Raw Fiber Creation

a)    Markers are generated by CAD-CAM equipment to maximize material utilization. Note the black areas on the left of the marker as they denote the 15-20% waste from patterns for garments that becomes our raw material.


 

b)    The fabric is spread on long cutting tables based on the marker and pattern lengths

 
c)    The marker is placed on the top of the layers of fabric

 
d)    The pattern pieces that make up the garment are cut, combined and labeled.

 
e)    The scrap is recovered, color sorted and bagged for collection for recycling.

 
f)    And is further sorted and baled to become our cotton field.

 
g)    The cotton scraps are chopped and opened to create new (recycled) fiber.

 
h)    At last, the color sorted recycled cotton fiber is now ready for the spinning process

The recycled polyester process
Post consumer recycled polyester (rPET), the source for which is discarded plastic bottles (and originate from oil), are used in the making of recycled polyester (rPET) staple fibers.

This is our oil field

  

Post-consumer plastic bottles are collected.

Here how the process works and why we think recycled polyester (rPET) is important as a sustainable fiber

Recycling companies will further treat the post-consumer plastic bottles by shredding the material into small fragments. These fragments still contain residues of the original content, shredded paper labels and plastic caps. These are removed by different processes - cleaned and chopped, resulting in pure PET fragments, or "rPET flakes".



 
Recycled PET (rPET) flakes are used as the raw material for our recycled polyester fiber.

The processed post-consumer bottle flake is blended, melted, and extruded to form recycled polyester (rPET) fibers.

 

Bales of recycled polyester (rPET) fiber…ready for blending and spinning into yarn.

To impart necessary physical properties, the fibers are drawn, crimped, cut, and then compressed into bales.

The recycled polyester fibers are further processed with recycled colored cotton to form spun yarns.

The Process (continued)

Raw Fiber Creation

Raw Fiber to Yarn

Knitting & Finishing

Cut & Sew