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FILOTEX Ltd. model of recycling ‘cutting waste’ is replicable globally

Due to the shifting of consumer behavior towards fast fashion, textile production and consumption has been increased considerably and leading to a higher amount of textile waste. Filotex Ltd is the pioneer in Bangladesh to produce recycled products from ‘cutting waste’ of garments industry.

FT Research Team

Filotex Ltd., a sister concern of Mosharaf Group, is playing a pioneering role in solving the solid waste problem in Bangladesh textile and apparel industry. The company is producing luxurious recycled products to be used for home furnishing and upholstery since 2014 using sophisticated recycling technology from valuable ‘cutting waste’ of garments industry.

cutting waste recycled yarn at Filotex
Figure 1: Colorful doormat made from cutting waste’ recycled yarn.

It is the first factory in Bangladesh working with ‘Circular Fashion’ and 3R (Reduce, Reuse, Recycle) concept introduced by the global brands. They think out of the cage to expel the concept of solid waste and need of virgin raw materials.

‘Circular Fashion’ and Filotex

Major global brands recently have committed to recycling back used garments into new recycled products to reduce the solid waste problem. Due to increasing consumer pressure for sustainable products ‘Circular Fashion’ is getting popular every day.

The global brands will be able to sell Filotex products under the criteria of ‘Circular Fashion’ by using the ‘Cutting Waste’ of those brands as the raw materials of those products. As most of the leading brands are producing their garments in Bangladesh, they will be able to send the ‘Cutting Waste’ from their vendor factories to Filotex to recycle them into fashionable sustainable products.

yarn packages processed from cutting waste at Filotex
Figure 2: Different color yarn packages processed from ‘cutting waste’.

Filotex product range

Filotex is producing different types of products with high quality. Filotex’s target is to achieve reliance on both national and international market by their high-quality product and they are on it. Available colors of the products are-

  • White
  • Red
  • Pink
  • Yellow
  • Black
  • Sky-blue
  • Royal blue
  • Orange
  • Light & Deep Green

Filotex product variety is-

  • Doormat
  • Table mat
  • Terry towel
  • Carpet etc
Filotex products
Figure 3: Lush and varied textures bring interest and visual movement to the home as subdued colors achieve a warm and understated elegance.

Production process

Filotex gives zero tolerance about quality and they have installed the world’s best machinery for recycle yarn production. Production process flow chart of recycled yarn-

  • Collecting the cutting wastage
  • Color-wise sorting
  • Beating
  • Mixing
  • Waste opener (Margasa Recycling)
  • Bale pressing
  • Mixing and Blending
  • Carding
  • Rotor spinning
  • Winding, Doubling, Coning
  • Sectional Warping
  • Warp and Crochet Knitting
  • Warp and Crochet Knitting
  • Jacquard

In Filotex mainly knit fabric cutting wastages are recycled because when knit fabric are beaten then easily turn into fiber stage, the quality and strength are better than compared to other textile wastage. Sometimes polyester is blended with cotton if the buyer has requirements and often the ratio is 90% cotton and 10% polyester. But most of the time it is 100% cotton.

Waste opener (Margasa Recycling) at FILOTEX Ltd
Figure 4: Waste opener (Margasa Recycling) at FILOTEX Ltd.

In the production process, every stage is controlled very carefully for ensuring the quality of the yarn. Filotex has 12 world class brand Rotor spinning m/c which capacity is 15 tons daily. They have installed Italian branded m/c e.g. Zerbo, Comet, Somet, Magetron, Comez etc. for producing qualitative final products mentioned before.

Environmental footstep

It is difficult to say the exact figure but assumed that China has about 26 million tons of textile wastage, where Japan has about 1 million ton, and the USA has about 1.2 million tonnes. Bangladesh also produces a considerably large amount of textile waste. In 2013, the knit fabric cutting wastage was 12,512 tons that reached 16,356 tons in 2017. It is expected that the amount of solid waste will be 43,000 tons in 2025.

The wastage not only comes from garments producing stage but also arrives from after use of a product. So, this is now a global headache but some of the countries use 3R to manage this wastage. In fashion waste management system i.e. landfilling, incineration or other processes are costly and not eco-friendly. Also, there are many limitations for many countries.

So, it is better to recycle and reuse the wastage than burning or landfilling them. In this regard, Filotex is utilizing and saving the environment by recycling the garments cutting wastage and producing luxurious upholstery products.

Conclusion

There is a huge demand for eco- friendly products in many developed countries. And what Filotex producing is absolutely eco-friendly. The recycled products price is a bit more than regular same type product where the quality is the same or better. There is a huge possibility of these recycled products both in the national and international market. The buyers and consumers should adopt the mindset of giving a better price to the suppliers as the textile supply-chain can ensure the concept of making sustainable products. So, Filotex could be an example for the Bangladesh textile industry regarding this situation.

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