Trützschler, a German family-owned company with more than 130 years of experience in textile machinery and a global footprint spanning spinning, carding and nonwovens, is pushing deeper into circular production with technology that transforms cotton waste into measurable profit.
At the heart of the strategy is the company’s Online Fiber Recovery Line, designed for use in blow room operations — the first and one of the most material-intensive stages of yarn production. Blow rooms traditionally lose between 3% and 7% of usable cotton during cleaning, a cost long accepted as unavoidable in spinning mills.
Trützschler’s system challenges that assumption. Its blow room lines already minimize waste through advanced cleaning and control technology. The remaining residual waste is then extracted online, carefully cleaned and directly reintroduced into the process, allowing valuable fibers to be recovered instead of discarded.
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According to company calculations, a spinning mill running a single blow room line at around 1,000 kilograms per hour and processing roughly 8,000 tons of cotton annually can recover up to 160 tons of fiber per year. At an average cotton price of about €1.80 per kilogram, that translates into approximately €288,000 in annual raw-material savings, effectively converting waste into profit with a short payback period.
The technology arrives as spinning mills worldwide grapple with volatile cotton prices, rising sustainability demands and shrinking margins. By increasing raw-material yield and reducing dependence on fresh cotton, Trützschler positions fiber recovery not just as an environmental measure but as a core profitability lever.
Industry observers say solutions like online fiber recovery signal a broader shift in textile manufacturing, where efficiency, cost control and sustainability are increasingly intertwined — and where waste is no longer a loss, but a resource waiting to be reclaimed.
