What Is Recycled Polyester? A Closer Look at This Eco-Friendly Fabric

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Did you know it takes about 10 plastic bottles to make a single piece of clothing from recycled polyester?¹ That’s wild! Every year, millions of plastic bottles end up in landfills and oceans, contributing to the growing crisis of plastic pollution. But instead of becoming waste, some of that plastic gets a second life as fabric—turning yesterday’s water bottle into today’s activewear, jackets, and even high-fashion pieces.

The fashion industry has a massive environmental footprint, from water-intensive cotton production to petroleum-based synthetic fabrics. But materials like recycled polyester fabric are shaking things up by reducing reliance on virgin plastics, cutting down energy use, and promoting a more sustainable fashion future. While it’s not a perfect solution (no fabric truly is), it’s a step toward environmental awareness and a way to keep plastic out of the waste stream for a little longer.

What Is Recycled Polyester?

Polyester isn’t actually a fabric—it’s a type of plastic made from petroleum-based chemicals, mostly PET (the same plastic used in water bottles). It starts as a liquid, is spun into fibers, and then woven into fabric. While it’s popular for being cheap and durable, virgin polyester production is energy-intensive, relies on fossil fuels, and adds to the world’s plastic pollution problem.

That’s where recycled polyester (rPET) comes in. It gives plastic waste a second life instead of sending it to landfills or the ocean. By breaking down PET plastic—mainly from discarded bottles—and turning it into fibers, rPET offers a more sustainable alternative to virgin polyester.

Is Recycled Polyester Safe?

Recycled polyester is generally considered safe to wear, but it’s not without its concerns. Since it’s from plastic waste—often old water bottles or food containers—there’s always the question of chemical contamination. However, reputable manufacturers follow strict cleaning and parsing methods to ensure that any improper residues are removed. Certifications like Global Recycled Standard or OEKO-TEX help verify that rPET fabrics meet safety standards.

That said, the biggest issue with recycled polyester isn’t skin irritation—it’s microplastic shedding. Just like virgin polyester, rPET fabrics release tiny plastic fibers when washed, which can end up in waterways. The best way to reduce this is to wash less often, use a Guppyfriend bag or a microfiber filter, and opt for air drying when possible.

How is Recycled Plastic Made?

Ever wondered how a plastic bottle transforms into a piece of clothing? The process is both innovative and efficient. It begins with collecting and sorting post-consumer plastic bottles, primarily water and soda bottles that would otherwise contribute to landfill waste. These bottles are then thoroughly cleaned to remove labels, adhesives, and any leftover residue before being shredded into tiny plastic flakes.

Next, the clean flakes are melted down and reformed into small pellets, known as rPET chips. These pellets are then heated once more and extruded through fine nozzles to create long thread-like fibers. The fibers are stretched, spun into yarn, and finally woven or knitted into fabric, ready to be used in clothing production.

This process not only gives plastic waste a second life but also reduces reliance on virgin polyester, making it a more sustainable alternative in the fashion industry.

Recycled Polyester vs. Virgin Polyester: Which One’s Better?

Polyester dominates the fashion industry—it’s in everything from leggings to backpacks, fast fashion to high-end gear. However, not all polyester is created equal. Is recycled polyester (rPET) better than virgin polyester, or is it just another greenwashing tactic?

Virgin Polyester: The Fossil Fuel Problem

Virgin polyester is made from petroleum, a fossil fuel that requires drilling, refining, and a lot of energy to turn into fabric. The process is resource-intensive, emitting nearly three times the amount of CO₂ as cotton production and consuming vast amounts of water and chemicals. Worse, polyester isn’t biodegradable—it sticks around in landfills for centuries, breaking down into microplastics that contaminate soil and water.

Given the environmental cost, it’s clear that making polyester from scratch is far from sustainable. This is where recycled polyester steps in as a potential solution.

Why Recycled Polyester is the More Sustainable Option

Recycled polyester (rPET) is made by repurposing existing plastic—primarily discarded water bottles but also old polyester fabric. Instead of relying on virgin petroleum, rPET gives waste a second life, significantly reducing its environmental footprint.

Here’s why rPET is a step in the right direction:

Less Plastic Waste: Every ton of recycled polyester saves about thousands of plastic bottles from landfills and oceans. Considering that the fashion industry is a major contributor to plastic pollution, rPET helps divert waste from ecosystems.
Lower Energy Consumption: Producing rPET requires 59% less energy than virgin polyester, meaning fewer fossil fuels burned in the process.²
Reduced Carbon Emissions: By skipping the petroleum extraction process, rPET cuts CO₂ emissions by nearly 32%, making it a more climate-friendly choice.³
Water Savings: The production of virgin polyester is highly water-intensive, with a water scarcity footprint of 5.98 m³ H₂Oeq per 100 kg produced. This means that for every 100 kg of virgin polyester manufactured, approximately 5.98 cubic meters of water are consumed. In contrast, recycled polyester (rPET) significantly reduces water usage. Its water scarcity footprint is just 1.90 m³ H₂Oeq per 100 kg, making it about 63% more water-efficient than virgin polyester.⁴

While it’s not a perfect fix, using recycled polyester is undeniably better than continuing to churn out new plastic-based fabrics.

The Drawbacks: Not a Perfect Solution

While rPET is a step up from virgin polyester, it’s still, at the end of the day, plastic. And plastic-based fabrics come with unavoidable problems:

Microplastic Pollution: Like virgin polyester, rPET sheds microplastics in the wash, which end up in waterways and marine ecosystems. Washing clothes in a Guppyfriend bag can help the bag capture microplastics released during washing, preventing them from entering the water system.
Limited Recyclability: Unlike materials such as aluminum, polyester can’t be infinitely recycled. Over time, the fibers degrade, meaning that even rPET will eventually become waste.
Cost & Accessibility: Producing rPET requires specialized recycling infrastructure, making it more expensive than virgin polyester. While prices are gradually coming down, some brands opt for cheaper, less sustainable options.

Where You’ll Find Recycled Polyester

Recycled polyester is gaining traction in the fashion industry, with brands incorporating it into a variety of products:

Activewear & Outerwear: Patagonia and Adidas have pioneered the use of rPET in jackets, leggings, and sneakers. The Girlfriend Collective also uses it in workout gear.
Luxury & Sustainable Brands: Stella McCartney and Eileen Fisher incorporate recycled polyester into high-end designs, proving sustainability doesn’t have to mean sacrificing style.
Home Textiles & Accessories: Some brands now use rPET for backpacks, blankets, and even rugs—expanding its potential beyond just fashion.

This Has Been About Recycled Polyester

New technologies are improving the way polyester is recycled. Closed-loop recycling is a growing field, where old polyester garments are broken down and remade into new fabric (instead of relying on plastic bottles). Some companies are working on bio-based polyester alternatives made from renewable materials instead of fossil fuels.

While recycled polyester may not be the perfect solution, it represents a crucial step toward sustainability. Whenever possible, choose natural fibers. However, when synthetic fabrics are necessary, opting for recycled polyester over virgin polyester is the eco-friendlier choice. To learn more about how slow fashion can help reduce waste and promote sustainability, check out my article on the Slow Fashion Movement.