Between public pressure and mounting environmental regulations, every sector is feeling the push to find more sustainable solutions. The textiles industry is no exception to this, but for many years it struggled with a persistent challenge: how to handle and recycle blended fabrics, which have traditionally been extremely difficult to break down.
This is a huge sustainability issue, as the global textile industry is massive, valued at $1.8 trillion as of 2023[1], and with this scale comes an equally enormous waste problem. Over 124 million tons (112 million tonnes) of textiles are produced annually, and the vast majority of these end up in landfills or are incinerated after their useful life.
Shockingly, only about 10% of textile waste is currently recycled, and much of that is downcycled into lower-value products such as insulation or rags[2]. This inefficient use of resources has prompted the need for more sustainable solutions, especially when dealing with blended fabrics composed of polyester (PET) and cotton, which make up a large portion of clothing and home textiles.
A leading solution to this issue comes in the form of an innovative process developed by Worn Again Technologies. With its proprietary chemical process, Worn Again can take in blended fabrics, separate and extract the valuable components, creating new products that are indistinguishable from virgin materials. In this way, it offers a scalable solution that not only reduces waste but also contributes to the creation of a circular economy.
Breaking down the process
Worn Again’s solution is rooted in a solvent-based chemical recycling process that efficiently separates and purifies both polyester and cotton from blended textiles. The technology focuses on preserving the integrity of the materials, allowing them to be reused in new products. Here’s how the process works:
The process begins with washing the textiles to prepare them. This removes typical contaminants such as other fibre materials, but also any residual biological or chemical compounds that might be left over from the textile’s previous life.
Once the textiles are prepared, they undergo a decolourisation process to remove dyes and other chemical additives. This step ensures that both the polyester and cotton are stripped of residual colours, making the recovered materials suitable for high-quality reuse. Unlike mechanical recycling, which often retains previous dye colours, Worn Again’s method delivers a neutral base material that can be recoloured or repurposed without limitations.
With the unwanted dyes and contaminants removed, the PET and cotton are separated through a sequential dissolution process. Specially formulated solvents selectively dissolve the PET and cotton at different stages, ensuring an efficient split without breaking them down into molecular components.
Once separated, the materials are purified and regenerated into new raw materials. PET is returned to its pure polymer form, while the cotton is converted into cellulosic pulp—a plastic-free material that can be used for fibre production. The result is two high-quality, virgin-equivalent outputs, free from residual contaminants and ready for reintroduction into the textile supply chain.
The final step is transforming these regenerated materials back into usable textile fibres. The circular PET resin pellets can be spun into new polyester fibres, creating material indistinguishable from virgin polyester. Similarly, the cellulosic pulp is processed into regenerated fibres, offering a valuable alternative to traditional cotton production. Both outputs provide a sustainable, scalable solution for textile manufacturers looking to reduce their reliance on virgin materials.
A broad impact
Worn Again’s technology is not just a solution for the fashion industry but has potential applications across countless other sectors. The ability to recycle PET and cotton into high-quality materials opens up possibilities for industries like automotive, packaging, and home goods, where recycled fibers can be used in a wide range of products ranging from packing to car dashboards.
By keeping these materials in circulation, Worn Again’s process supports the growth of a circular economy—one where products are continually reused and repurposed, reducing the need for new raw materials. This allows businesses to not only improve their sustainability credentials, but also align with growing regulatory pressures, such as Extended Producer Responsibility (EPR) regulations, which mandate that textile manufacturers take responsibility for the collection and recycling of their products.
As the global textile industry grapples with the need to become more sustainable, Worn Again Technologies provides a glimpse into what the future of recycling could look like. Through its innovative chemical recycling process, Worn Again is not only tackling the issue of textile waste but also paving the way for a more circular, environmentally responsible industry.
[1] https://www.grandviewresearch.com/industry-analysis/textile-market
[2] https://www.businesswaste.co.uk/your-waste/textile-recycling/fashion-waste-facts-and-statistics
