ECOSPIN: FROM FACTORY SCRAPS TO CIRCULAR FASHION
Lakshaya Shree K V, Andria P J
Keywords: Circular economy, Cutting waste recycling, Fiber-specific chemical dissolution, Sustainable textiles, Wet/melt spinning
Abstract
The garment industry generates substantial volumes of freshly cut fabric scraps during pattern planning and cutting, much of which is discarded or used in low-value applications. To address this challenge, a modular and computerized recycling system has been conceptualized to transform fabric cutting waste into high-quality, spinable yarns. The design features four dedicated chambers for cotton/viscose, polyester/synthetics, nylon, and wool/silk fibers, each applying fiber-specific chemical dissolution or depolymerization to generate polymer solutions. These solutions are purified and extruded through controlled wet or melt spinning units, depending on the fiber type, to produce continuous filaments comparable to virgin quality without the need for blending. Inline sensors and a PLC-based control system continuously monitor chemical concentrations, polymer dope parameters, and spinning conditions to ensure safe operation, consistent performance, and product quality. The resulting yarns retain key fiber properties, making them suitable for apparel applications such as jerseys, jeans, jerkins, and other premium textiles, as well as upholstery and technical fabrics. By combining solvent recovery, chemical safety, and advanced process automation, the system provides a sustainable closed-loop pathway for fabric scraps. This approach minimizes landfill waste, reduces reliance on virgin fiber production, and supports the growing demand for eco-labeled fabrics, ultimately advancing the circular economy within the textile sector