What is Recycled Polyester? Is It Really Sustainable?

Ever rocked a jacket that used to be a pile of soda bottles? That’s recycled polyester aka rPET, and it is crashing the sustainable-fashion party hard. I’ve spent more than 20 years sourcing and lab-testing fabrics for brands, so I’ve seen the wins, the flaws, and the marketing gloss. So, let me walk you through what’s really going on: how bottles turn into yarn, the little performance quirks (like why rPET soaks up dye faster), call out the downsides, and see if the “eco” badge is only a hype or it is actually legit. Stick around cus we are gonna break down all of them. Ready? Let’s jump in!

 

Read more: Sustainable Fabrics: How Eco-Friendly Are They Really?
 

So... what is recycled polyester?

Recycled polyester, or rPET, is a human-made synthetic material, composed of a common type of plastic called polyethylene terephthalate. It is made by bottles being shredded into small flakes which are then melted down and extruded to form long, continuous fibers. These fibers are spun into yarns, which can be woven or knitted into new fabrics. While rPET is often associated with recycling plastic bottles and containers discarded by consumers, it can actually be made from both post-industrial and post-consumer materials. However, recycled polyester is rarely made from the fibers of old clothing because it’s quite challenging to recycle old garments that are made from a mix of different materials. 
 

Polyester vs. recycled polyester

Virgin polyester fabric is made from new polyester fibers that come from petroleum-based materials. The process involves extracting and refining raw materials into polyester fibers, known for their durability, resistance to shrinking, and versatility in clothing and home textiles.

Recycled polyester, or rPET, is made from used plastic products like bottles that are cleaned and processed into polyester fibers. The big difference between the two is the environmental impact: recycled polyester cuts down on the need for new petroleum, saves energy, and keeps plastic waste out of landfills and oceans. Both types of polyester offer similar durability, but recycled polyester is the more eco-friendly choice.
 

	Virgin Poly (the “new” stuff)	Recycled Poly (rPET)
Feedstock	Fresh crude-oil chemicals	Used bottles & factory scrap
Manufacturing process	Crack petroleum → spin fibers	Shred, melt, respin plastic trash
Energy burn	Heavy—about 60–70 MJ per kilo of yarn	Roughly 30–40 MJ (≈ 40 % less juice)
CO₂ footprint	Full tank—≈ 5 kg CO₂ per kg fiber	Cuts that almost in half
Mechanical performance	Super consistent strength & shrink-resistance	Same strength if IV stays ≥ 0.62 dL/g
Secret sauce	Melts at 260 °C, loves disperse dyes	Melts ≈ 8 °C lower, so mills save heat and need ≈ 5 % less dye for dark shades
Environmental impact	Burns fossil fuel, adds fresh plastic	Eats waste, spares oil, keeps bottles out of oceans
Limitation	Brand-new plastic keeps piling up	Still sheds micro-fibers in the wash

 

What’s good about recycled polyester?

Recycling is basically a rescue mission for rogue plastic, snatching bottles before they are torched, buried, or set sail in the Pacific. That grab-and-go move matters cause scientists warn that if we keep tossing trash at today’s speed, we could end up with more plastic than fish by 2050 (yikes). Flip that bottle into recycled polyester and you get fiber that performs just like the virgin stuff but guzzles about half the energy, spits out far less CO₂, and skips the need for fresh crude oil. Plus, rPET isn’t a one-trick pony anymore: the same flakes that become yoga leggings are showing up in carpet backing, insulation panels, and even 3-D-printed furniture. All that collecting, shredding, and spinning sparks jobs and fuels new tech, something similar like enzyme-powered “chemical recycling” that can break PET all the way back to its original molecules and run the loop again and again without losing quality. In other words, every bottle you drop in a blue bin keeps oil in the ground, jobs on the line, and plastic out of a sea turtle’s lunch.
 

The not-so-shiny side of rPET

1. Supply concerns and decline in recycling

Is there really enough recycled polyester to keep up with the growing demand from manufacturers? This is a question that's being closely examined by experts, consumers, and environmental groups. The key to verifying the authenticity of recycled polyester claims lies in the ability to track it throughout the entire supply chain.

