March 31, 2025 – Aquafil has launched its first demonstration plant for the chemical separation of elastane and nylon in Slovenia, marking a significant milestone in the textile fiber industry. This pioneering move not only highlights the company’s profound expertise in research and development but also reinforces its unwavering commitment to sustainable innovation.
After over a decade of relentless research and development, Aquafil has unveiled a revolutionary technology that achieves the chemical separation of elastane and nylon. This new demonstration plant signifies a major turning point in the textile fiber sector, showcasing Aquafil’s determination and vision in overcoming challenges and embracing responsible innovation and circularity.
According to insights from the Color Masterbatch Industry Network, this innovative journey began in 2013 when Aquafil collaborated with the Georgia Institute of Technology on a joint research project, leading to the filing of an initial patent. Although the path to industrialization was long, Aquafil’s researchers persevered, and their perseverance and dedication bore fruit in 2022 with the announcement of an improved new technology patent, ready for semi-industrial scale testing.
Giulio Bonazzi, CEO of Aquafil, stated that with the launch of this demonstration plant, laboratory achievements have successfully transitioned into real-world applications, effectively separating elastane from nylon in mixed fabrics for the first time. The recycling of mixed fabric waste, particularly from sportswear and swimwear, has long been a challenge due to the tight interweaving of different fibers, making them nearly impossible to recycle. However, Aquafil’s breakthrough process has successfully addressed this challenge, unlocking the potential of discarded materials.
Currently, Aquafil aims to optimize every stage of this process, laying the groundwork for future large-scale industrial plants. The company has activated a network of strategic stakeholders to ensure a steady supply of waste and established an efficient supply chain, supporting an increasingly beneficial recycling model.
The nylon recovered through this technology will be entirely utilized in Aquafil’s ECONYL® regeneration plants, where it will be processed into new recycled nylon, ready for new textile applications. This initiative not only reduces reliance on virgin resources but also makes a tangible contribution to minimizing the environmental impact of the textile industry.
Giulio Bonazzi concluded that this project once again demonstrates Aquafil’s ability to turn vision into action. The company will continue to invest in cutting-edge solutions that combine research, technology, and circularity, providing concrete solutions to global environmental challenges and transforming today’s waste into tomorrow’s valuable resources.
About Aquafil and ECONYL®, as pioneers of the circular economy, Aquafil brings new products to life from waste through its innovative and sustainable ECONYL® regeneration system. Today, Aquafil stands as a leader in sustainable new production systems, with operations spanning three continents and 19 production sites worldwide.