Apparel manufacturing giant Crystal International Group Limited is aiming to recycle 40% of the fabric waste generated by its Sri Lanka factories this year following the success of a fabric waste upcycling pilot project.

Hong Kong based Crystal International last year teamed up with US technology firm PurFi on the initiative, which sorts and converts fabric waste generated from garment production processes such as cutting into high quality raw fibre for yarn manufacturing.

Crystal’s Sri Lanka factories manufacture mainly sportswear and intimate wear – and each year generate an average of 400 tonnes fabric waste. Much of this is synthetic and non-biodegradable polyester or nylon-based.

PurFi says its “proprietary rejuvenation process” combines the best of chemical and mechanical recycling, and “will always match or exceed the quality of virgin counterparts.”

The company, which is now working with a multinational European textile manufacturer, owns 14 patents related to rejuvenating industrial waste – and says its technology has been commercialised for companies including Walmart, M&S and NIKE. Among its products are yarn and filaments for fashion, performance wear and industrial wear.

Fabric waste upcycling involves just a few simple steps, Crystal International says. Its fabric waste is collected, sorted and packed in bags, then labelled and weighed, before being shipped to the overseas recycling plant where it converted into high quality fibre.

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“We want to pioneer a wave of change for the garment industry by setting a good example in our waste management approach, taking the initiative to upcycle our fabric waste and regenerate useful materials,” explains Catherine Chiu, general manager of corporate quality and sustainability. “There is a robust system for tracking transportation and upcycling processes, which provides high transparency and avoids improper disposals.”

Following the success of the trial, Crystal’s Sri Lanka factories are going to drive up the upcycling fabric target to reach 40% of fabric waste by 2019, and expand the types of fabric waste for collection.

The company also plans to scale up by extending the initiative to more of its factories. In total, the group operates around 20 production facilities in Vietnam, China, Cambodia, Bangladesh and Sri Lanka making lifestyle wear, denim, intimate, sweater, and sportswear and outdoor apparel.