The future of textile resource recovery: Latest innovations in QLD

Annually, Australia imports 373,000 tonnes of new clothes and produces 10,000 tonnes domestically.

Australia is the second-largest per capita consumer of textiles in the world, after the US. It’s estimated that over one million tonnes of textiles are dumped into landfill in Australia every year, with a significant portion generated by the hospitality industry.

Just before I headed off to work at the Paris Olympics in August (more about that in my next column), I had the opportunity to visit the inspiring textile resource recovery facility of BlockTexx in Loganholme, Queensland.

I was invited by Graham Ross, the co-founder of this amazing operation, to learn all about their journey and the innovations they’ve made since it all began in 2018. It is a one-of-a-kind, commercial-scale textile resource recovery facility – the only one in the world able to recover cellulose and PET plastic from mixed polyester and cotton fabrics at scale.

In just over five years, the operation has developed, tested, patented, and commercialised its clothing recycling business. Rather than calling it recycling, they use the term “re-manufacturing.” The chemical separation technology they employ is called S.O.F.T.™ (Separation of Fibre Technology).

At their facility, BlockTexx can process up to 116,000 garments per day, which equates to three semi-trailers a week or 10,000 tonnes a year. The commercial part of the operation only began processing in January 2024 after being developed during the height of COVID-19.

The process is fascinating and divided into “Before the Gate” – before the feedstock (or resource, not waste) enters the facility – and “From the Gate,” which refers to what happens after the clothing has been re-manufactured. Clients pay for the cost of logistics and decommissioning; however, it is still less expensive than traditional waste management.

The actual re-manufacturing process takes several stages. The textile waste is shredded to break the product down. It is then separated, where the polyester and cotton blends are treated with the S.O.F.T.™ process. This unlocks the components of polyester and cellulose, which are thoroughly washed and separated during the drying process. Once separated, the polyester is further dried and extruded into pellets, while the cellulose, which is 43 percent carbon, is dried to optimise product usability.

The “Before the Gate” process involves collecting and decommissioning clothing in preparation for shredding. This is the most labour-intensive part of the operation – zips, buttons, logos, fastenings, and elastic all need to be cut out and removed. This is where the social sustainability aspect comes into play. The BlockTexx team works with social impact partners, including The Big Issue, HELP Enterprises, Queensland Corrective Services, and charity partner Vinnies Queensland, supporting skills development, the disability sector, and long-term employment opportunities for those in need.

At the other end of the process, “After the Gate,” PET pellets are used to make polyester goods, and cellulose can be used in agriculture. Currently, 70 million tonnes of raw PET is made per year globally, including 23 million tonnes of plastic bottles and hard plastic. The “After the Gate” stage is where the money is made, selling products such as cellulose for agriculture, packaging, and building products. The latest developments include hydro-mulch for growing grass and cellulose packaging. This makes BlockTexx a true circular economy business. There are still challenges. The plant cannot yet process spandex, nylon, or wool. The focus is on poly-cotton and plant-based blends, which make up 93 percent of the world’s fabric. The team uses infrared spectrometers to determine the exact content of each fabric.

The challenge is to branch out into all sectors, including hospitality. Hotels and hospitality operations generate significant landfill waste in the form of bed sheets, towelling, bedding, and uniforms, so we should all take a closer look at this fantastic opportunity right on our doorstep. BlockTexx is always on the lookout for new partners, so now is the time to improve sustainability options in hospitality.

BlockTexx brings $43 million annually to the local economy and employs 20 staff. The current 4000-tonne processing capacity is scaling up to 10,000 tonnes annually. They are the world’s largest commercial-scale mixed textile resource recovery facility. So, what’s the future?

The goal is to create a second plant with a 40,000 to 50,000 tonne capacity in Australia.

By Liz Lycette Founder, Lycette and Associates Housekeeping Management Consulting