What is Recycled Fabric? 4 Common Types of Recycled Fabric and The Most Innovative Ones

What Is Recycled Fabric?

Recycled fabric refers to textile materials created from used fibers, plastic bottles, marine debris, or even coffee grounds, and transformed into new, usable materials. The recycling process typically involves collecting waste materials, breaking them down, and re-spinning them into fibers that can be woven or knitted into new fabrics. However, the specifics can vary depending on the source of the materials. So, what exactly can be turned into recycled fabrics? Let’s learn more.

Read more: Sustainable Fabrics: How Eco-Friendly Are They Really?
 

4 Common Types of Recycled Fabrics 

Before we get into the details, let’s look at the 4 most common types of recycled fabrics, including recycled polyester fabrics, recycled nylon fabrics, recycled wool fabrics, and recycled cotton fabrics.
 

1. Recycled Polyester (rPET) Fabrics

Recycled polyester, or rPET, is primarily made from recycled plastic bottles and other PET plastics. The production process begins with collecting and sorting plastic bottles from various sources. These bottles are carefully sorted to ensure only suitable plastics are used and then thoroughly cleaned to remove any contaminants or residues. Once cleaned, the bottles are shredded into small flakes, which are then melted down and extruded to form long, continuous fibers. These fibers are spun into yarns, which can be woven or knitted into new fabrics. This process not only transforms waste materials into valuable textiles but also helps reduce the environmental impact of plastic waste.

Read more: What is Recycled Polyester? Is It Really Sustainable?
 

Virgin Polyester Fabric vs. Recycled Polyester Fabric

Virgin polyester fabric is made from new petroleum-based materials, involving high energy consumption and significant environmental impact. Recycled polyester fabric on the other hand is produced from recycled plastic waste like bottles, using less energy and reducing environmental impact, making it a more sustainable option. 

 

We’ve created a table below to help you understand better.

 

Feature	Virgin Polyester Fabric	Recycled Polyester Fabric
Energy Consumption	Higher energy consumption	Uses up to 59% less energy
Greenhouse Gas Emissions	Higher CO2 emissions	Reduces CO2 emissions by up to 32%
Environmental Impact	Greater impact due to raw material extraction	Lower impact, as it uses waste materials
Recyclability	Can be recycled but is initially made from new raw materials	Can be recycled but only a few times before degrading
Raw Material Requirement	Requires new raw materials (petroleum-based)	Uses existing plastic waste (e.g., bottles)
Waste Reduction	Contributes to plastic waste	Diverts plastic waste from landfills
Sustainability	Less sustainable due to higher resource use	More sustainable due to resource efficiency
Lifespan Extension	Single-use before recycling	Extends lifespan of plastic waste through recycling

  

Where to Find Recycled Polyester Fabrics?

There are several companies that specialize in making recycled bottle fabrics, but there’s one that stands out particularly to us– SAYA fabrics.

 

SAYA specializes in creating high-quality fabrics from recycled bottles and overstock materials. The company has innovated recycled fibers made from four types of recycled components, including garment offcuts, deadstock and overstock fabric, waste yarn, and recycled PET bottles. SAYA transforms single-use, low-value, high-volume plastic bottles into durable, functional fibers. Each year, they recycle over 100,000 tons of plastic bottles (equivalent to 8 billion bottles) and upcycle them into performance fibers that are not only durable and functional but also recyclable.

 

What makes SAYA special from other recycled fabrics is that they don’t use decolorization, which preserves the original color of the fibers. This not only saves energy but reduces carbon emission as well. 

Read more: What is Deadstock Fabric? Is it Really Sustainable?

 

2. Recycled Nylon Fabrics

Recycled nylon comes from both pre-consumer waste, like manufacturing scraps, and post-consumer waste, such as old fishing nets and discarded nylon products. After collecting and sorting these materials to make sure only suitable nylon waste is used, the materials go through hydrolysis, a chemical process that breaks down the nylon's molecular structure. This is followed by re-polymerization, where the broken-down materials are chemically reformed into new nylon fibers.
 

