Sustainability in Textiles: Why Spinning Mills running Recycled-Fibre Choose Green Compact Technology

The textile industry is at a turning point. With rising buyer demand and tightening regulations, spinning mills are under pressure to shift from a linear take–make–waste model to a circular, low-carbon future.

For mills working with recycled fibres, whether coarse counts, PC blends, or linen-cotton, the challenge is to spin consistent, high-quality yarn while staying profitable. This is where Rotorcraft’s Green Compact system, represented in India by K.M. Associates, makes the difference.

Why is recycled-fibre spinning different?

Recycled fibres, especially mechanically recycled cotton and post-consumer textiles, are shorter and more irregular than virgin fibres. That leads to:

• Weak fibre cohesion in the drafting zone.

• Higher yarn hairiness.

• More end-breaks during ring spinning.

  
  

For mills producing coarse counts below 50s or PC blends, these issues reduce yield, increase rework, and cause more rejections in export markets.

Why Green Compact is designed for recycled fibres

Recent studies confirm that recycled cotton can be blended into ring-spun yarn at commercial levels. Research published in 2022 shows up to ~25% recycled cotton can be used in 30 Ne yarns (medium counts) with the right process controls. This proves recycled fibres can be scaled, but it requires the right technology.

Green Compact compact-spinning improves fibre alignment and cohesion before twist insertion. For recycled fibres, this delivers:

• Stronger yarn: Compacts short fibres effectively, improving tensile strength and reducing end-breaks.

  
  

• Reduced hairiness & cleaner yarn: Lower fly waste and smoother surfaces — critical for weaving/knitting.

  
  

• Lower energy consumption: Green Compact uses low suction, cutting power bills while lowering CO₂ emissions.

  
  

• Retrofit friendly: Easy integration into existing machinery without huge capex.

  
  

These features directly address the recycled-fibre challenge while keeping mills competitive.

Policy drivers: Adoption is a necessity

Global regulations are reshaping textiles:

• EU Strategy for Sustainable and Circular Textiles (2030): Sets targets for textiles to be durable, repairable, and largely made from recycled fibres. Buyers sourcing for Europe will expect proof of recycled content.

  
  

• Extended Producer Responsibility (EPR): Countries in Europe are mandating EPR schemes where brands must finance textile collection and recycling. This incentivises brands to work only with suppliers who can reliably spin recycled fibres.

  
  

For mills, this means that buyers will increasingly demand recycled-capable yarns that meet traceability and sustainability standards.

Market signals: recycled fibres are going mainstream

Global brands are investing heavily in textile recycling and scaling sustainable sourcing. Major apparel groups are securing recycled fibre supply chains and working directly with mills that can process recycled blends at scale. This trend means buyers are actively seeking mills with proven recycled fibre spinning capacity.

The direction of the industry is clear: recycled fibres, stricter sustainability laws, and buyer pressure will shape the future of spinning.

Mills that adopt Green Compact technology now will not only cut costs and improve quality but also position themselves as preferred suppliers for global brands sourcing recycled yarns.