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Innovative Textiles & Circular

Economy

A DETAILED STUDY ABOUT THE FIBER

- Poojitha Hegde
SCI WS_2nd Semester

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Sr. No Title of Content Page No.

INTRODUCTION

CORE INNOVATION OF FIBER

BASE MATERIAL COMPOSITION

SUSTAINABILITY ANALYSIS

PRODUCTION LOCATION

END-OF-LIFE RECYCLING & CIRCULAR

ECONOMY
SCALABILITY ASSESSMENT

INDUSTRY EXAMPLES & BRAND ADOPTION

REFERENCES

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REPREVE: An Innovative iber solution

Introduction
REPREVE®, based in USA, is the world’s leading brand of recycled
performance ber which was launched in 2007. REPREVE® has transformed
billions of recycled plastic bottles into sustainable polyester. Using cutting-
edge textile technology, REPREVE® delivers better comfort, durability and
functionality. Trusted by brands worldwide to power their sustainable
commitments, it is the only traceable and certi able eco-performance
polyester.
REPREVE® is wholly owned by Uni , Inc. one of the world’s leading textile
manufacturing innovators. Uni owns and operates vertically integrated,
large-scale manufacturing facilities across the U.S. and major textile regions
globally. Uni operates with a foundational commitment to ethical and
sustainable practices that are consistent throughout its supply chain.

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CORE INNOVATION OF FIBER

The core innovation underlying REPREVE ber resides in its paradigm-
shifting approach towards sustainability and resource conservation within
the textile industry. This pioneering ber solution derives its distinctiveness
from its meticulous utilization of recycled materials, particularly post-
consumer plastic bottles, thereby addressing two critical imperatives: the
mitigation of plastic waste and the preservation of nite resources.
The hallmark of REPREVE ber lies not only in its sustainable provenance
but also in its seamless integration of environmental stewardship with
optimal performance characteristics. The ber retains its inherent strength,
durability, and tactile appeal, aligning with the stringent quality
requirements of traditional polyester. Consequently, the versatility of
REPREVE ber renders it amenable for a diverse array of textile
applications, reinforcing its standing as an avant-garde solution within the
realm of sustainable bers.
The hallmark of REPREVE ber lies not only in its sustainable provenance
but also in its seamless integration of environmental stewardship with
optimal performance characteristics. The ber retains its inherent strength,
durability, and tactile appeal, aligning with the stringent quality
requirements of traditional polyester. Consequently, the versatility of
REPREVE ber renders it amenable for a diverse array of textile
applications, reinforcing its standing as an avant-garde solution within the
realm of sustainable bers.

BASE MATERIAL COMPOSITION

The primary component of REPREVE bre is recycled polyester that is
carefully recovered from post-consumer plastic bottles. The bottles are then
placed on a conveyor belt to be carefully cleaned and sorted. Bottle labels
are also erased using steam during this procedure.

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The inventive method entails gathering and sorting the bottles, then
thoroughly cleaning and pulverizing them to produce tiny akes. Polyester
chips are created from these akes after additional processing. The
sustainable REPREVE bre is created by melting the chips and extruding
continuous laments into resins.
The bottles are thoroughly cleaned before being cut into akes then melted
and extruded into chips. These pieces are then melted into a liquid polymer,
which is then extruded once more via small holes in a spinneret.
Continuous laments made through this method are what make up
REPREVE bre. The bre then wound onto spools, where it is spun into
yarn. An air-jet texturing procedure, which is the nal phase, modi es the
ber's physical form.

SUSTAINABILITY ANALYSIS:
Comparing the unique REPREVE bre to other commonly available bers
on the market, there are various sustainability bene ts. These features assist
it be more environmentally friendly and leave a less ecological footprint.

