Abstract
Reya: Reuse Yarn is a practice-led research project that investigates scalable methods for reducing pre-consumer waste in commercial knitwear manufacturing. Positioned within a circular manufacturing framework, the study re-evaluates knit as product, process, and practice to generate new insights into sustainable production. The research addresses the environmental and economic impacts of deadstock yarn, particularly low-value synthetic blends that are typically discarded due to limitations in quantity, aesthetics, and material consistency. Drawing on interdisciplinary knowledge from knit and visual colour psychology, the project employs a Knit Thinking methodology, combining tacit material understanding with explicit technical knowledge through iterative, material-led enquiry. The research exploits optical colour mixing in knitted fabrics, where blended yarns and stitch structures create a perceptually unified colour rather than identifying individual colours in the blend of small, evenly distributed contiguous points of colour. This demonstrates minor colour inconsistency with yarn substitutions. A pilot study and two commercial trials demonstrated the viability of this approach. Findings reveal that optical mixing enables the effective use of small quantities of yarns while maintaining consistent garment aesthetics and handle. Consumer testing further indicates widespread acceptance of minor colour variation, challenging industry assumptions regarding the necessity of colour uniformity. The research concludes that integrating blended yarn techniques into existing manufacturing processes offers an immediately implementable, cost-neutral strategy for waste reduction. By reframing acceptable colour tolerance, Reya: Reuse Yarn proposes a shift in industry practice that supports circularity, reduces environmental impact, and aligns with emerging legislative pressures such as Extended Producer Responsibility.
Keywords
Knit Thinking; Deadstock Waste Reduction; Yarn; Colour
DOI
10.21606/TI-2026.158
Citation
Gaston, E.(2026) Reya: Reuse Yarn. Product, Process and Practice, in Jane Scott, Sophie Skach, and Rebecca Stewart (eds.), Textile Intersections 2026, 17-18 September 2026, London, United Kingdom. https://doi.org/10.21606/TI-2026.158
Conference Track
researchpapers
Included in
Reya: Reuse Yarn. Product, Process and Practice
Reya: Reuse Yarn is a practice-led research project that investigates scalable methods for reducing pre-consumer waste in commercial knitwear manufacturing. Positioned within a circular manufacturing framework, the study re-evaluates knit as product, process, and practice to generate new insights into sustainable production. The research addresses the environmental and economic impacts of deadstock yarn, particularly low-value synthetic blends that are typically discarded due to limitations in quantity, aesthetics, and material consistency. Drawing on interdisciplinary knowledge from knit and visual colour psychology, the project employs a Knit Thinking methodology, combining tacit material understanding with explicit technical knowledge through iterative, material-led enquiry. The research exploits optical colour mixing in knitted fabrics, where blended yarns and stitch structures create a perceptually unified colour rather than identifying individual colours in the blend of small, evenly distributed contiguous points of colour. This demonstrates minor colour inconsistency with yarn substitutions. A pilot study and two commercial trials demonstrated the viability of this approach. Findings reveal that optical mixing enables the effective use of small quantities of yarns while maintaining consistent garment aesthetics and handle. Consumer testing further indicates widespread acceptance of minor colour variation, challenging industry assumptions regarding the necessity of colour uniformity. The research concludes that integrating blended yarn techniques into existing manufacturing processes offers an immediately implementable, cost-neutral strategy for waste reduction. By reframing acceptable colour tolerance, Reya: Reuse Yarn proposes a shift in industry practice that supports circularity, reduces environmental impact, and aligns with emerging legislative pressures such as Extended Producer Responsibility.