Innovative Recycling of Polycotton Blended Textiles
Regenerated cellulose textile fibres produced with the Nordic Bioproducts Group’s technology
Europe is drowning in textile waste. Each year, the continent generates between 7 and 7.5 million tons of textile waste. This staggering figure is not only due to private consumers discarding clothing and home textiles but also significantly contributed by professional users, including public procurers. Millions of tons of potential resources end up in landfills or incineration plants, representing a colossal loss. A particularly challenging aspect of this issue is the recycling of polycotton blended textiles, a widespread material in the fashion and textile industry. Polycotton, a mix of polyester and cotton, poses a significant recycling challenge due to the difficulty in separating the fibres for reuse, especially back into textile fibres.
The PESCO-UP project wanted to tackle this issue.
PESCO-UP partner Nordic Bioproducts Group realised they could use their patented Aaltocell™ technology to address the recycling challenge posed by polycotton textile waste. The technology facilitates the separation of cellulose and synthetic materials from mixed polycotton textile waste and modifies the cellulose for use as a valuable raw material in the production of new textiles. Since then, Nordic Bioproducts Group has been dedicated to refining this method to efficiently use polycotton textile waste and separate the different fibres to be used as high-value intermediates for various industries. PESCO-UP is scaling up this technology, marking a significant step towards widespread implementation.
This solution stands out due to its cost-effectiveness and environmental consideration. Unlike other textile recycling technologies that rely on expensive solvents, making scaling up difficult, this approach uses conventional, non-harmful chemicals. It also leverages existing market equipment, simplifying large-scale operation and making the solution economically feasible.
The technology combines chemical and mechanical separation methods to divide cotton and polyester from blended polycotton textile waste. This process, which is not only simple but also effective in achieving high purity in separating cellulose and polyester, allows both fractions to be used as raw materials for textiles, packaging, and composite applications. Currently, as part of the PESCO-UP project, Nordic Bioproducts Group successfully produced new regenerated cellulose textile fibres from 100% polycotton waste-derived cellulose. While the development is still at the lab scale, the results are promising. The regenerated cellulose from this process could also serve as a drop-in solution for viscose and Lyocell production, demonstrating its potential versatility and utility in the textile industry.
What’s next?
The next phase involves scaling the technology from lab to pilot-scale proof of concept, with the aim of collaborating with commercial partners to bring the solution to market on a large scale quickly. Partners are also exploring the use of larger equipment to process increased amounts of material, a critical step towards eventual industrial-scale implementation. In parallel, PESCO-UP will tackle more complex textile waste streams, focusing on removing dyes, finishing chemicals, and elastane from the feedstock, further refining the process.
The textile waste problem in Europe is vast, but innovative solutions offer a promising path forward. By efficiently separating and recycling polycotton textile waste, PESCO-UP not only addresses this significant environmental issue but also opens up new routes for sustainable textile production. With the support of the 18 other PESCO-UP partners comprising international companies and research institutes, Nordic Bioproducts Group is well-positioned to scale up this solution and create a sustainable and economically viable solution to Europe's textile waste problem.