1. Use of Recycled materials: By using 100% recycled materials, derived from

post-consumer plastic bottles and pre-industrial waste as its main raw
material, REPREVE de nes itself. They are also certi ed and traceable.
By drastically reducing plastic waste in land lls and oceans, this novel
strategy contributes to the ght against the problem of plastic pollution
on a global scale. When compared to bers made from non-recycled
sources, REPREVE reduces the demand for virgin resources by reusing
these bottles, which results in energy savings and a smaller carbon
footprint.
2. Lower Environmental Impact: When compared to the energy-intensive
processes needed to extract and re ne virgin polyester, recycling plastic
bottles into polyester chips is more energy-e cient. The eAFK
EvoCooler technology they developed in partnership with Oerlikon

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Barmag has decreased the energy needed to texture the yarn. The
quantity of water and energy needed in the dye process has been
decreased by using REPREVE® SmartDyeTM and WaterWiseTM, two
exclusive technologies. They have a solar farm at their main production
facility in Yadkinville, North Carolina. Repreve’s recycled content and
manufacturing processes are also certi ed by Scienti c Certi cation
Systems (SCS) a trusted third party in the environmental space.
3. Waste Reduction: By repurposing plastic bottles, REPREVE actively
reduces waste. Instead of ending up in land lls or polluting the
environment, these bottles are transformed into a valuable textile
material. This waste reduction contributes to a more sustainable waste
management system and helps alleviate the burden on waste disposal
infrastructure. By recycling over 30 billion water bottles to make Repreve,
Uni has saved enough energy to power over 280,000 homes for a year,
provide yearly drinking water for 3.5 billion people and eliminate the CO2
emissions from 1.8 billion barrels of oil.
4. Consumer Appeal and Market Demand: REPREVE® is made with less
carbon, using non-toxic products. It reduces global warming potential
compared to conventional virgin polyester. They empower brands and
consumers to take a positive step. Their US-wide, mobile education tour
helps encourage planet-healthy behavior. The market demand for
sustainable products further drives the adoption of REPREVE ber in
various industries.

PRODUCTION LOCATION:
Since Recycled bottles and post-industrial waste is collected worldwide,
they have sustainably-focused facilities all over the world. REPREVE ber is
primarily produced at manufacturing facilities located in the United States.
The brand's commitment to sustainability and quality control is re ected in
their vertically integrated production process, which involves closely
monitoring and managing the entire ber manufacturing cycle. While

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speci c details regarding the exact locations of their production facilities is

not publicly available, REPREVE maintains a robust supply chain that
encompasses collection centers for post-consumer plastic bottles, recycling
facilities, and ber manufacturing plants.
Also every strand of REPREVE® is embedded with FiberPrint®, a proprietary
tracer technology. This means, like human DNA, the product’s origins can
be known and can be veri ed with their U Trust™ certi cation.

END-OF-LIFE RECYCLING & CIRCULAR ECONOMY:

At the end of its life cycle, REPREVE bre o ers viable recycling options,
promoting a closed-loop system and reducing environmental impact. One
critical factor considered in the life cycle assessment of the bre is its
potential to be recycled.
As long as practicable, materials and goods should be kept in use to reduce
waste and resource-intensive new manufacturing. Repreve is working with
top organizations to get the wheels going on a circular economy, a new
foundation for the planet.
At the conclusion of its useful life, products incorporating REPREVE ber
can undergo mechanical recycling. This process involves the mechanical
breakdown of the ber into smaller components, followed by the conversion
into polyester chips. These chips serve as the raw material for the
production of new REPREVE ber, completing the recycling loop.
Mechanical recycling is a well-established technique within the polyester
recycling domain, enabling e cient material recovery.
To facilitate the recycling of products made with REPREVE ber, the brand
has established partnerships with recycling facilities and organizations.
Collaborations with these entities ensure the seamless collection and
processing of discarded items, thereby enabling the reintroduction of
recycled material back into the manufacturing process. Through these
alliances, REPREVE ensures an e cient and e ective recycling
infrastructure.

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REPREVE also actively engages consumers in the recycling process through

initiatives like the "#TurnItGreen" campaign, which promotes awareness and
encourages individuals to recycle products containing REPREVE ber. By
fostering consumer participation and disseminating information on
recycling centers, the brand empowers individuals to contribute to the
circular economy by responsibly disposing of their products.
While recycling options and infrastructure may vary by region, the
commitment of REPREVE to recycling and its collaborations with recycling
partners exemplify a proactive approach to establishing robust recycling
options for the ber. These e orts underscore the brand's dedication to
waste reduction, resource conservation, and the promotion of a sustainable
textile industry.

CIRCULARITY RATING:
8 out of 10, as in the end its still a plastic. Polyesters, whether recycled or
not, are what's causing the micro ber shedding problem.

