00:03This is an Indian post consumer material after the person has worn the cloth and then yeah, then they throw
00:08it away and then we get it collected through various NGOs
00:36The mountain behind me isn't garbage. It's fashion. It's wall trove.
00:41There are lots from around the world, somebody's old t-shirt, old sweater, old blanket and what not and somehow
00:46all of them have ended up here in one Indian city and that's Panipat.
00:51A place where old discarded clothes from across the world are given a new life.
00:56From your old cloth to making the yarn and to converting it to another cloth, we're gonna track what happens
01:01next when you throw your clothes away.
01:06This is where we have post consumer so this is what we collect from this is the Indian post consumer
01:12material.
01:12So after the person has worn the clothes and then yeah, then they throw it away and then we get
01:17it collected through various NGOs right and we buy it from them and then we sort it on the basis
01:22of colors.
01:23If you would have not purchased it, it would have gone to the landfill. So this is how your old
01:28wardrobe goes into recycling and then we make next product which is fiber from fiber to yarn and yarn to
01:34any product like a bath mat or a denim right or a t-shirt.
01:38We can make multiple products. So if you see over here, we have multiple colors just like white, red, orange,
01:44yellow. So all of these are sorted on the basis of color by color.
01:47And that is how you see many colors. Oh yea, the sorting out the colors, the beige, brown will be
01:51in one family. And then once they make the lot, they make a bunch of sack of it and then
01:55they will put it over the same lot again.
01:56Like the pink is there. Yeah, like the pink is there. And all the blues are here. Yeah.
02:03I'm about to be 40 years old.
02:04From 40 years old, I'm doing different things.
02:07Yeah.
02:07After the year we're working on it, you can find it here.
02:10You get to know everything about the clothes, the clothes, everything about the clothes.
02:14We have a name for everyone.
02:16Can you put it in the color?
02:18Yes, without it.
02:19Put it in the color?
02:20What?
02:20Put it in the color.
02:22Wow, what a lot!
02:26Let's put it in the color.
02:28I'll try it.
02:34We provide training to all of our staff.
02:36We do the health check-ups also.
02:38Plus, we provide them training.
02:40And all are actively, you know,
02:43they can do first aid in case of any emergency.
02:46So, every floor,
02:47we just give them their information
02:49in case of any problem,
02:50any labor can contact them
02:51and they'll help them out.
02:57So, this is when a new garment is made,
02:59there is a fresh table cutting,
03:01right, while making a new garment.
03:02So, here we assign multiple colors,
03:05pre- and post-consumer separately.
03:06So, if you see over here,
03:08you can see white, orange,
03:10and over there, you can see black.
03:12And then, we have multiple,
03:13maybe more than 50 colors over here.
03:16And then, whatever we need,
03:17we sort it on the basis of color and composition.
03:19Right.
03:19So, now, what is happening is,
03:21to bring a circular textile,
03:23right, every person,
03:25being a recycler, being a sorter,
03:27they are working together.
03:28So, whatever we are doing,
03:30is economically viable.
03:31We have solar energy here.
03:34We have no water usage,
03:36no chemical usage.
03:37Everything is eco-friendly.
03:38So, this is the first process.
03:40We will get the bags.
03:41For example, you saw those black bags over there.
03:44They are going to put these black bags,
03:47placed over this belt,
03:48conveyor belt.
03:49And this will go into the machine.
03:51There is a rotary cutter inside.
03:52It will cut into the multiple small, small pieces.
03:54And then, these can be recycled.
03:56As you saw over there.
03:58So, they are filling it up.
03:59You just have one machine like that?
04:01Yeah, this can cut around 1500 kgs in one hour.
04:04Oh!
04:05Yeah.
04:05One is enough.
04:07One is enough.
04:10These are called knits.
04:11So, this is usually from t-shirts, pajamas,
04:14like a hosiery kind of item.
04:15They are kind of similar fabric also.
04:17Not just the color,
04:18the fabric is also similar.
04:20Yeah, the fabric is also similar.
04:21So, basically, this is called knits.
04:23So, mostly the t-shirts are made out of the knits.
04:25So, how long will it take to recycle these?
04:27Make around 15 tons a day over here with two machines.
04:32Right?
04:33And we can produce more.
04:35We have total seven machines like this.
04:37Yeah, these are the machines.
04:40So, this guy will pick up the fabric waste
04:42from that bunch of lot
04:44where the ladies are picking up the contamination
04:46and the contaminated free material will pick it up
04:49and put it into the machine.
04:51After feeding it into the machine,
04:52this fabric will be converted into fiber.
04:55Come, I will show you.
05:01What we have put in the machine is the fabric clip.
05:04And what we have got is the fiber.
05:07From here, from this machine,
05:08it will go into the bale paste machine.
05:11So, from there,
05:12the material is coming into this bale paste machine.
05:15And then the bale is made.
05:17This bale will be used again for spinning purpose.
05:20Come with me.
05:21I will show you.
05:26So, once we have done the recycling,
05:29now the next process is we want to make yarn out of it.
05:32So, here you can see recycled fiber stacked up.
05:36We mix, depending upon the requirement,
05:38we mix some pet fiber in it or fresh cotton,
05:42depending upon the customer requirement.
05:43So, all of these machines do more cleaning of the material.
05:47So, we get other colors also, right?
05:49Yeah.
