To fortify its spinning and denim manufacturing operation, Vietnam-based XDD Textile has built a recycling process designed to divert more products from landfills, which would help alleviate the estimated 25 billion pounds in annual textile waste produced, according to the Council for Textile Recycling.
Recycled cotton prevents additional textile waste and requires far fewer resources than conventional or organic cotton.
The waste is often classified into two categories: pre-consumer waste, which includes scraps created by yarn and fabric byproducts, and post-consumer waste, which includes garments from previously recycled finished goods in partnership with a local factory.
The larger volume of recycled cotton sources is produced through pre-consumer waste. XDD has two methods to produce its recycled cotton, both of which were certified by Control Union, Recycled Claim Standard (RCS) and Global Recycle Standard (GRS): the first is using the leftover from its own spinning yarn process, and the second is recycling from its own denim production waste. XDD has been spinning a high yarn count since 2013, notably spinning for brands such as Supima.
XDD’s circular Closed Loop System was designed so that the textile mill can collect and regenerate the cotton, and further increase its capacity to produce 100 tons of recycled cotton per month.
The main purpose of the system, which is powered by the XDD Sewage Recycle Process, is to reuse and recycle waste, particularly since Vietnam restricts waste imports.
To develop a more traceable and transparent cotton supply chain for its partners, XDD purchases 100 percent BCI-certified cotton from different countries worldwide. Additionally, all cotton bought from the U.S. has received certifications from the U.S. Cotton Trust Protocol and Higg Index, ensuring that the fabric is both traceable and transparent. The company has collaborated with Textile Genesis, which is a platform for customers to trace the source of their sustainable fibers.
XDD also is purchasing organic cotton from Turkey and India, which is also certified by both the Global Organic Textile Standard (GOTS) and Organic Content Standard (OCS). Despite the current global cotton shortage, XDD can ensure that it preserves a stock keep of over 20,000 tons, and is ready for any order size to meet buyer demands, as a stable cotton supply is part of its “never out-of-stock” promise.
Latest innovations at XDD
XDD plans a stable foundation for its future development, with aims to further produce collections that can benefit both the consumer and the environment alike, while also increasing its product variety and capacity.
In 2023, the manufacturer will launch a piece dye and greige factory located within the denim mill. It is expected to have a production capacity of 1 million yards per month.
To maintain its status as a true vertical mill factory that strives to embed continuous improvement in the manufacturing process, XDD will launch its new spinning factory in 2024. The facility, based in Vietnam’s Quang Ngai province, will be located next to the denim mill.
The new facility’s purpose is to spin different types of products, particularly TENCEL™ Lyocell™, EcoVero™ and Modal™, as well as TENCEL™ x REFIBRA™, but also with T400, Creora® and other cotton products.
As part of the plan to expand and develop the company’s business, XDD aims to launch a garment factory in 2025. The facility would help the mill widen its range of production possibilities to provide more options to customers, and become a true vertical factory in the future.