Valérius 360 & Trützschler develops high-quality recycled yarn

Portuguese textile supplier, Valérius 360 has partnered with German spinning technology company Trützschler to produce high-quality recycled yarn – opening up the massive potential to drive measurable progress toward a circular and sustainable textile industry.

In 2017, Valérius 360 was established in Portugal. It creates yarn by recycling byproducts of its own spinning and knitting operations, which keeps more material in the economic cycle for longer, reduces waste, and significantly improves sustainability. With the ambitious goal of improving the quality of yarn made from recovered waste fiber, its specialists recently started a new initiative. But there are a number of challenges in processing recycled fibers. For instance, the fiber quality decreases when fabrics are opened up to the tuft.

Trützschler supports spinners with applications involving recovered waste fibers thanks to its cutting-edge technologies and extensive knowledge. Their professionals are highly knowledgeable about the crucial impact that fiber and spinning preparatory steps have on the final yarn’s quality. We looked at ways to help Valérius 360’s project succeed in collaboration with them.

But there are a number of challenges in processing recycled fibers. For instance, the fiber quality decreases when fabrics are opened up to the tuft.

Trützschler supports spinners with applications involving recovered waste fibers thanks to its cutting-edge technologies and extensive knowledge. Their professionals are highly knowledgeable about the crucial impact that fiber and spinning preparatory steps have on the final yarn’s quality. They looked at ways to help Valérius 360’s project succeed in collaboration with them.

The Valérius 360 team was looking for ways to enhance the production of yarns that were 50% recycled and 50% virgin cotton. It was specifically looking for methods to lessen thick and thin patches, which interfere with the aesthetic of the textile surface.

The company conducted specialized tests at the Trützschler Technical Center in Mönchengladbach that demonstrated the superiority of a direct spinning process for this application over a procedure with a draw frame passage for rotor yarns.

In direct spinning, the card’s sliver is drawn straight into the draw frame that is built into the can stock. Compared to employing an autoleveller draw frame, this requires one fewer process step, saves space, and gives staff more time for other operations.

The ability of direct spinning to decrease the quantity of flaws in the yarn was evident. Thus, the yarn breaks were 30% less frequent and the Total IPI was 38% less frequent. Energy usage is also positively impacted by the direct spinning process: For a medium-sized plant, direct spinning provides a 5% potential savings advantage over the method with a draw frame passage. Savings of more than 5,000 euros per year are possible at an energy cost of 0.20 euros per kW.

Additionally, the Trützschler Customer Service division provided in-house training for the Valérius 360 team. Together, they looked at the process at the Valérius 360 production facility and made major improvements.

This makes it easier to reach the 50% Usterstatistics threshold for yarns derived from recycled raw materials. This serves as the benchmark for yarns produced from virgin raw materials. Therefore, 50% of all yarn manufacturers who use raw cotton for rotor yarns and yarn counts that are comparable create yarn of worse quality.

Trützschler is steadfastly committed to assisting its clients in the transition to a textile industry that is more environmentally friendly. This case study demonstrates how customers can use preparation systems from Trützschler to enhance the processing of recycled materials. This includes fiber preparation plant innovations like T-Blend and the TC 19iR. Additionally, it covers spinning preparatory ideas such as direct spinning using Trützschler’s distinctive IDF. This includes fiber preparation plant innovations like T-Blend and the TC 19iR. Additionally, it covers spinning preparatory ideas such as direct spinning using Trützschler’s distinctive IDF. Because quality is determined at the preparation stage, these cutting-edge solutions assist customers in utilizing the maximum potential of the material they are processing.

Miklós Pál Nagy, Manager at Valérius 360, said that they feel that right now the fashion industry is in a position to actively play a pioneering role in healing the environment and so recovering humanity, and they want to make their contribution to that. Trützschler has been and will continue to provide them with excellent support at all levels, including product development, assembly and customer service.