1. Recycled Polyester Revives U.S. Facility
Unifi’s Yadkinville plant in North Carolina has found new life with its flagship Repreve fiber, made from recycled plastic bottles. Since inception, over 42 billion bottles have been repurposed into fiber. Repreve claims a 60 % reduction in greenhouse gas emissions compared to virgin polyester.
Nevertheless, environmentalists argue that this diverts materials from bottle recycling loops and raises concerns about toxic chemical exposure during processing. Unifi is addressing these through compliance and ongoing safety research .
2. AI-Enhanced Robotics for Textile Sorting
Researchers at Universität Klagenfurt are advancing robotic recycling systems featuring AI-powered "sensor skins" to boost speed and accuracy in separating mixed-fiber textiles. These intelligent grippers aim to improve the quality and throughput of textile-to-textile recycling.
3. Shift Toward Chemical Recycling of Polyester
With bottle-to-fabric recycling reaching scale, attention is now on chemical recycling techniques. The EU’s Extended Producer Responsibility and PEFCR regulations are catalyzing demand for fiber-to-fiber recycling technologies that can break down polyester to its monomers and rebuild virgin-quality yarn.
Summary
This week highlights a turning point in fabric sustainability: existing mechanical recycling approaches (e.g., Repreve) are scaling up, while AI-driven sorting and chemical recycling R&D prepare the ground for a fully circular textile ecosystem. Despite residual concerns around safety, feedstock diversion, and brand-level demand, growing regulatory support and innovation momentum point toward a transformative era for the fabric supply chain.