Even though there's plenty of plastic in our environment, actual recycling efforts are on the decline. In the U.S., only 31% of plastic beverage bottles are recycled, with the rest ending up in landfills, littering the environment, or polluting our waterways. A report from the American Chemical Council highlights that the amount of recycled polyester plastic bottles has dropped by 27 million pounds in 2019 compared to the 1.7 billion pounds recycled back in 2017.
 

2. Complications in Usage

The U.S. lacks enough wash-and-flake plants, which means bottles are baled in, say, Los Angeles, shipped to Southeast Asia for washing, pelletized in a second country, then spun into yarn in a third. Every stop adds freight emissions and plenty of wiggle room for greenwashing. In fact, Chinese regulators have caught a few operators making brand-new bottles just to “recycle” them, definitely not the circular economy we are after.
 

3. Quality Issues with Recycled Polyester

Each melt cycle chops PET chains a little shorter, dropping intrinsic viscosity (think of it as the fiber’s “backbone”). Dip below roughly 0.62 dL/g and tensile strength, dye depth, and pilling resistance all start to slide. Recyclers can dose chain extenders to prop the IV back up, but go overboard and the yarn can turn brittle or lose colorfastness. Most spinners cap mechanical loops at three-to-four trips before down-cycling the material into strapping or thermoform trays.
 

Is recycled polyester sustainable?

Yes, we consider recycled polyester “more” sustainable if you compare it with virgin polyester or wool. A study by Utrecht University found that using mechanically or chemically recycled polyester fibers can lead to some impressive environmental benefits. Specifically, it reduces energy use by 45% to 85% and cuts the global warming potential by 24% to 76% compared to producing virgin polyester. Plus, using recycled bottles and making products out of them not only keeps these bottles from piling up in landfills or becoming litter but also prevents them from ending up in rivers or oceans. 

But we don’t see recycled polyester as the most sustainable option. Whether it is recycled or not, synthetic fibers are a major source of microplastics, which are tiny particles that are incredibly harmful to the environment. Bethanie Carney Almroth, a biologist and ecotoxicologist at the University of Gothenburg, points out that these microplastics are released from garments throughout their entire life cycle, from production to use, washing, and even disposal. They end up in our waterways, causing significant damage to marine life. In our view, the real solution lies in companies adopting their own closed-loop systems for fiber-to-fiber recycling. This way, every garment produced can be remade into a new one at the end of its life, significantly reducing the reliance on virgin materials.
 

Is recycled polyester greenwashing?

It really depends on the company’s intentions when it comes to recycled polyester. Recycled polyester can easily become a case of greenwashing if a company is simply using it to boost profits without addressing the larger environmental impact. However, if a company genuinely strives to drive change in the industry and is committed to tackling the environmental issues we face today, then recycled polyester can be part of the solution rather than greenwashing.
 

Is recycled polyester better than cotton?

Yes, we believe that recycled polyester is better than cotton. As we mentioned earlier, even though recycled polyester has its drawbacks, it still helps keep plastic bottles out of landfills and the ocean. On the other hand, conventional cotton isn’t as eco-friendly as it is often portrayed. It’s one of the thirstiest and most chemical-dependent crops, requiring tons of water and pesticides that damage the environment and pose risks to the people involved in its production. So, while recycled polyester isn’t perfect, we see it as a more sustainable choice compared to conventional cotton.

Given that cotton remains the most widely used fabric, it’s tough to avoid it entirely. But if you are aiming to make a more responsible choice, go for recycled cotton. Recycled or upcycled cotton helps cut down on water and energy use, and it also keeps cotton garments out of landfills.
 

Is recycled polyester safe?

Recycled polyester, which is often seen as a more sustainable alternative to virgin polyester, is generally considered safe for use in clothing and other products. However, it is important to note that while recycled polyester reduces the need for new plastic production and helps keep plastic waste out of landfills and oceans, it isn’t without its environmental concerns. One of the most significant concerns is the release of microplastics during washing. According to a study by Plymouth University in the UK, each cycle of a washing machine can release over 700,000 plastic fibers into the environment. This means that whether garments are made from virgin or recycled polyester, they both contribute to microplastics pollution, which can have harmful effects on marine life and the broader ecosystem. To sum up, yep, recycled polyester is safe to wear, but when you wash it, microplastic fibers can be released, eventually making their way into the ocean, and potentially into the fish that end up on your plate.
 

