking. What makes our WECYCLED® yarns special is their high quality. We achieve this through a textile recycling process that uses only high-quality cotton offcuts from our own production. We also blend in extra-long-staple virgin cotton. Both factors contribute to high tensile strength, uniformity and good processing properties. We have verified these qualities through numerous tests and optimisations during the development process. There is one distinctive feature when it comes to dyeing: the blend of recycled and virgin cotton does not result in a completely uniform solid colour, but rather in mottled shades.
What does ‘low waste’ mean at WECYCLED®?
For us, ‘low waste’ means avoiding the disposal of reusable production offcuts wherever possible and instead reusing them as raw materials. Experience has shown that, both at our premises and those of our customers, some of the yarn remains unused on the cardboard spools in the weaving mill; in addition, there are offcuts from further processing. In the WECYCLED® system, suitable cotton scraps are recycled. The yarn and cardboard spools are separated so that the materials can be recycled separately. The cotton scraps are processed and reused as raw material for WECYCLED® yarns.
What types of textiles can be produced using WECYCLED®?
In principle, any textiles for which high-quality conventional or recycled cotton yarns would be used. WECYCLED® yarns can be processed into woven and knitted fabrics for clothing, bed linen, home textiles and much more. We optimise the yarn to meet your requirements and carry out tests to ensure it meets the desired specifications.
Is WECYCLED® sustainable?
WECYCLED® combines environmental, economic and social considerations. Suitable cotton offcuts are reused as raw materials, replacing some of the new cotton that would otherwise be required. At the same time, the disposal costs for the returned offcuts are eliminated. An inclusive workshop in the region is responsible for sorting and preparing the materials. In this way, WECYCLED® combines resource conservation with economic benefits and social inclusion.
