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The World’s Favorite Fiber is A Terrible Thing to Waste
Each year, nearly 30 million tons of cotton is discarded as waste. Approximately 85% is buried in landfills or incinerated, while less than 1% is recycled into new garments.
Conventional cotton recycling methods rely on mechanical shredding, which damages the cotton fibers making them unusable for high quality textile yarns, and are unable to separate the cotton out from blended fabrics.
Apani has developed a patented chemical process capable of extracting cotton from both pure and blended textile waste and regenerating it into virgin-quality fiber. This innovation transforms a global environmental and economic liability into a sustainable, high-value asset.
100m
tons of textile waste discarded every year
85%
of textile waste is buried in landfills or incinerated
<1%
of textile waste is recycled into new garments
The Apani Process
WASTE PREPARATION
Textile waste is cleaned and mechanically shredded to prepare it for processing. Apani’s proprietary chemistry selectively targets cellulose, allowing it to process both 100% cotton textiles and cotton-rich blends.
ARC FIBER™ EXTRUSION
The dissolved cotton solution is injected into a water-based coagulation bath, where it reforms into cotton cellulose fibers. Apani’s chemistry separates from the cotton cellulose and is collected and reused in a closed-loop system.
DISSOLUTION
Cotton is dissolved into a liquid solution to create a ‘spinning dope’. When processing blended fabrics, all non-cellulosic fiber material remains in solid form and is separated out and recycled in a separate process.
Introducing, ARC Fiber™.
100% COTTON
Apani Recycled Cotton (ARC)™ is 100% cotton, made from cotton waste.
CUSTOMIZABLE
ARC Fiber™ is engineered to meet customer specifications. Tunable parameters include staple length, diameter size, profile shape, elasticity, flame retardance, traceability markers, and more.
ENVIRONMENTALLY FRIENDLY
ARC Fiber™ is produced in a closed-loop system without toxic chemicals or energy intensive processes. All reagents and solvents are collected and reused.
OUR
WASTE
SOURCES
PRE-CONSUMER
It is estimated that nearly half of all grown cotton is discarded as waste before ever being used in a finished product. Apani will collect this waste from gins, knitting, and cutting facilities, diverting it from landfills and turning it into high quality, 100% cotton yarn.
POST-CONSUMER
Every year, consumers discard ~100 million tons of textile waste. This waste is buried in landfills or incinerated where it produces millions of tons of greenhouse gasses including CO₂ (carbon dioxide) and CH₄ (methane).
The Apani Process
Textile waste is collected, cleaned and shredded before processing. Apani's chemistry can process 100% cotton and cotton blended materials.
WASTE PREPARATION
Prepared material is added to Apani's chemistry where cotton is dissolved leaving synthetic materials behind to be recycled elsewhere.
PROCESSING
The solution is then injected into a water-based bath where new cotton fibers are created. Apani's chemistry is recaptured and used over and over.
REGIN™ YARN EXTRUSION
Every ton of waste cotton reclaimed by Apani will save:
5
Tons of CO₂ equivalent emissions
500,000
Gallons of fresh water
100,000
Square feet of land
30%
Reduction in chemical emissions