Where to find recycled polyester fabrics?

There are plenty of companies out there making fabrics from recycled bottles, but SAYA fabrics really stands out to us. SAYA is all about turning recycled bottles and overstock materials into high-quality fabrics. They have come up with innovative ways to use four different types of recycled components such as garment offcuts, deadstock fabric, waste yarn, and recycled PET bottles to create their fibers. Every year, SAYA recycles over 100,000 tons of plastic bottles (and that’s about 8 billion bottles!) and transforms them into durable, functional, and recyclable performance fibers.

What sets SAYA apart is that they skip the decolorization process, and keep the original color of the fibers. It might sound like nothing to you, but his approach actually saves energym, cuts down on carbon emissions and extra chemical pollution, which makes their fabrics even more eco-friendly!
 

Certifications for recycled material

 

When it comes to recycled polyester, not all fabrics are created equal. After 15+ years in the industry, I can tell you firsthand that certifications matter a lot. Two of the most important ones to look for are GRS (Global Recycled Standard) and OEKO-TEX® Standard 100. These aren’t just fancy logos slapped on a tag. They are a sign that what you are wearing meets strict standards for environmental and human safety.

GRS does the heavy lifting in making sure the recycled fibers come from verified sources and that manufacturers follow responsible social, environmental, and chemical practices. Basically, that means less greenwashing, and more accountability. And then there’s OEKO-TEX 100, which goes a step further by testing the final product for harmful substances. Bottom line? If something has been certified to this standard, it has been vetted for safety on your skin and for the planet!

🔍 Quick tip from the factory floor: If a fabric claims to be "recycled" but doesn’t mention these certifications, it's totally okay to ask questions. Certifications keep everyone honest.

Read more: What is Oeko-Tex? Everything You Need To Know
 

What are other recycled fabrics?

Let’s break down a few other recycled fabrics that are gaining traction. Not just because they are eco-friendly, but because they actually work.
 

1. Recycled Nylon Fabrics

Recycled nylon is made from materials like manufacturing scraps, old fishing nets (we call it "ghost gear" in the industry), and other discarded nylon products. It is a much more environmentally friendly option compared to virgin nylon, significantly cutting down on CO2 emissions. For example, Formosa Plastics reports that nylon recycled from marine sources uses 15% less energy and reduces carbon emissions by 49% compared to producing new nylon from petrochemicals. However, the recycling process isn’t without its challenges... it's expensive and requires careful cleaning and handling to make sure that the fibers maintain their quality. Despite that, we still consider it as a more sustainable fabric. 
 

Where To Find Recycled Nylon Fabrics?

Taiwan’s Formosa Plastics has created various functional products made from environmentally friendly fibers, including antibacterial, cooling, and heat-generating types. These products, made from recycled fishing nets, are as good as those made from fresh raw materials. 
 

2. Recycled Cotton Fabrics

Recycled cotton comes from old cotton garments and industrial cotton waste. Recycled cotton offers several environmental benefits, including reducing the demand for new cotton, saving water, and lowering pesticide use. We would choose recycled cotton fabrics over cotton or organic cotton because they are more environmentally friendly and more sustainable. 
 

3. Recycled Wool Fabrics

 

Wool’s a bit tricky. Recycled wool keeps the good stuff like insulation and breathability, but doesn't completely eliminate concerns around animal welfare. A lot of the recycled wool you see on the market is blended with synthetics to add strength, which helps the fabric hold up over time. But be careful... some products branded as “eco wool” don’t tell the full story, and that is where greenwashing can sneak in.

Reality check: Recycled wool is better, but it’s not perfect. Still, it's a move in the right direction.
 

4. Coffee Charcoal Fabrics- S.Café Yarn

Coffee grounds, usually seen as just waste, are actually turning out to be a hidden gem in the textile industry. While they have traditionally been used to mask bad odors, they are now being repurposed as a sustainable material. Through a high-temperature process known as calcination, coffee grounds are transformed into a special type of carbon that can be woven into polyester fibers. The fabric that results from this process is pretty impressive! It dries super quickly, retains heat really well, and offers excellent UV protection. Plus, by giving coffee grounds a new life, this innovative approach helps promote a circular economy and cuts down on our carbon footprint.
 

