Sustainable Fiber Innovation: Sulochana Cotton Spinning Mills' PET Bottle Yarn Journey

Recycling has become a prominent focus in the textile industry, with exciting breakthroughs making headlines. One company at the forefront of sustainable innovation is Sulochana Cotton Spinning Mills, based in Tirupur. Known for their pioneering efforts in PET bottle and post-industrial waste recycling, as well as their commitment to sustainable production, Sulochana is shaping a greener future in the textile industry. In an exclusive interview with S. Krishna Kumar, Managing Director, and Girish, Head of Sustainability, we delve into the company’s history, product range, sustainability initiatives, and future plans.

Humble beginnings

The Sulochana Group’s eventful journey dates back to 1938 when it began as a cotton trading unit. “We are now a fourth-generation business. We had humble beginnings as cotton traders with our own gin and press, sending our cotton to Gujarat. We were considered frontrunners in the field back then. Due to our experience in the cotton industry, we ventured into spinning mill operations in 1990, with Sulochana Cotton Spinning Mills,” stated Krishna Kumar. Over the years, the group has also diversified into the manufacturing of industry-grade mattresses and solar panels.

Right from its inception, the management of the group aimed to distinguish themselves from the crowd. “While others were primarily focused on manufacturing generic yarns, we ventured into producing mélange yarns. As you may know, mélange yarns are created by combining two different fibers, such as two shades of cotton. Typically, polyester and viscose are used in the manufacturing process, with polyester being our primary choice. We initially started on a small scale with approximately 6,000 spindles, which has now expanded to 1.6 lakh spindles across four locations. With a daily output of 80,000 kilograms of yarn, we are recognized as one of the leading producers of mélange yarn in the southern region,” he elaborated.

The company’s product range includes, mélange yarn, recycled polyester fiber, cotton yarn, knitted fabrics and garments.

Manufacturing infra & exports

Sharing the highlights of the company’s manufacturing infrastructure, Krishna Kumar stated, “We have a total of six manufacturing plants. Specifically for spinning, we operate four units, with one each in Coimbatore, Dindugal, Kallipalayam, and Chitambalam. The last two locations are situated in close proximity to Palladam. Our polyester recycling unit is situated in Chitambalam. Additionally, we have two garmenting units in Palladam. We have a comprehensive presence across the textile value chain. Our daily fabric production amounts to 20,000 kilograms, and we manufacture 800,000 garments per month.” The company employs approximately 3,500 staff members across its units.

Over the years, the company has significantly expanded its global presence. When discussing its primary export markets, he stated, “We hold a prominent position as one of the largest suppliers of sustainable cotton mélange yarns to Bangladesh. Additionally, we export to Egypt and South Korea. Similarly, we have a substantial export volume to the USA. In terms of garments, our main focus is on European countries. We have established a strong presence in Bangladesh and continue to expand our operations there.”

A strong emphasis on research and development (R&D) is another core strength of Sulochana Spinning Mills. “At our organization, we view R&D as a fundamental aspect. Our R&D center is dedicated to testing various new fibers sourced from different parts of the world. We take pride in being the first to collaborate with anyone seeking to test a fiber, and we seize the opportunity to spin that specific fiber. We are always prepared to collaborate with like-minded individuals who share our commitment to sustainability,” highlighted Krishna Kumar.

Trash to textiles

Sulochana Spinning Mills is recognized as one of the pioneers in PET bottle recycling. Girish explained the main reason behind their decision to venture into PET bottle recycling, saying, “We embarked on the sustainability path long before it became an industry buzzword. We initiated our recycling journey at a time when recyclers were seen as mere rag pickers. Our commitment to sustainability extended beyond just the product; it also encompassed the entire process. By diverting 7 million PET bottles from landfills, we are mitigating environmental hazards. It is worth noting that PET bottles take a minimum of 450 years to degrade, and in some cases, it can even take up to 1000 years.”

During this period, the textile industry in Tirupur was grappling with pollution-related challenges. Girish pondered, “Why can’t we produce polyester in a different way?” They decided to take the recycled route and began recycling PET bottles into polyester fiber in 2007. Initially starting with a capacity of 50 tons per day, they have now scaled up production to approximately 135 tons per day. They recycle an impressive 7 million PET bottles (standard 1-liter bottles) every day.

