Giovanardi’s sustainable project based on the recycling of acrylic waste from awnings
The story of Giovanardi is the story of a family business that, with determination and commitment, has reached an international dimension. Founded in 1963, the company is now run by Carlo and Daniela Giovanardi, who have made it their mission to constantly strive for quality and to interpret the requirements of a constantly changing market in the best possible way. In 2023, the Mantua-based company will celebrate its 60th anniversary, confirming its position as a benchmark in the market.
Specialising in the production of technical and innovative textiles, Giovanardi has always looked to the future, offering high quality solutions and products for every sector: from sun protection to interior design, from transport to boating, from advertising to design.
In recent years, the company has initiated innovative projects in the field of recycled fabrics, creating interesting paths in the circular economy.
Introducing Raytent®, the sustainable choice
Raytent® is a green economy brand based on the recycling of acrylic fabric from the awning industry to create high quality yarns for the furniture, sun protection, fashion and industrial markets.
Raytent® acrylic yarn is made from 50% recycled fibres, through a process that uses less water and chemicals, emits less CO2 and extends the use of natural resources.
“The Raytent® project is pre-consumer recycling,” explains Alessandro Pasquali, a technician in the R&D and quality control department. “In the production of an awning there is about 10 per cent material waste. We collaborate with a network of our customer and non-customer suppliers, from whom we take this waste, separate it into four categories, according to colour intensity and pattern, and fray it using a mechanical process. Braiding is a very old process, particularly well known in the textile district of Prato. The result obtained is very similar to a fibre that we mix with the virgin fibre to make the yarn. We offer 13 different colours and 3 new ones are in the pipeline. In this way, we are able to make a new awning or upholstery from the waste of an awning.
The resulting fabric is soft to the touch, weather and UV resistant, water repellent, stain resistant and durable, fully comparable to virgin fibre fabrics.
Raytent® is the ideal material for creating sustainable outdoor and indoor products. The project, which started 5 years ago, has been so successful in a number of areas that this year we are launching a range of 100% recycled Raytent® interior fabrics. The Raytent® yarn is ReMade In Italy certified and we are considering extending the certification to the fabrics of the derived lines, as a rewarding criterion for CAM in sustainable construction”.
The added value of the workshop
“At Giovanardi, research never stops to ensure high quality and new solutions. Our laboratory is equipped with cutting-edge equipment because, working in the field of solar protection and proposing long-term installations, it is crucial for us to understand how our products will behave over time. We have developed a programmed and accelerated ageing test that, in about 50 days of exposure, shows what the fabric will look like in three years’ time and what physical and visual degradation might occur. Through consistent production, we have developed accurate statistics on the progress of the processes.
Our aim is to guarantee quality products with virtually everlasting colours and mechanical resistance equal to that of new fabrics. At the same time, we want to communicate the importance of sustainability through recycling, which must not be seen as a cheap product, but rather as a technological evolution that leads to a reduction in the consumption of water and raw materials, as well as waste to be disposed of.
We are also studying the properties of polyester, which is more recyclable than acrylic, but unfortunately degrades much faster”.
The Refelter project by Giovanardi
Refelter is an innovative recycling project for end-of-life printed polyester fabric displays, particularly from the fashion and retail sectors. Through a controlled supply chain of recovery and mechanical processing involving various partners, Refelter recycles a textile waste with a high environmental impact, such as that generated by advertising campaigns whose communication is subject to frequent changes, generating very large quantities of waste.
The result is a flame-retardant recycled polyester felt that is highly versatile and allows the manufacture of environmentally friendly products, even thermoformed, suitable for various applications.
In furniture, Refelter can be used for decorative and sound-absorbing panels, upholstery for seating and home accessories. In the industrial and automotive sectors, it can be used as an insulating and filling material.
“This is still a fledgling project, ” explains Pasquali. “We take the discarded banner and apply a mechanical recycling process to obtain a 100% recycled polyester felt. We are now working on the flammability class, which is crucial for us to be able to use the material indoors. The pilot production that we have carried out consists of 120×60 cm thermal and acoustic insulating panels that can be used either in a raw state or in an aesthetic installation (polished version) or coated with 100% recycled polyester.
The basic concept we are pursuing here is the importance of working with a single material, which is the future because of the infinite possibilities of recycling”.
