How CircularFabrics is Redefining Nylon Recycling Through Low-Impact Chemistry

You mentioned that Nyloop enables the production of outputs like powder, pellets, or yarns. What are the performance characteristics of these outputs compared to virgin nylon? This is significant. How do they behave across different end-use applications such as fashion, automotive or maritime industries?
Josephine Mayer: Our goal is to produce recycled nylon outputs that are functionally comparable to virgin nylon in key areas such as strength, durability, and processability. So far, our lab-scale materials have demonstrated promising performance in tests for textile and other industrial uses.

In fashion, they’ve shown the potential to match the flexibility and softness of premium nylon yarns. In industrial contexts—such as automotive or maritime applications—we’re exploring how the materials can meet more stringent performance needs. We’re currently preparing for more extensive validation testing in collaboration with potential partners.

One of the key differentiators you've cited is cost-effectiveness—a critical pain point in textile-to-textile recycling. How have you managed to reduce energy consumption and CO₂ emissions while also making the economics work, particularly at this early TRL 5 [Technology Readiness Level 5] stage?
Josephine Mayer: Our approach is designed for simplicity and efficiency. By avoiding depolymerisation and repolymerisation steps, we significantly reduce process complexity, energy input, and reliance on high temperatures. We're also working with a closed-loop system that employs reusable, low-impact chemicals to further reduce operational costs and emissions.

At TRL 5, we’re focused on refining a scalable batch process and transitioning toward a continuous-flow model. Our projections at this stage suggest commercial viability of our approach at scale, which will be further validated as we move toward pilot deployment.

Circularity in synthetics often breaks down at scale due to issues around feedstock consistency and availability. What are your strategies for diversifying input streams? More important, how are you addressing the logistical and sorting challenges that come with textile and maritime waste?
Josephine Mayer: Feedstock variability is a major barrier to scaling circular systems for synthetics, and it's something we've prioritised from the start. Europe provides a strong foundation thanks to regulation-led efforts like mandatory textile collection and EPR schemes, which are increasing feedstock quality and volume.

We're also exploring high-nylon input streams, such as discarded fishing gear, which aligns with our technology's ability to work with complex blends. To address sorting and transport challenges, we’re building partnerships with collectors, logistics providers, and brands to co-develop efficient take-back models. Our long-term vision includes the development of portable recycling modules and regional facilities in high-feedstock areas—but we're taking a phased approach, validating each step carefully.

You’re based in Munich, which is described as a hub for green innovation. In practical terms, how have the local ecosystem—whether it’s policy, partnerships, or workforce—contributed to CircularFabrics’ development? Do you think this geography offers clear-cut advantages over other European startup hubs?
Josephine Mayer: Munich has been a strong launchpad for CircularFabrics—especially as a deep-tech startup at the intersection of science and sustainability. The city offers a vibrant startup ecosystem with excellent support structures for early-stage ventures, from funding access to expert mentoring and education.

The TUM Venture Labs have played a key role in supporting greentech and deep-tech founders like us, and we’re also benefitting from the region’s strong talent pool in chemistry, engineering, and materials science as we plan to expand our team.

Being in Germany also places us close to EU policy developments on circularity and sustainability, which directly align with our mission. Compared to other hubs, Munich combines industrial heritage with scientific excellence — making it an ideal base to scale a technology like Nyloop.

With increasing EU regulatory pressure on brands to adopt circular solutions, how are you aligning CircularFabrics’ offering with upcoming compliance frameworks, and do you see your technology as a way for brands to meet Extended Producer Responsibility (EPR) targets more effectively?
Josephine Mayer: We see Nyloop as a valuable enabler for brands aiming to meet upcoming circularity regulations, including EPR schemes and the EU’s Ecodesign Directive. By recovering high-quality nylon from actual post-consumer waste—including complex blends—we’re working toward providing a traceable, recycled input that helps brands meet their recycled content goals.

Our team is also exploring ways to ensure transparent verification, which could support Digital Product Passport (DPP) requirements in the future. While much of this ecosystem is still developing, we aim to be a reliable technical partner for brands navigating this evolving landscape.

Looking ahead, you plan to deploy modular recycling units. Can you elaborate on the rationale behind this decentralised approach, and how it might change the economic or logistical models of synthetic fibre recycling for partners across different regions or sectors?
Josephine Mayer: We're developing a concept for modular, automated recycling units that could eventually be deployed closer to the source of nylon waste. The idea is to reduce transport emissions and increase operational efficiency by placing systems at major sorting centres, garment factories, or coastal waste sites.

Right now, this is a mid-to-long-term goal. We're currently focusing on scaling our core process in a centralised pilot setting to prove its economic and technical viability. Modularisation is part of our roadmap, and we're engaging with partners to understand how and where such units could be most impactful.