Alliance Fibres Expands into Textile-to-Textile Recycling with T2T Polyester Fibres
Alliance Fibres Expands into Textile-to-Textile Circularity
Gujarat-based Alliance Fibres, one of India’s early pioneers in recycled polyester manufacturing, is expanding into textile-to-textile (T2T) recycling with a new range of recycled polyester staple fibres (T2T r-PSF) and recycled polyester filament yarns (T2T r-PFY).
Led by Mr. Kuldeep Sangani, the company will manufacture T2T chips and downstream polyester products derived from both pre-consumer and post-consumer textile waste. The move strengthens Alliance Fibres’ position in India’s growing circular textile economy and supports the industry’s shift toward sustainable raw materials.
From Humble Beginnings to Industry Leadership
Alliance Fibres Pvt. Ltd. was established in 2006 in Kim near Surat, Gujarat, by three family groups under the vision of Mr. Chhaganbhai Sangani. The idea for entering the PET recycling industry emerged after a visit to the ITMA exhibition.
The company began operations with a recycled polyester staple fibre (r-PSF) manufacturing capacity of 20 tonnes per day, becoming Gujarat’s first PET recycling facility and India’s third.
According to Mr. Kuldeep Sangani, Director of Alliance Fibres, the company has consistently expanded its operations through technology adoption and product diversification.
Major Expansion Milestones
Alliance Fibres has achieved several milestones over the past two decades.
In 2010, the company added another 50 tonnes per day of r-PSF production capacity. A year later, it introduced India’s first mechanical recycled polyester filament yarn technology with an initial capacity of 20 tonnes per day, which was later doubled by 2020.
In 2015, Alliance Fibres established what it describes as the world’s first recycled PET rope manufacturing facility using PET bottle waste.
The company further expanded in 2023 with a 100 tonnes per day food-grade compliant PET washing facility catering to bottle-to-bottle recycling applications, PET sheets, and industrial-grade uses.
Manufacturing Scale and Product Portfolio
Alliance Fibres operates from a single 35-acre manufacturing complex in Gujarat.
The facility currently produces:
- 24,000 MT per annum of recycled polyester staple fibre (r-PSF)
- 14,000 MT of recycled PET filament yarns
- 1,000 MT of recycled PET ropes
- 46,000 MT of prime-grade PET bottle flakes
- 18,000 MT of recycled polypropylene (r-PP) and recycled HDPE granules
Combined annual production is approximately 100,000 metric tonnes, serving both textile and plastics industries.
The company manufactures technical fibres and filament yarns used across multiple sectors including:
- Geotextiles
- Automotive textiles
- Industrial filtration
- Insulation
- Medical and hygiene textiles
- Construction materials
- Home furnishings
- Acoustic panels
- Sportswear
- Technical apparel
- Flame-retardant and UV-resistant applications
Alliance Fibres also supplies raw white and dope-dyed specialty fibres for advanced textile applications.
Supplying Global Brands
Alliance Fibres has secured nominations from several international retail and apparel brands, including IKEA, Target, Inditex, H&M, and C&A.
The company’s recycled polyester products are also indirectly supplied to apparel and home furnishing brands across Asia, Europe, and the United States, reflecting rising global demand for sustainable textile sourcing.
Innovation Backed by In-House R&D
Innovation remains a central part of Alliance Fibres’ growth strategy.
The company operates a dedicated in-house research and development facility focused on developing advanced fibres and filament yarns through pilot spinning technology. Its R&D work includes experimentation with texture, structure, colour combinations, and technical additives.
According to Mr. Sangani, the R&D division has played a major role in launching new product lines and entering new markets. The company also develops customised recycled fibre solutions tailored to brand-specific requirements.
Alliance Fibres aims to create recycled products that closely replicate the appearance, feel, and performance of conventional fibres, helping brands replace natural fibres in several applications without compromising functionality.
Sustainability at the Core
Sustainability initiatives remain a key focus for Alliance Fibres.
Approximately 70% of the company’s energy requirements are currently met through solar and wind power. The company has also installed 15 MW of ground-mounted solar capacity to increase renewable energy usage further.
Alliance Fibres has reduced fossil fuel consumption by up to 80% by replacing coal and lignite with bio-briquettes and biomass pellets.
The company’s expansion into textile-to-textile recycling aligns with growing global efforts to reduce textile waste, improve circularity, and lower the environmental footprint of polyester manufacturing.
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