SCALABILITY ASSESSMENT:
More than a million plastic bottles are sold around the world each minute.
And the number of bottles sold yearly will increase to 583.3 billion in 2021,
according to Euromonitor.
High scalability and tremendous possibilities are displayed by REPREVE
bre in the textile sector. Its creative use of recycled materials and unique
response to sustainability issues place it as a leading solution for brands and
customers who care about the environment.
Multiple reasons contribute to REPREVE ber's scalability. First o , post-
consumer plastic bottles are widely available as a raw material source,
making them a sustainable and convenient feedstock for the manufacture of
bre. The supply of feedstock is further boosted by the rising awareness of
and attention on plastic recycling, boosting the scalability of REPREVE
bre.

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Second, the large-scale production of REPREVE bre has a strong

foundation thanks to the well-established infrastructure for recycling
polyester. The most common recycling technology for polyester, mechanical
recycling, has been improved through time and is capable of handling
considerable amounts of plastic trash. The recycling of post-consumer
plastic bottles into recycled polyester chips, which serve as the basis for
REPREVE bre, is made possible by the already-existing
infrastructure.Additionally, there is a substantial market opportunity for
REPREVE bre due to the rising demand for eco-friendly products and
sustainable textile solutions. Consumers and brands are actively looking for
less harmful substitutes for conventional bres. The high sustainability
credentials of REPREVE make it a perfect t for this market trend and
provide it the chance to gain a sizable market share.
Furthermore, REPREVE bre can be used in a variety of industries and
product categories, including fashion, home textiles, automotive textiles,
and more because to its adaptability. The fact that it can serve a variety of
market segments thanks to its adaptability increases the likelihood of its
wide acceptance and scaling.

INDUSTRY EXAMPLES & BRAND ADOPTION:

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REPREVE®'s brand partners recognize that creating a sustainable future

must begin now. That's why together we've diverted more than 30 billion
plastic bottles from the waste stream. These leading brands are using
REPREVE® ber to make high-quality products from trusted recycled
content. From surf-wear to outdoor gear to car interiors, we're helping
tomorrow by making yesterday count.

Below are the few brands working together and some examples :

Volcom:Volcom has partnered

with Repreve® since 2013, using Repreve's bre made from recycled plastic
bottles in t-shirts, in an e ort to address the e ects of their raw material
sourcing. Since then, Volcom has increased the use of Repreve bre by
incorporating it into top-selling men's and women's trousers, shorts and
swimwear. As part of their ongoing commitment to environmental
sustainability, they have also continued to look for opportunities to
incorporate the bre into other products across the entire line. For instance,
Volcom recently switched out the minimal amount of polyester used in
certain styles and washes of jeans with Repreve.

Additionally, since 2013, Volcom has assisted in the recycling of more than
120 million plastic bottles, which have found a second life as parts of their
clothing.

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Patagonia: Today, Patagonia produces new polyester bres for clothing

using recycled polyester materials made from used soda bottles and
unusable manufacturing waste. And extensive eld testing demonstrates
that it functions at least as well as equipment made of virgin polyester.
Utilising recycled fabrics reduces their reliance on oil as a source of raw
materials, lengthens the life of land lls, and lessens toxic emissions from
incinerations. All Patagonia materials will be made from recycled materials
to a degree of 69 percent this autumn. By utilising recycled materials instead
of virgin ones, the company also decreased their carbon footprint by 13,000
tonnes of CO2e. By 2025, they intend to use only recycled or renewable
materials in their products.

REFERENCES:
Assoune, Alex. “The Truth about Repreve Polyester by Unifi.”
Panaprium, 7 Sept. 2020, www.panaprium.com/blogs/i/repreve-
polyester-unifi.
“REPREVE: All You Need to Know about the Recycled Fabric.”
Techfashionista, thetechfashionista.com/repreve-fabric/.
“Sustainability.” REPREVE®, repreve.com/sustainability.

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Unifi. “REPREVE® - Made for the Good of Tomorrow.” Unifi, 6

Sept. 2020, unifi.com/repreve.
“Volcom Hawaii Pipe Houses Powered by Solar Electricity.” Volcom
US, www.volcom.com/blogs/truetothis/repreve-fibers-recycled-
plastic-bottles-clothing-sustainability.
“What We’re Doing about Our Plastic Problem - Patagonia.”
Eu.patagonia.com, 13 June 2019, eu.patagonia.com/gb/en/stories/
what-were-doing-about-our-plastic-problem/story-72799.html.

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