Recycled nylon offers significant environmental benefits, including a substantial reduction in CO2 emissions compared to virgin nylon production. According to Formosa Plastics, nylon recycled from marine sources saves 15% more energy and reduces carbon emissions by 49% compared to freshly produced caprolactam from petrochemical refining. However, the recycling process is expensive and complex, requiring thorough cleaning and careful handling to maintain the quality of the fibers.
 

Where To Find Recycled Nylon Fabrics?

You might have heard about marine creatures like sea turtles, endangered sharks, and even whales getting trapped in fishing nets and starving to death. Taiwan’s Formosa Plastics has developed a solution to help reduce the impact of ocean waste on ecosystems. They have created various functional products made from environmentally friendly fibers, including antibacterial, cooling, and heat-generating types. These products, made from recycled fishing nets, are as good as those made from fresh raw materials.

  

3. Recycled Cotton Fabrics

Recycled cotton comes from old cotton garments and industrial cotton waste. After collecting and sorting used cotton products, the fabrics are then shredded into raw fibers, breaking down the old garments into a form that can be respun into yarn, which can be woven or knitted into new fabrics.

Recycled cotton offers several environmental benefits, including reducing the demand for new cotton, saving water, and lowering pesticide use. However, to maintain the strength and durability of the final product, recycled cotton often needs to be blended with virgin cotton. This blending ensures the fabric retains its desirable qualities while still incorporating recycled materials.
 

4. Recycled Wool Fabrics

Recycled wool is made from used wool garments and waste wool products. Just like other recycled fabrics we mentioned about, recycled wool fabrics begin with collecting and sorting wool items, often by color though, to reduce the need for additional dyeing. Once sorted, the wool is shredded into fibers, which are then spun into yarns and woven or knitted into new fabrics.

Recycled wool retains many of its original qualities, like warmth and softness, making it a great material for new textiles. Often, it is blended with other fibers to enhance durability and strength. This blending ensures that the final fabric maintains the desirable properties of wool while being more sustainable. Recycled wool is a valuable resource for creating high-quality, eco-friendly textiles.

Read more: What is Natural Fabric? 5 Most Common Natural Fabric and Fiber Types

 

What are other recycled fabrics made from?

Surprisingly, most recycled fabrics are not made from old clothes. Unlike other recyclable materials, textiles are more difficult to turn back into durable, strong fabric. Instead, many recycled fabrics are made from recycled plastic bottles or fishing nets. There are other innovative recycled fabrics in the market now, and we can’t wait to introduce them to you! 
 

1. Coffee Charcoal Fabrics- S.Café Yarn

Coffee grounds, often dismissed as waste, are proving to be a hidden treasure for the textile industry. Traditionally used to mask unpleasant odors, these grounds have found a new purpose as a sustainable material. Through a high-temperature process called calcination, coffee grounds are transformed into a unique form of carbon that can be integrated into polyester fibers. The resulting fabric boasts impressive properties: it dries exceptionally fast, offers superior heat retention, and provides excellent UV protection. Moreover, by repurposing coffee grounds, this innovative process contributes to a more circular economy and reduces our carbon footprint.

 

2. Shell fabrics

Oyster shells, once discarded as waste, are now finding new life as a sustainable material. Traditionally ground into powder for fertilizers or construction fillers, these marine treasures are undergoing a transformation. In recent years, innovative companies have explored the potential of oyster shells in a variety of applications. From creating durable, plastic-free shoe soles to developing biodegradable materials for masks, the possibilities are vast. Even more impressively, scientists have managed to transform oyster shell powder into a chemical-free yarn called "Seawool" by combining it with recycled PET. 
 

Where to Find Oyster Shell Fiber?

There are several companies providing shell fabrics. Creative Tech Textile leads the pack with its Seawool yarn, offering innovative products like antibacterial insulating cotton and deodorizing socks. Shun Yuan Sportswear has joined the movement with its Seawool-based sportswear, while Lea Lea Group's Oceaya® yarn brings unique properties like anti-static and deodorizing benefits. Even fashion designers, like DYCTEAM, are embracing oyster shell fabrics to create stylish and sustainable garments. Taiwan Sugar Corporation, known for its diverse operations, has also ventured into this space, producing functional fabrics and exploring other applications for oyster shell materials.
 

