REPREVE Has Found The Solution For Fashion’s Plastic Problem

With many innovative brands coming to market with the prefix “Re” in front of their name, few have had the foresight to recycle the materials they use in their business – to create more business. Recycled fashion, also known as upcycled, or sustainable fashion, is a growing trend focusing on repurposing and reusing materials to create new garments and accessories. It is a response to the environmental and social impacts of the fast fashion industry.

Maxus REPREVE socks are a sustainable and eco-friendly choice for individuals looking to reduce their environmental footprint. These socks use REPREVE material, a leading recycled fiber brand developed by Unifi. By incorporating REPREVE into the production process, Maxus creates socks that are made from recycled plastic bottles, diverting them from landfills and giving them a new life.

Unifi-REPREVE is a renowned recycling center making significant strides in promoting sustainable practices within the textile industry. Unifi-Repreve Factory in Greensboro, NC, is a trusted facility that adheres to third-party certification standards, such as the Global Recycled Standard, for over 50 years. George Allen Mebane IV founded Unifi in 1971 with a vision to disrupt the textile industry through a unique “outsider” perspective, the brand states on its website, foreshadowing a looming plastic epidemic.

In 2007, Unifi found its dedicated calling and took sustainability to the next level. The development of REPREVE, the world’s leading branded recycled fiber, began as a means to recycle their own manufacturing waste and soon expanded to include the recycling of PET bottles. This complex resource is discarded into landfills by the billions, but REPREVE processing can create multiple lifespans for the plastic.

Recognizing the potentially enormous impact they could have by repurposing these bottles, Unifi embarked on a mission to transform them into high-quality recycled fibers. By diverting PET bottles from landfills, they address the issue of waste while also reducing the demand for virgin resources in the textile industry, making their own yarn for manufacturing.

Unifi, the parent company of REPREVE, made a significant investment of $35 million in 2016, building a bottle-processing plant in Reidsville, North Carolina. “Roughly 62% of what comes in is usable, and about 58% of it is clear PET [Polyethylene terephthalate],” says a long-time manager at the Unifi facility. “The remaining 4% roughly is color bottles, which we do use that too into different items. We operate 24 7. We have about a hundred people. Um, and, um, we’re on the output. We’re generating about 1.4 million pounds of clear p e t, uh, which is in that upper cylinder of that display.“ The factory produces yarn with 62% PET, of which 58% is clear and 4% is color PET.

The REPREVE factory operates a bail yard for receiving materials, and a sorting line called the “BSF” is employed to separate materials from contaminants with an effective mud control and plastics sorting process, ensured by a three-step process. The factory receives approximately 40-60 truckloads per week and holds around 5 million pounds of material, weighing roughly 40,000 pounds. Usually, 225,000 pounds are received and processed per shift, with 125,000 pounds of material cleaned.

The yarn production process at REPREVE is highly efficient, with a dyeing rate of 1000 meters per minute. It prides itself on being the world’s lowest water and energy consumer. The factory maximizes efficiency by reusing water from bottle washing in the dyeing process. It strives to establish a reputation for quality, similar to the iconic “Cheers” bar in America. The Unifi Yakenville facility, established in 2008, is known for its distinctive smell of polyester.

Unifi-Repreve operates in an environmentally responsible manner, being landfill-free and composting all compostable waste. Any remaining waste is managed efficiently through third-party distribution. With a vertically integrated supply chain, the factory utilizes spring tubes and interdependent parts. It employs around 1800 workers and converts nearly 1 million pounds of material into yarn per week.

Unifi specializes in blending and processing recycled materials, ensuring proper drying and fitting. A continuous chemical process for making polyester utilizes the resulting pellet, producing around 3000 meters per minute, and the REPREVE facility primarily focuses on multifilament yarn production, including fishing line yarn as a single filament.

With a commitment to environmental stewardship, Unifi-REPREVE specializes in transforming plastic bottles into high-performance recycled fibers. These fibers are sewn into brands like Hagger Clothing Co., Peony Swimwear, and bags by Dange Dover, and United By Blue.

The use of REPREVE in Maxus socks conserves valuable resources but also reduces energy consumption and greenhouse gas emissions compared to traditional manufacturing methods. Despite their eco-conscious design, Maxus REPREVE socks do not compromise on comfort or style. They are crafted with attention to detail, providing a soft and comfortable fit while offering durability for everyday wear. With Maxus REPREVE socks, individuals can make a positive impact on the environment without compromising on quality or style.

With REPREVE, Unifi has set a new standard for eco-friendly fibers, offering a sustainable alternative without compromising on quality or performance. Their commitment to recycling and sustainability has made a significant contribution to minimizing environmental impact and promoting a circular economy

Recycled fashion promotes the concept of circularity, where items are given new life instead of being discarded. This approach reduces waste, minimizes resource consumption, and helps mitigate the negative effects of fashion production on the planet. Designers and brands are creatively transforming pre-existing textiles, such as vintage clothing or surplus fabrics, into unique and stylish pieces. Embracing recycled fashion is a conscious choice to support ethical and environmentally-friendly practices while expressing their personal style.

Factories in America have played a vital role in its economy and industrial landscape in its early years, and Unifi-REPREVE is fostering the next generation of the industrial revolution. Manufacturing facilities like Unifi can be the core pillars responsible for producing a wide range of goods, from automobiles and electronics to clothing and furniture. The epitome of REPREVE is to take those materials and recreate them for reuse.

American factories are known for their technological advancements, efficiency, and adherence to stringent quality standards. They serve as hubs of innovation and job creation, providing employment opportunities for millions across various sectors. Unifi-REPREVE has invested in itself and its country, ensuring it is taking steps toward a circular economy and protecting the environment while providing sustainable resources for the fashion industry.