Girish proudly mentioned, “Around one-third of our plant area is filled with vegetation. We have strategically planted trees that bear fruits throughout the year, attracting a diverse range of birds to our premises. Artificial nests are provided, resulting in an excellent egg-to-bird ratio due to the absence of predators. Currently, we have around 10,000 sparrows on our premises. On the water front, we have implemented a Sewage Treatment Plant (STP) to recycle and utilize water for vegetation. Solid waste is utilized to generate biogas, powering our canteen, which has been operating on 100% biogas for the past two years.”

Cutting waste recycling

The company is also known as a trendsetter in the region for their recycling of cutting waste. Girish explained, “In the apparel industry, achieving 85% efficiency is considered commendable, which means 15% waste is generated. Previously, this waste was used for cleaning purposes in workshops without adding any real value. However, we have successfully shredded the cutting waste into fibers and combined them with our recycled polyester, breathing new life into them as they are reintroduced into the fashion stream. What was once considered waste, we have effectively transformed into valuable resources.”

Key differentiators

According to Girish, while many others entered recycled yarn production, spinning the yarn through the OE (Open End) spinning method, Sulochana distinguishes itself through certain key factors. “One significant difference is that we spin recycled yarn in ring spun route, same method as how virgin fiber is spun. This ensures superior hand feel and maintains good quality. Another distinguishing factor is that we use 100% renewable energy to spin our recycled yarn,” he observed.

“We have conducted product life cycle analysis (LCA) as well as process LCA, as it is essential to assess and substantiate sustainability claims. The results have been fantastic. For example, if we consider a blend of 55% recycled cotton and 45% recycled polyester, compared to conventional cotton, it saves approximately 96% in terms of carbon emissions (GAG), 78% on energy consumption, and 99.2% on water usage due to the elimination of cultivation and dyeing water,” he noted.

Another notable sustainable initiative at the premises is the replacement of electric grass cutters with goats. Girish explained, “Electric grass cutters consume a significant amount of electricity, so we introduced around 40 goats five years ago for grazing. Now, the number has grown to 360 goats, completely eliminating the need for electric grass cutters. Wherever possible, we have implemented sustainability initiatives. I would say that a commitment to sustainability is inherent in our top management.”

Process sustainability

While PET bottle recycling was discussed earlier, the company also ensures a high sustainability quotient in the manufacturing process. “The 135 tons of polyester we produce are dyed without a single drop of water. We employ the dope dyeing method, where coloring pigment is directly added to the molten plastic. In comparison to conventional dyeing methods, we estimate that we save around 9 million liters of water daily. All the energy we use is sourced from renewable sources, with 94% coming from wind energy and 6% from a dedicated solar plant, including rooftop solar installations. Furthermore, all the solar panels we use are manufactured by us,” he mentioned.

CSR initiatives

The company is actively engaged in various corporate social responsibility (CSR) initiatives. One such initiative involves running a shelter for stray dogs. Girish explained, “Our shelter currently provides care for approximately 700 dogs. People bring in dogs that have been involved in accidents or have lost limbs, and we take responsibility for their well-being. We have dedicated veterinarians who ensure their proper care. Additionally, we operate a pet clinic where the general public can avail subsidized treatment for their pets. Similarly, we have pharmacies located in different areas, as well as a diagnostic laboratory where the charges are significantly lower than commercial rates. Furthermore, we are proud to be a part of ‘Vanathukkul Tirupur,’ an NGO established by the industry, which has successfully planted over 1.5 million trees in just six years.”

Price neutrality

While striving for sustainability, the company also aims to maintain cost-effectiveness for end customers. Girish expressed, “Ultimately, the game revolves around the price. We strive for price neutrality, which can only be achieved by adopting a holistic approach. If you compare recycled yarn to virgin yarn, the former may appear more costly. However, when considering the entire process, it’s important to remember that there is no need for dyeing. This eliminates dyeing costs, resulting in a lower final fabric cost. Therefore, our goal is to provide price neutrality while delivering the best in sustainable value. However, there must be stakeholders who share the same vision. We encourage the industry to seize this opportunity and collaborate with Sulochana Spinning Mills. We have recently started manufacturing dope-dyed filaments, primarily used in the athleisure and activewear segments. Globally, only a few players are involved in dope-dyed filament production.”

Textile to textile recycling

The company has an intriguing initiative lined up for the near future: textile-to-textile recycling. Girish emphasized its significance in reducing the amount of textile waste that accumulates in landfills. He noted, “Globally, only approximately 1% of textiles are currently recycled.” Sulochana Spinning Mills has already begun taking steps toward this objective by aligning with it 9 SDGs, which focuses on sustainable development goals related to Industry, Innovation, and Infrastructure. “By 2030, we aspire to excel in all nine goals and become industry leaders,” Krishna Kumar concluded.