Environmental Benefits of Recycled Fabrics

Using recycled fabric materials offers numerous environmental advantages. Firstly, it reduces waste by diverting textile waste from landfills, thus decreasing the volume of waste and its environmental impact. This helps manage waste effectively and prevents overburdening landfill sites. Recycling fabric materials also lowers pollution by lessening the need for new raw materials. This reduction in demand for virgin materials means fewer emissions and less contamination of air, water, and soil during extraction and processing activities.

Another significant benefit is conserving natural resources like water, cotton, and petroleum, which are heavily used in the production of virgin fabrics. For example, producing recycled polyester from plastic bottles conserves petroleum and reduces the environmental impact of oil extraction and processing. Producing recycled fabrics typically requires less energy than manufacturing new materials, leading to lower carbon emissions. This energy efficiency helps combat climate change and promotes more sustainable manufacturing practices.
 

Limitations of Recycled Fabrics

Despite the benefits, recycled fabrics have several limitations. One major concern is quality. Recycled fibers can be of lower quality than virgin materials, which may affect the durability and texture of the fabric. This can make recycled fabrics less desirable for certain applications where strength and consistency are crucial. Another limitation is the recycling process itself. It can be complex and costly, requiring advanced technology and infrastructure to convert waste materials into usable fibers efficiently. This complexity can make the production of recycled fabrics more expensive and less accessible.
 

Additionally, not all fabrics can be recycled. Some materials, due to their composition or previous treatments, are difficult to recycle effectively. Even those that can be recycled often have a limited number of times they can go through the recycling process before they lose their properties and become unusable. This limitation means that while recycled fabrics can reduce waste, they are not a perfect solution and must be part of a broader strategy for sustainable textile production.
 

How Do You Make Recycled Fabric?

Here’s a closer look at each step involved:
 

1. Collection

The first step in making recycled fabric is gathering waste materials from various sources. These sources can include post-consumer waste like discarded clothing, plastic bottles, and other textiles, as well as pre-consumer waste such as manufacturing scraps and offcuts. Efficient collection systems are crucial for amassing a sufficient volume of raw materials needed for recycling.
 

2. Sorting

Once collected, the materials are sorted based on type and quality. Sorting is a critical step because it ensures that only suitable materials are processed together. For example, different types of plastics, cotton, wool, and other textiles are separated to maintain the integrity of the recycled fibers. Proper sorting also helps reduce contamination and improve the quality of the final product.
 

3. Cleaning

The sorted materials undergo a thorough cleaning process to remove contaminants, such as dirt, dyes, adhesives, and other impurities. Cleaning is particularly important for ensuring that the recycled fabric is free from harmful substances and suitable for use in new products. Various cleaning methods, including washing, chemical treatments, and mechanical cleaning, are employed to achieve this.
 

4. Shredding

After cleaning, the materials are broken down into fibers through a process called shredding. Shredding involves cutting or tearing the materials into smaller pieces, which are then further processed into raw fibers. This step is essential for converting waste materials into a form that can be re-spun into yarn.
 

5. Re-spinning

The shredded fibers are then spun into yarns. This step involves twisting the fibers together to form long, continuous strands of yarn that can be woven or knitted into fabric. Re-spinning is a critical process that determines the texture, strength, and usability of the recycled fabric.
 

6. Weaving/Knitting

The spun yarns are woven or knitted into fabric. Weaving involves interlacing yarns at right angles to form a fabric, while knitting involves interloping yarns to create a fabric. Both methods produce different types of fabrics, depending on the desired properties and end-use.
 

7. Finishing

The final step in the production of recycled fabric is finishing. This involves applying various finishes to enhance the fabric’s properties, such as softness, durability, colorfastness, and water resistance. Finishing processes can include dyeing, coating, heat setting, and other treatments that improve the recycled fabric's performance and appearance.

Read more: Textile Production: How Textile Is Made From Fiber to Fabric
 

What Can You Make Out of Recycled Fabric?

Recycled fabrics can be transformed into a wide variety of products across different industries:
 

• Clothing: T-shirts, jackets, activewear, and denim are commonly made from recycled fibers, offering comfort and style while reducing environmental impact.
   
• Accessories: Bags, hats, scarves, and shoes are often crafted from recycled materials like polyester and nylon, appealing to eco-conscious consumers.
   
