Recycled cotton should perform as reliably as the material it replaces. By using pre-consumer yarn waste instead of cutting waste, fibre length is preserved, waste is reduced at the source, and performance remains consistent. The innovative recycled cotton feels better, decorates better, and lowers environmental impact.
Rethinking where recycled cotton begins
For years, recycled cotton was made from cutting waste generated in our garment production, using fabric offcuts from our manufacturing lines. This helped reduce waste, but it also set clear technical limits.
Once fabric has already been knitted and dyed, recycling it means shredding it back into fibres. That process shortens fibre length, weakens yarn strength, and restricts colour options. To reach acceptable performance, a high proportion of virgin organic cotton must then be added back in.
These limits showed that if recycled cotton is expected to deliver comfort, durability, and reliable decoration results, the solution is not only to recycle more, but to start recycling earlier.
A new source for recycled cotton
Instead of working with fabric waste, we recover cotton at the yarn stage. During spinning, some fibres naturally break or fall out. This hard waste is clean and undyed, and rather than being discarded, it’s collected and recycled into new yarn.
Because the fibres haven’t been dyed or made into fabric, their quality stays high. Fibre length is retained compared to cutting-waste recycling, supporting strength and a soft handfeel. The undyed base also keeps full colour freedom without additional dyeing.
Longer, cleaner fibres create smoother surfaces, supporting sharp printing, crisp embroidery, and consistent decoration results. This way, recycled cotton from yarn waste comes closer to the performance of organic cotton, while using fewer virgin resources.
Reducing waste at the source
Recycling pre-consumer yarn waste improves waste management inside the factory. Acting earlier in production allows recycling to happen upstream, before fibre becomes fabric, reducing material loss at the factory level.
This lowers environmental impact while maintaining the consistency expected from blank T-shirts and other core garments. Internal data shows that recycled cotton made from hard waste can reduce emissions by up to 8 percent compared with an average organic cotton T-shirt.*
*Comparison between an average organic cotton T-shirt and a recycled cotton T-shirt.
Why this matters
Responsible design is about using resources better. Turning yarn waste into high-quality recycled cotton allows us to move beyond the usual limits of recycled fibres.
This approach drives innovation through improved material performance, delivers smooth and decoration-friendly surfaces, and reduces waste without compromising consistency.
