New process recovers both nylon and elastane from mixed-fibre textile waste

Recycling clothes made from blended materials has long been one of the toughest tasks in textiles. Items like swimwear, tights, and leggings often combine nylon and elastane, making it difficult to separate the fibres. Most of these garments end up being burned or landfilled simply because no process could recover the materials.

Radici InNova, the research and innovation arm of RadiciGroup, has now developed a selective-dissolution process that can recover both nylon and LYCRA® fibre from mixed textile waste. The method uses safe, non-flammable solvents and works with both PA6 and PA66. Since both fibres and the solvent can be recovered, the process is financially viable and can be scaled.
To test the approach, Radici InNova partnered with The LYCRA Company and the lingerie brand Triumph. Together, they successfully produced a fully recycled lingerie set using fibres reclaimed from mixed-fibre waste.

Stefano Alini, CEO of Radici InNova, shared that this development proves the potential to recycle blended fabrics and use the fibres again in new garments. He noted that the project opens up meaningful possibilities for textile recycling and lays a solid base for the next steps.

Nicholas Kurland, Product Development Director at The LYCRA Company, added that the recovered LYCRA® fibre performed well after being re-spun. Its stretch, comfort, and recovery properties remained intact, showing that elastane can be brought back into the production cycle without compromising quality.

The project began four years ago with initial lab work focused on dissolving and separating fibres from multi-material fabrics. Once the team obtained small quantities of recovered LYCRA® fibre, they were sent for recyclability checks. Triumph later provided its production surplus fabric containing 16% LYCRA® fibre. From this material, Radici InNova recovered both fibres. The LYCRA® fibre was re-spun by The LYCRA Company, while RadiciGroup converted the regenerated nylon into Renycle® yarn.

Using these two recycled yarns, a 60-meter black fabric was produced. Triumph turned this fabric into a coordinated bra and brief set. The result is a working prototype that demonstrates a closed-loop process waste garments transformed into new clothing.

Vera Galarza, Global Head of Sustainability at Triumph, expressed that the brand is excited to contribute to the early stages of this work. The company now aims to develop a capsule collection and explore product identification and traceability systems to support true circularity. She noted that the project strengthens Triumph’s belief that recycling garments made from mixed fibres is achievable with the right collaborations.

The partners consider this first set a proof-of-concept, but it marks a clear step toward practical recycling solutions for blended fabrics, one of the industry’s most persistent waste challenges.