Usha Yams, as a regenerated yarn manufacturer is known for thie own in-house research, quality control, and the most modern production facilities which ensure consistent global standards of high quality for every product. They consistently deliver flawless colored regenerated yarn to produce knitted and woven garments acceptable as per global standards. By using pre-consumer garment cutting waste and polyester made from recycled PET bottles to produce a quality recylced pre dyed yarn, they make sustainable products with a significantly reduced environmental footprint at a lower cost.

Tell us a brief about your product line and your capacity.

Our product line is distinguished by a harmonious blend of sustainable and recycled fibers, firmly rooted in circularity principles. We offer a diverse range of blends that include both pre and post-consumer cotton, polyester, and viscose. Usha Yarns are available in a Ne count range of 8 to 30s, offering precolored shades that eliminate the necessity for additional dyeing processes. These yarns are widely recognized for their exceptional quality and are wellsuited for manufacturing both knitwear and woven fabrics, making them highly desirable for various clothing and garment applications. Usha Yarns have the capacity to annually produce over 18,000 metric tons of recycled yarns, catering specifically to renowned global brands.

We are unrivalled in the recycled yarn industry, pioneering with a gold standard of quality. Our dedication to excellence ensures larger lot sizes and higher volumes, offering a wide spectrum of colors, blends, and consistently superior quality with 100% recycled content.

Today, our customers rely on us for more than just yarn. They trust in our commitment to uphold the highest standards in quality, traceability, chemical compliance, social responsibility, and environmental sustainability. Supported by numerous verified claims and certifications such as GRS, RCS, OCS, ISO 14001, ISO 45001, IGBC, Higg FEM, Higg FSLM, SLCP, INTERTEK GREEN LEAF, and OEKO, we take pride in exceeding expectations and leading the charge in sustainable textile manufacturing.

What are your unique products and what contribution they have in your company as well as industry's growth?

Our latest 'Puneh' materials represent a unique offering, featuring a variety of sustainable fiber blends. The name 'Puneh', derived from Sanskrit meaning 'again', embodies our commitment to sustainability. These blends include pre-consumer cotton fibers alongside sustainable options such as Liva Reviva, Recycled Postconsumer Cotton, Organic Cotton, and Recycled Polyester. They are designed for creating both knitted and woven fabrics, suitable for garments and home textiles. Our fourth facility, operational since November 2023, is dedicated to the advancement of our newest series of Puneh material blends.

What is your USP? Who are your competitors and what sets you apart from your competitors?

We are unrivalled in the recycled yarn industry, pioneering with a gold standard of quality. Our 
dedication to excellence ensures larger lot sizes and higher volumes, offering a wide spectrum of colors, blends, and consistently superior quality with 100% recycled content. Today, our customers rely on us for more than just yarn. They trust in our commitment to uphold the 
highest standards in quality, traceability, chemical compliance, social responsibility, and environmental sustainability. Supported by numerous verified claims and certifications such as GRS, RCS, OCS, ISO 14001, ISO 45001, IGBC, Higg FEM, Higg FSLM, SLCP, INTERTEK GREEN LEAF, and OEKO, we take pride in exceeding expectations and leading the charge in sustainable textile manufacturing.

What is the potential of Recycled/Sustainable products in Indian as well as Global market?

The global sustainable products market is currently experiencing a significant upswing with a highly promising outlook. This growth is driven by several factors, including heightened consumer awareness of environmental issues, proactive government initiatives promoting sustainability, increasing emphasis on corporate social responsibility, ongoing innovations in eco-friendly technologies, and rising international demand for sustainable products.

In this converging landscape, India stands poised to lead in the global sustainable fashion and textiles sector. Leveraging its rich history in textile production and a burgeoning ecosystem of sustainability-driven enterprises, India has the potential to shape theindustry's future significantly. By harnessing its strengths and adopting sustainable practices across the entire value chain, India not only meets the increasing demand for eco-conscious products but also sets new benchmarks for sustainability on a global scale.

How do you source PET bottles and what challenges you face in your procurement?

We do not directly source PET bottles. Instead, we procure recycled polyester staple fibers from certified third-party suppliers, which we blend with our recycled cotton.

What are major challenges you are facing in production process?

Managing color and blend consistency, chemical compliance, and supply chain traceability are major challenges in textile recycling, which we excel in managing better than any other.

How do you ensure the quality and purity of recycled yarns? What modern technology you are using for this process?

At Usha Yarns, ensuring quality and purity throughout the recycling process is our top priority. We leverage cutting-edge technology to achieve this. Our process begins with advanced digital scanning devices that meticulously test blends to identify various materials and colors.

To effectively separate colors and blends, we utilize state-of-the-art machinery from renowned brands like Rieter, Trützschler, and Schlafhorst. These machines are specially designed to handle diverse blend types and ensure efficient separation.

We have collaborated closely with leading manufacturers of spinning and recycling machinery to develop equipment tailored specifically for recycling purposes. Notably, we are globally recognized as the first spinner to utilize Rieter's COM4RECYCLING ROTOR technology and Trützschler's TRUCYCLED system. These innovations underscore our commitment to sustainability and exceptional quality.

Complementing these advanced technologies is our in-house testing facility, which plays a pivotal role. Here, we conduct rigorous quality control checks at every stage of the recycling process. This ensures consistent high quality in our recycled yarns across different material colors and blends.

As a sustainable business, what specific initiatives have you undertaken to minimise environmental impact?

Sustainability is at the core of our values. As a committed Science Based Targets (SBTi) company, we rigorously monitor our scope 1, 2, and 3 emissions,striving for decarbonization and aiming to achieve net zero by 2050. Our participation in the Business Ambition for 1.5°C campaign underscores our pledge to halve global emissions by 2030, aligning with a leading coalition of companies dedicated to this critical goal.

In 2023, we achieved a notable 7.6% reduction in our total GHG emissions (Scope 1 + 2). We also made significant strides in lowering the intensity of GHG emissions per tonne of yarn by 2.24% and reducing CO2 emissions per crore of revenue by 47.69%.

Energy conservation is integral to our daily operations at Usha Yarns. We continuously optimize our energy usage through initiatives such as installing LED lights, repairing air leakages, and adopting solar panels. Over the past three years, these efforts have resulted in a remarkable 44% reduction in energy per 10 million INR turnover and a 17?crease in energy per tonne of production.

We ensure the integrity of our recycled materials through certifications like the Global Recycling Certificate, ensuring compliance across all aspects. By leveraging tools like the Higg MSI and conducting Life Cycle Assessments (LCAs), we integrate Usha Recycled Fibre into the Higg Index materials library, enabling brands to evaluate its environmental impact. Additionally, we've transitioned to a resource-efficient dry process for producing dyed yarns, completely eliminating water and chemical usage.

Our commitment to sustainability extends to the wellbeing of our workforce. We prioritize employee safety and security through robust systems such as Hazard Identification and Risk Assessment (HIRA) and stringent fire prevention measures.

What are the certifications and Compliances needed for developing this business in Indian as well as Global markets?

We must ensure that all products and facilities comply with both environmental and social standards to attain global certifications. Among the sought-after certifications are GRS, RCS, OCS, ISO 14001, ISO 45001, IGBC, Higg FEM, Higg FSLM, SLCP, INTERTEK, and OEKO-TEX.

What role you foresee the Govt need to play in supporting the sustainability in this business and what are your expectations from Govt?

The textile recycling industry holds a promising future with substantial returns in terms of employment, environmental benefits, and economic growth, provided that the government extends its support. This backing can be facilitated by attracting global technologies, innovations, and solutions to enhance the industry, while also creating more opportunities for market, business and investment.