Mr. M. A. Jabbar, Managing Director of DBL Group, was recognized by the Global Compact Network Bangladesh (GCNB) as Bangladesh’s 2023 SDG Pioneer. The GCNB is the local chapter of the United Nations Global Compact, which is the world’s largest corporate sustainability initiative. His recognition was due to DBL Group’s contribution to the Circular Economy: by Producing yarns from recycled materials.
The textile industry generates a substantial amount of waste: however, it has been discovered that some of the non-hazardous waste is raw materials for brand-new items in the market. DBL has been contributing to various environmental sustainability initiatives throughout its supply chain, beginning from the Spinning Mill. Special processes are used that make use of pre-consumer waste – the recycled materials – from the various stages of the apparel manufacturing supply chain.
Matin Spinning Mills PLC, DBL Group’s Spinning Mill, is creating these special yarns through the philosophy of innovation, implementation, and inspiration. These yarns can even steer clear of some resource-intensive operations like Fabric Dyeing since their actions affect the remainder of the supply chain. DBL also took part in a project that tackles the global problem of plastic pollution: creating a path for a sustainable fashion industry.
The production of such types of yarns dates back to 2012. A committed Yarn Development Team is present, continually examining unique textiles and looking for the best ways to manufacture yarns. Additionally, the Development Team also works in accordance with sample swatches provided by the buyers. From this, more than 300 samples are being produced each month.
Our Spinning Mill makes use of different processes that reduce the consumption of cotton. Recycled textile materials are used instead of raw cotton, including wastes from:
- Blow Room in Spinning Mill
- Combing process in Spinning Mill
Garments cut-clips from the Cutting process in the RMG manufacturing operations
The consumption of raw materials is decreased by up to 60% when using yarns for loop and brush applications. Cotton Neppy Mélange yarns are decorative goods made from virgin fiber with up to 30% recycled materials. Neps of various colors are visible in the body of the yarn (made from recycled polyester), and this serves as decoration for the fabric’s surface. A snow appearance is created in the completed textiles by mixing waste from the Spinning Mill’s blow room, and this look contributes to a new trend in the fashion industry.
With H&M, DBL also worked on a project to use recycled plastic from pet bottles of Coca-Cola and mixed the polyester created with virgin cotton. From 9,300 kg bottles, 30,560 kg cotton-polyester blended yarns were created, which in turn were used to create 164,171 cotton-poly-terry apparel products having 20% recycled polyester.
In 2022, DBL used around 890,000 kg of recycled cotton, which prevented the need for 8,632,332,500 liters of water on cotton fields. By decreasing or even completely eliminating Fabric Dyeing procedures, this “Innovation in Yarn Production” has an influence on the forward linkage processes as well. The process elimination reduced energy use by 32,040,000 MJ, carbon emissions by 1,575,300 kg, waste by 35,333 kg, and water by 81,880,000.
There is now a substantial demand for these materials in terms of scale. We have even formed a new company to assist circularity as we scale our operations to increase capacity. To increase the present recycling capacity of 2 tons per day to 6 tons per day, DBL invested in the establishment of a specialized recycling business unit, DBL Textile Recycling Ltd.
By 2025, DBL aims to transform into a more sustainable business while continuing to be in line with the needs of all stakeholders on a global scale.
As a proud sister concern of the DBL Group, Eco Thread and Yarns is walking in the footsteps of the DBL Group toward a sustainable future through the manufacture of recycled and biodegradable sewing thread to support the global circular economy.