Final thoughts

If you are having trouble finding the perfect recycled fabric for your products, don’t hesitate to reach out! As a textile manufacturer, we are experts in knowing what fabric will work best for your needs. And even if you aren't quite ready to switch to recycled materials but have questions about sustainable fabrics, feel free to ask us anything! We are always here and more than happy to help.
 

FAQs

1. Is recycled polyester cool in summer?

Recycled polyester, like regular polyester, is not known for being the coolest fabric in summer. It tends to trap heat and moisture, which can make it feel less breathable compared to natural fabrics like cotton or linen. However, many brands blend recycled polyester with other materials or treat it with moisture-wicking finishes to improve its comfort in warmer weather. So, while it’s not the coolest option, advancements in textile technology are helping to make recycled polyester more summer-friendly.
 

2. Does recycled polyester shrink in wash?

Recycled polyester is quite resistant to shrinking, just like virgin polyester. It holds its shape well, even after multiple washes. This durability is one of the reasons it’s so popular in activewear and other garments that require frequent washing. However, it's always a good idea to follow the care instructions on the label to prevent any potential issues.
 

3. How is polyester recycled?

Polyester is typically recycled through one of two processes: mechanical or chemical recycling. Mechanical recycling involves collecting, cleaning, and shredding post-consumer plastic (like bottles) into flakes, which are then melted down and spun into new fibers. Chemical recycling, on the other hand, breaks down the polyester into its basic molecules, which are then used to create new fibers. Both methods help reduce the demand for virgin polyester and decrease the amount of plastic waste in the environment.
 

4. What does recycled polyester feel like?

Recycled polyester feels very similar to virgin polyester. It’s smooth, lightweight, and can vary in texture depending on how it’s processed. It can be soft and silky, or more structured and durable, making it versatile for different types of clothing. Some people might notice a slight difference in softness compared to virgin polyester, but generally, the feel is quite comparable.
 

5. What is recycled polyester made of?

Recycled polyester is made from post-consumer plastic products, primarily PET (polyethylene terephthalate) bottles, and sometimes from post-industrial waste like fabric scraps. These plastics are collected, cleaned, and processed into new fibers that can be spun into yarn and woven or knitted into fabrics.
 

6. What is the difference between polyester and recycled polyester?

The main difference between polyester and recycled polyester lies in their source materials. Virgin polyester is made from newly produced, petroleum-based materials, while recycled polyester is made from existing plastic waste, such as PET bottles. Both types of polyester have similar physical properties, but recycled polyester has a lower environmental impact because it reduces the need for new petroleum resources and helps divert plastic waste from landfills and oceans.
 

7. Is recycled polyester good quality?

Yes, recycled polyester is generally considered to be of good quality. It retains most of the desirable properties of virgin polyester, such as durability, resistance to stretching and shrinking, and ease of care. Some argue that it might not be quite as strong as virgin polyester due to the recycling process, but it is still a reliable, high-quality fabric suitable for a wide range of applications.
 

8. Is recycled polyester more expensive than polyester?

Recycled polyester can be more expensive than virgin polyester due to the additional steps involved in collecting, cleaning, and processing the recycled materials. However, as demand for sustainable materials increases and recycling technology improves, the cost difference is expected to decrease over time.
 

9. Is 100% recycled polyester safe?

Yes, 100% recycled polyester is generally safe to wear. However, the safety concern mainly revolves around the environmental impact, particularly the release of microplastics during washing. While wearing recycled polyester is safe, it’s important to consider the broader environmental implications.
 

10. Does recycled polyester release microplastics?

Yes, like virgin polyester, recycled polyester does release microplastics when it’s washed. These tiny plastic particles can make their way into waterways and oceans, contributing to pollution and posing a threat to marine life. This is a significant environmental concern, even for fabrics made from recycled materials.
 

11. Which is better: polyester or recycled polyester?

Recycled polyester is generally considered better than virgin polyester from an environmental perspective because it reduces the need for new plastic production and helps keep waste out of landfills and oceans. However, both types of polyester contribute to microplastic pollution. So while recycled polyester is a more sustainable option, neither is a perfect solution. The choice depends on balancing the benefits of recycling with the need to address the environmental impact of microplastics.