05:49Just like, you know,
05:51it is a whole eco-friendly and sustainable process.
05:54We make multiple colors.
05:55Just like you have seen,
05:56we were recycling the black material.
05:58So, we are going to make black from black,
06:00white from white,
06:01red from red,
06:02yellow from yellow.
06:03So, this is also not a natural cotton color.
06:06This means this was a white t-shirt.
06:08This was a white t-shirt or a white sweater.
06:11And we have recycled again into white fiber.
06:15Otherwise, you need to make fiber white.
06:18Now, you don't need to make it white.
06:19So, you are going to save a lot of water,
06:21a lot of chemical and a large amount of CO2 emission.
06:28So, all of this machine, right?
06:30We are going to process it, clean it and take it ahead.
06:34So, this material will be turned up for carding.
06:36Then, we will make it more fine.
06:39These are the carding machines.
06:40They make the fiber into the form of sliver.
06:44So, now you have seen the fiber.
06:45It is converted into the form of sliver.
06:47Let me show you.
06:52You see?
06:53Now, it is converted into the form of sliver.
06:55Now, it is more fresh, more clean.
06:58And it is ready for spinning purpose.
07:00From six slivers, we are making one sliver.
07:05So, the sliver will go inside the machine and turn it into the yarn.
07:11You see?
07:11It is going inside and the yarn is being made.
07:15Here, we call it a rotor spinning process.
07:20You see?
07:25This is how the yarn is formed.
07:32That's right.
07:33And once the yarn is ready, its possibilities are endless.
07:36The clothes you are wearing, the wetsheets you sleep on,
07:39the carpets in your home and even this rug all begins with yarn.
07:43Our next stop was a factory that manufactures rugs and supplies them to both Indian and international markets.
07:51We have made yarns.
07:51Once the yarn is made, you are in the factory.
07:54Yes, in the factory.
07:55What is the process of the yarn?
07:56After it we make paper.
07:59After it we make paper.
08:00After the yarn is cut, and then it is cut.
08:03After the yarn is cut, and then it is cut.
08:03Yes, how do you see.
08:04The yarn is cut.
08:06After the yarn is cut, we make fabric.
08:09So, the fabric is made.
08:10So, the fabric will be made.
08:12When we make fabric, we cut it in pieces, like this one.
08:18We cut the piece and we cut the piece
08:21so that we put the piece in the edges
08:25so that the piece will cut the piece
08:28After cutting and fitting, we cut the piece
08:31so that we cut the piece like this
08:34This is the finished product?
08:36Yes, this is the finished product
08:37Do you have your new products?
08:41We go all over the world
08:44This is the major market in the US
08:46Europe, Abu Dhabi, UAE
08:49and all countries
08:50So this is made from the roof
08:54The waste material is made from the roof
08:58The waste material is made from the roof
09:01After making this product, this is the final stage of the packaging
09:05So we put the stitching and labelling
09:07We put it on the floor
09:08where our QC team packs and passes
09:11and we dispatch it
09:14Now we put the U card and tagging
09:16and we put it in the cart
09:18Okay, these are cards
09:19The barcodes and rates
09:22Yes
09:23It's so fascinating
09:25And how much sustainable is it?
09:28100%
09:29Because there is no waste material
09:31It's totally eco-friendly
09:33Because it is made from the waste material only
09:35That's why
09:36And our unit is also recycled unit
09:38So whatever waste we have generated
09:40We again spin it into the yarn
09:41And then that yarn comes into the factory
09:43And then we again make the product
09:48What they told us
09:49And what we saw inside the factory
09:51Was very different from the hazardous image
09:53Of the textile industry often seen online
09:56Or is it painted a different picture?
09:59But is that the new reality of the industry?
10:00Look at these jeans
10:02These jeans are made from 30% recycled waste
10:04Which was discarded
10:05And there is no waste
10:09And in this way
10:10This jeans
10:10For the jeans
10:11There is a recycled fabric
10:13Used for the jeans
10:14And there is no chemical use for it
10:16And there is no waste
10:18And in this way
10:19There is no waste
10:20In this way
10:22That there is a second factory
10:23Which is daily
10:25The textile waste
10:26We are recycling
10:27Look at sustainability
10:30There is no option
10:31There is no responsibility
10:33There is no responsibility
10:34Bleaching
10:34In the dying
10:35In the water
10:37In the water
10:39In the water
10:40In the water
10:40In the water
10:42It is a myth
10:43And the recycling industry
10:45In the reality
10:46It is a myth
10:47What you have seen
10:51It's a myth
10:52organized sector that is more than 90% organized. We are making color-to-color.
11:01We are saving water. If you dye something, you can use 1 kg of cotton for 1 kg of water.
11:13Or for 1 kg of dyeing, you can use 5,000 kg of water. But we don't have to use
11:20any
11:20water. If you look at it, it will probably be 2 or 3 % of this industry. And it is
11:31also
11:31taking an ETP plant. It is also thinking that it will also take an ETP plant and take it
11:38license. But it is not a part of our association. I have to clear it.
11:49A few weeks ago, this was somebody's old clothing. Today, it's a rug. That's the journey
11:54millions of discarded garments go through Panipat every year. A city proving that for clothes,
11:59the end of one story can be the beginning of another.
12:04Long.
12:05Long.
12:05Long.
12:06Long.
12:06Long.
12:06Long.
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