As consumers become more environmentally conscious, the apparel industry is undergoing a much-needed shift toward sustainability. One innovation at the forefront of this change is recycled yarn—a responsible and resource-efficient alternative to virgin fibers. From t-shirts and polos to hoodies and track pants, recycled yarn is helping brands create high-quality apparel while minimizing environmental impact.
At Apparel Factory, we specialize in manufacturing premium blank and custom knitwear using sustainable materials like recycled yarn—helping forward-thinking brands bring eco-conscious collections to life.
What Is Recycled Yarn?
Recycled yarn is made by repurposing waste materials—either pre-consumer textile scraps or post-consumer products like used garments and plastic bottles. Instead of discarding these items into landfills, they are processed into new yarns that can be woven or knitted into fresh, sustainable fabrics.
Whether you're building an ethical fashion label or refreshing your product line, choosing garments made with recycled yarn is a smart move for both your brand and the planet.
How Is Recycled Yarn Made?
There are two primary processes used in recycled yarn production:
1. Mechanical Recycling
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Step 1: Textile or garment waste is collected and sorted.
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Step 2: Materials are shredded into fibers.
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Step 3: Fibers are spun into new yarn, ready to be used in fabric production.
This process is common for recycled cotton and wool. It often includes pre-dyed materials, reducing the need for further dyeing.
2. Chemical Recycling
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Used mostly for synthetic fibers like polyester.
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Breaks fibers down into base molecules through depolymerization.
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These molecules are purified and polymerized into new, high-quality yarn.
Common Materials Used in Recycled Yarn
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Recycled Polyester (rPET) – From plastic bottles or discarded polyester clothing.
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Recycled Cotton – From cutting waste, unused stock, or used cotton textiles.
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Recycled Nylon, Wool, and Blends – From old garments or industrial scrap.
At Apparel Factory, we work closely with sustainable yarn mills to source premium recycled yarn blends tailored for softness, durability, and performance.
Why Recycled Yarn Is Environmentally Friendly
Recycled yarn helps brands and consumers take a stand for the planet. Here's how:
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Waste Reduction: Keeps plastic bottles and textile waste out of landfills.
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Water Conservation: Requires far less water than virgin cotton production.
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Energy Savings: Producing recycled polyester uses up to 75% less energy.
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Lower Carbon Emissions: Reduces greenhouse gas emissions during production.
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Fewer Chemicals: Many recycled yarns are created from pre-dyed materials, reducing chemical use.
Looking to reduce your carbon footprint with your next apparel line? Apparel Factory offers low-impact production using recycled yarns without compromising quality or style.
How Recycled Yarn Is Used in Apparel
Recycled yarn enables brands to deliver sustainability without sacrificing comfort, function, or fashion. Here's how it's being used in modern apparel:
👕 T-Shirts & Polos
Soft, breathable, and durable—ideal for brand merch, teamwear, or casualwear.
🧥 Hoodies & Sweatshirts
Mid- and heavyweight recycled blends provide warmth and structure with a modern fit.
👖 Track Pants & Joggers
Comfort-focused pieces made for movement—perfect for loungewear or activewear brands.
🧢 Caps & Accessories
Recycled yarn is making waves in sustainable headwear and add-ons too.
Want to launch your own eco-friendly collection? Apparel Factory manufactures and supplies premium blanks and custom garments made with recycled yarn, ready for screen printing, embroidery, and private labeling.
The Apparel Factory Advantage
Choosing Apparel Factory means choosing a partner who understands both quality manufacturing and sustainable innovation. We help emerging labels and established brands create premium knitwear that looks good, feels great, and aligns with eco-conscious values.
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🌍 Sustainable Options: Recycled yarns, organic blends, and low-impact dyes.
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🧵 Premium Construction: Engineered fits, reinforced stitching, and fine finishes.
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🎯 Flexible Customization: From blanks to fully custom designs.
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📦 Reliable Global Supply: Trusted manufacturing and worldwide shipping.
Let’s Stitch Sustainability Into Your Next Collection
Recycled yarn is more than just a material—it's a movement. And with the right partner, it’s easier than ever to align your products with the values your customers care about most.
Partner with Apparel Factory to create your next line of t-shirts, polos, hoodies, sweatshirts, and more—crafted from premium recycled yarn and built for conscious consumers.