One of the things that the COVID-19 pandemic has brought to light is that now, more than ever, sustainability is important for our future. An EPA study found that every 10,000 tons of materials recycled supports nearly 16 jobs and $760,000 in wages. Customers are demanding sustainability because they know it makes a difference in the health of people and our planet.
One company’s unique storyUnifi, Inc., one of the world's leading innovators in recycled yarns, is a champion for sustainability. The North Carolina-based company transforms recycled plastic bottles into performance fibers. It all begins when you make the decision to throw your plastic bottle into a recycling container instead of a trash can. Recycled bottles are collected and taken to material recovery facilities, then brought to the REPREVE® Bottle Processing Center in Reidsville, N.C. where they are sorted, cleaned and chopped into bottle flake. That flake is melted and extruded into REPREVE chip, which is then spun into REPREVE performance recycled yarn. The yarn is either woven or knit into fabric that goes into items you use every day, including apparel, shoes, socks, home furnishings and automotive seating.
Unifi recently reached a key milestone: the company has recycled more than 25 billion PET bottles and transformed them into REPREVE, which is now used by more than 800 global brands and textile manufacturers worldwide. To put this milestone into context, 25 billion single-serve plastic bottles can physically circle the earth approximately 126 times or fill the Empire State building 18 times. Unifi is now on track to reach its goal of recycling 30 billion bottles in 2022.
Sustainable and Transparent
In addition to keeping bottles out of landfills and giving them a second life, REPREVE production uses less energy and water, while also producing fewer greenhouse gas emissions compared to manufacturing virgin synthetic fibers. REPREVE just received its Higg Materials Sustainability Index (Higg MSI) scores. The Higg MSI (version 3.2) is the most comprehensive tool for sustainability analysts, designers and product developers who want to make more informed materials choices.
The Higg MSI study confirms that U.S.-manufactured REPREVE reduces the global warming potential by 21% compared to generic, mechanically-recycled polyester and 42% compared to conventional virgin polyester. The Higg MSI global warming potential is related to greenhouse gases. Based on the score, REPREVE is verified to have a lower carbon footprint than comparable materials. By using REPREVE, organizations and consumers can greatly reduce their environmental impact compared to using generic rPET (recycled Polyethylene Terephthalate), one of the most commonly used plastics in the world. Additionally, REPREVE is the only eco-performance fiber with U TRUST® verification to certify recycled content claims.
“We continue to build on our commitment to transparency by having the results of our REPREVE Life Cycle Assessment verified and accepted into the Higg MSI,” said James Cooper, Unifi Sustainability Manager. “REPREVE manufactured in the U.S. has a lower global warming potential than standard rPET, providing our customers with a verified pathway to lower their environmental impact and meet their sustainability goals.”
It’s important to note that transparency is what makes REPREVE different. There are several 3rd party certification services available that certify recycled content. Unifi uses Scientific Certification Systems (SCS), an international leader in third-party certification, validation, and verification for environmental, sustainability, and food safety and quality performance claims. The company also goes one step further and includes a proprietary tracer in every pound of REPREVE polyester and nylon it produces throughout the world—REPREVE fibers are embedded with a proprietary FiberPrint® technology that helps Unifi’s customers avoid false environmental claims. The company issues its own U-Trust® Certifications by testing fabrics and/or garments for the presence of REPREVE® fiber to further assure its customers their product is recycled.
Protecting Our Oceans
Customers are serious about reducing ocean plastic waste. When the World Economic Forum released a report in 2016 predicting that by 2050 there would be more plastic in the ocean than fish, Unifi wanted to help play a role in reducing ocean pollution. That’s why the company launched REPREVE Our Ocean® fiber—an expansion of its REPREVE product line—made specifically with ocean-bound plastic.
Unifi collects post-consumer plastic bottles within 50 kilometers of coastlines in countries and regions that lack formal waste or recycling systems. Because 80% of ocean plastic comes from land-based sources, and 75% of that is uncollected waste, the company’s approach prevents plastic waste from ever entering the ocean.
“People around the globe are asking, ‘how can we save our oceans from plastic pollution?’ We listened and carefully designed meaningful processes to address this problem directly,” said Unifi CEO Eddie Ingle. “Several swimwear, footwear, and backpack and bag brands are using REPREVE Our Ocean, and we’re proud to provide a textile solution to help protect this critical ecosystem.”
As the demand for transparency and accountability from organizations around the world increases, so does the demand for sustainable alternatives. REPREVE continues to grow each year and we source, manufacture and sell innovative, high-quality REPREVE performance fiber in every major textile-producing region in the world. In fact, REPREVE currently makes up nearly 40% of Unifi’s sales revenue.
Supporting a Circular Economy
In a circular economy, garments and home furnishings are made of reused components, and after a product is discarded, the materials and parts are reused, repaired or recycled. Unifi is committed to and a proud proponent of circular economy solutions, including textile takeback programs. As more companies adopt circular economy commitments, and more consumers make the choice to recycle, it’s likely to boost takeback programs into the mainstream – which could, in turn, create new jobs throughout the supply chain.
Unifi continues to make progress every day through its REPREVE textile takeback program. The emergence of Fast fashion has drawn increased attention to the amount of textile waste around the globe. Americans discard 81 lbs. of clothing/year, with only 15% of that being donated or recycled. From a consumer perspective, keeping items longer, and donating or recycling to give their garments a second life is the next step. Brands should design with a second life in mind, beginning with the use of sustainable fibers in their designs, and encouraging consumers to donate, repair, reuse or seek out other textile take back solutions. Unifi manages textile take back programs for some of our customers and continues to seek ways to expand the program as a reflection of its commitment to the circular economy.
The Catalyst for a Better Future—That Starts With You
Unifi envisions a world where fibers solve many of life’s everyday challenges, where recycled products with high performance have become the norm, and where being sustainable creates an innovative closed loop that continues for generations to come.
“We see sustainability as a movement – not a moment,” Ingle added. “It is a core strategic pillar that permeates all aspects of our organization. We strive to create a positive impact for our people, our business and our planet, while supporting our customers’ growth and sustainability goals through our product offerings.”
Unifi’s sustainability process starts with you. When you make the choice to throw your plastic bottle into a recycling container, you’re making a choice for the good of tomorrow. That bottle can become your shirt, a part of your car, the next bottle in your hand, or the hat on your head. The demand for recycled materials continues to grow because of you. Unifi encourages every person to contribute by recycling right.
Building momentum
When it comes to sustainability, Unifi is always stretching to do more. True innovation starts in the fiber, and for REPREVE, innovation is focused on anticipating consumers’ needs and working with the company’s customers to bring that innovation to the market, allowing them to grow their business by delivering sustainable, high-quality, high-performance solutions today and tomorrow.
The company is committed to helping brands reach their sustainability goals. In addition to helping them switch from virgin to recycled REPREVE polyester, Unifi has also been a pioneer of textile takeback programs for the last 10 years, with plans to further increase its efforts. Unifi leaders believe this is the next sustainability step for the textile industry and their goal is to be at the forefront of this transformation. Unifi created REPREVE because it cares about our planet. And, we have to. It’s the only one we have.
To learn more about Unifi, recycling and REPREVE, visit Unifi.com and REPREVE.com.
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