Fukui textile waste recycled into premium yarn through Guru Guru Yarn

Guru Guru Fukui completed a demonstration experiment for its Guru Guru Yarn project, which establishes a circular model that recycles textile production waste into new yarn. This project successfully demonstrated horizontal fibre-to-fibre recycling, a process that remains rare within the domestic industry. The association developed a material-recycled yarn using polyester waste generated in Fukui Prefecture and is now moving towards commercialising products such as fleece and sweatshirts.

Fukui Prefecture is a textile production centre that manufactures a wide range of products, including long-fibre fabrics, knits, and ribbons. According to regional statistics, the region produces approximately 156 million square metres of fabric annually. However, this large-scale production inevitably generates a huge volume of waste, such as offcuts and scraps. While the region possesses advanced technical capabilities, managing this waste remains a challenge. Currently, less than 1% of recycled polyester comes from fibre-to-fibre recycling, as most textile waste is either incinerated or downcycled due to the difficulty of separating blended materials.

The Guru Guru Yarn project seeks to move from a linear make, use, dispose structure to a “make, use, return” model. To overcome local technical limitations, Guru Guru Fukui collaborated with several partners across Japan, including SHINDO Co., Ltd. and Monster Co., Ltd. in Fukui, as well as firms in Hiroshima, Tochigi, Osaka, and Wakayama.

The process involves collecting polyester waste, melting it down, and re-moulding it into pellets. These are then spun into fibres and blended with premium New Zealand Merino wool. By combining recycled polyester with high-grade wool at a 30% ratio, the project created a yarn that offers better durability and elasticity than pure wool while remaining cost-effective.

The recycled yarn is already being utilised in several high-value applications. Apparel manufacturers such as A-GIRL’S Co., Ltd. and Monster have produced fleece and sweatshirts that highlight the texture of the recycled material. Additionally, the outdoor brand T.K Garment developed knit hats and neck gaiters for sale at the Campanella outdoor shop. Furthermore, the manufacturer SHINDO is using yarn made from its own production waste to replace materials in its existing wool knit binder tape line. Guru Guru Yarn model proves that production waste can be treated as a valuable resource rather than mere refuse.