UNIFI is an American global textile solutions provider manufacturing synthetic and recycled performance fiber.
You have a background in mechanical engineering. Looking back, where did your interest in sustainability, especially within the textiles industry, originate from?
I grew up in Dublin in a large family where resources were always tight. Reusing, recycling, fixing, and repairing were integral to my upbringing. My mother, who grew up during the war, often emphasized the idea of "waste not, want not." I was the fixer in the house, always mending things rather than replacing them. This early mindset naturally influenced my career.
In terms of polyester and recycled polyester, these materials became relevant when bottles began being used as feedstock in the 1970s. UNIFI entered the recycled polyester market in the early 2000s, starting with our own waste materials. By 2003, we trademarked REPREVE®, recognizing the demand for both performance and a sustainable narrative in polyester textiles.
What is the biggest change you’ve observed taking place within the industry since you first began?
The biggest shift is a move toward textile circularity, focusing on recycling textiles into textiles rather than just using recycled bottles. We launched REPREVE® Takeback in August, which incorporates at least 50% recycled textile waste.
Currently, only about 10% of polyester garment production inputs come from bottles, with minimal textiles recycled back into textiles. Consumers and the industry are demanding more circular solutions, and REPREVE® Takeback is our answer to this demand.
UNIFI launched REPREVE® Takeback last year. Given the continuous advancements in technologies, what’s the next frontier in textile innovation?
We’ve recently launched two products: REPREVE® Takeback and ThermaLoop™ insulation. ThermaLoop uses 50% recycled textile waste in insulation for jackets and comforters. It’s the first padding to achieve 100% recycled content, eliminating the need for virgin materials, even in low-melt components. ThermaLoop also offers consistent performance and allows brands to share a clear circularity story. It represents a significant step toward creating scalable, circular solutions for the industry.
The key lies in designing for circularity. By creating 100% polyester garments that mimic the feel and performance of poly-cotton blends, we can significantly increase the recyclability of textiles. Much like the shift from mixed-material bottles to fully polyester ones, we need to apply the same thinking to garments. Designing with circularity in mind from the outset will unlock new possibilities for sustainable textiles.
UNIFI has collaborated with some of the world’s most recognisable brands. Which partnerships are you particularly proud of?
We’ve had some fantastic collaborations. For example, Teva® uses REPREVE® in the webbing of its shoes, combining performance with sustainability—an ideal for outdoor enthusiasts. TOMS® has also integrated our materials into their footwear, aligning with their mission of doing good. On the furniture side, we work with LoveSac®, which blends comfort and sustainability. In performance apparel, Under Armour® demonstrates that there’s no need to compromise on performance or environmental impact, showcasing the strength of our partnerships across diverse sectors.
We collaborate best with brands built on sustainability, like Rothy’s®, which received an award for its dedication to sustainable practices. Large, publicly traded companies with clear sustainability targets are also ideal. Our role is to help brands and retailers meet their goals. With technologies like our FiberPrint® tracer and U-Trust® certification, we ensure that products using REPREVE® are truly sustainable, and we support our partners in telling that story to their customers.
UNIFI has a presence across the Americas, Asia, and Europe. Where do you see the most demand for your products going into 2025?
While much of our revenue in Asia supports brands in Europe and the U.S., we see significant growth in non-traditional markets like footwear and bedding. For example, shoe uppers, laces, and linings are now focusing on performance and sustainability, much like apparel did years ago.
The bedding market is also exploring sustainable solutions, particularly in mattress fabrics. These emerging sectors represent exciting opportunities for growth and innovation.
The demand for more sustainable and ethical fashion is ever-growing. How do legislative differences between regions like Europe and the U.S. impact this progress?
There are multiple pressures, including legislative initiatives in Europe and some U.S. states, like New York and California. Legislation drives change, but I believe the differences between regions are overstated. For example, U.S. initiatives like the Clean Water Act pushed the industry toward sustainability. While Europe may talk more about its efforts, countries worldwide share the same goals: clean air, clean water, and a sustainable future. Asia is also worth noting—waste there is minimal because reuse is ingrained in the culture, similar to how I grew up.
However, consumer demand is also pivotal. People love sharing their stories, such as wearing garments made from recycled materials like REPREVE. Ultimately, I believe consumer enthusiasm for circularity will drive the market further. They are eager to see innovations like garments made not just from bottles but also from recycled textile waste. The biggest challenge lies in building supply chains for recycled textiles. Unlike bottles, which are relatively uniform, textiles vary greatly in material and color. Ensuring 100% polyester content in feedstock is essential for circularity but adds complexity. Encouraging collection and sorting through viable commercial incentives is key. Currently, we focus on waste fabric, but we see a future where garments themselves are recycled back into textiles.