• Home Textiles: Upholstery, curtains, rugs, and bedding made from recycled fabrics enhance home decor with sustainability in mind.
   
• Industrial Products: Recycled fabrics are durable and sustainable, supporting various industrial applications in insulation, automotive interiors, and geotextiles.
   

Recycled Fabrics vs. Reclaimed Fabrics

Now we know what recycled fabrics are, but what exactly are reclaimed fabrics? Are they the same? 
 

What Are Reclaimed Fabrics?

Reclaimed fabrics are materials salvaged from leftover, unused, or discarded fabric scraps during the production process. These fabrics are repurposed directly without being broken down into fibers.
 

Differences Between Recycled and Reclaimed Fibers

Aspect	Recycled Fabrics	Reclaimed Fabrics
Source	Post-consumer waste, plastic bottles, old garments	Industrial scraps, leftover fabric from production
Processing	Broken down into fibers and re-spun into new fabric	Repurposed directly without breaking down
Environmental Impact	Significant reduction in waste and resource use	Minimal waste reduction, primarily upcycling
Quality	Can be lower than virgin materials	Typically retains the original quality
Applications	Clothing, home textiles, accessories	Fashion, accessories, patchwork

 

Are Recycled Fabrics More Expensive?

Recycled fabrics can often be more expensive than virgin materials due to the complex and energy-intensive processes involved in recycling. The infrastructure required for collecting, sorting, and processing waste materials further adds to the cost. However, as technology advances and demand for sustainable products increases, this cost difference is expected to decrease.
 

Is Recycled Fabric Sustainable?

Recycled fabric is considered more sustainable than virgin fabric due to its lower environmental impact. It reduces waste, conserves resources, and requires less energy to produce. However, recycling is not entirely without environmental costs, as the process itself consumes energy and resources. Sustainable practices such as responsible sourcing and reducing consumption are essential to maximizing the benefits of recycled fabrics.
 

Certifications for Recycled Fabrics

Recycled fabrics, especially those used in products for babies and sensitive applications, must meet stringent safety standards to ensure they are free from harmful substances. Certifications such as OEKO-TEX Standard 100 play a crucial role in this regard. The OEKO-TEX Standard 100 certification tests fabrics for a wide range of harmful chemicals and substances, ensuring that they are safe for human use. This certification is particularly important for products like baby clothing, bedding, and other items that come into close contact with the skin.
 

Read More: What is Oeko-Tex? Everything You Need To Know
 

Several certifications focus on sustainability and responsible sourcing to authenticate the environmental claims of recycled fabrics. The Global Recycled Standard (GRS) and the Recycled Claim Standard (RCS) are prominent certifications in this area. The GRS ensures that a product's recycled content is verified and that the entire supply chain is environmentally and socially responsible. This includes criteria for traceability, environmental principles, social requirements, and chemical restrictions.

Read more: What is GRS? 6 Steps to Get GRS and RCS Certified
 

Final Thoughts

Recycled fabrics offer a promising solution to the environmental challenges faced by the fashion and textile industries. By utilizing recycled fabric materials, the industry can reduce waste and conserve valuable resources, leading to a more sustainable and eco-friendly future. However, choosing the right recycled fabrics for your products requires some effort and knowledge. If you are interested in using recycled fabrics but aren’t sure where to start, we are always here to help!
 

FAQs

1. What can be made from fabric waste?

Through recycling processes, fabric waste can be transformed into new clothing, accessories, home textiles, and industrial products.

2. What fabrics can be upcycled?

Most fabrics, including cotton, wool, polyester, and nylon, can be upcycled into new products.

 

3. What fabrics are hard to recycle?

Fabrics blended with multiple fibers, heavily treated or coated textiles, and certain synthetics can be challenging to recycle.

 

4. What is the upcycled fabric?

Upcycled fabric refers to materials repurposed from existing fabrics without breaking them down into fibers, often used creatively to reduce waste.

5. Is recycled fabric strong?

The strength of recycled fabric depends on the source material and recycling process. While some recycled fabrics may be less durable, advances in technology are improving their quality.

6. What textiles cannot be recycled?

Textiles that are heavily contaminated, coated, or made from certain synthetic blends may be difficult or impossible to recycle.