Recycled polyester is often considered a sustainable alternative to conventional polyester in the fashion and textile industries. Instead of producing new polyester from fossil-based raw materials like petroleum, existing plastics are reused. At first glance, this sounds convincing: plastic waste gets a second life, the demand for new raw materials can decrease, and existing resources are used for longer.
However, the situation is not quite that simple. According to current figures from Textile Exchange, about 98% of recycled polyester comes from PET bottles and not from used textiles. At the same time, the share of fibers made from recycled used textiles in the global fiber market remains below one percent.
Recycled polyester can therefore be a sensible alternative to virgin polyester. However, this does not yet make it a fully recyclable or inherently sustainable fiber. For corporate fashion, the choice of material should always depend on the intended use, the desired durability, and the functional requirements.
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Is recycled polyester really sustainable?
Polyester is polyethylene terephthalate, or PET for short, and is a synthetic fiber. Conventional polyester is made from fossil-based raw materials. Recycled polyester, on the other hand, uses existing material. This reduces the need to rely exclusively on new fossil-based raw materials for fiber production. Textile Exchange therefore views the shift from new fossil-based polyester to recycled material as an important step.
However, rPET remains a plastic. Polyester is not biodegradable, and microfibers can be released when synthetic textiles are washed. The European Environment Agency identifies the wearing and washing of synthetic textiles as a source of microplastics. An estimated 200,000 to 500,000 metric tons of microplastics from textiles enter the global marine environment each year.
“Recycled” should therefore not automatically be equated with “sustainable.” What matters much more is which alternative is available for the garment in question.
Recycling: How a PET Bottle Is Turned Into Recycled Polyester
Today, mechanical recycling is the predominant method used in the production of recycled polyester. Put simply, used PET products are collected, sorted, cleaned, shredded, and melted down. New polyester fibers can then be spun from the processed plastic. In addition, there are chemical recycling processes that could become more important in the future.
In our view, the key problem lies elsewhere: A PET bottle that is turned into a garment changes the product cycle. The textile industry would truly become circular, above all, if new textiles were produced from used polyester textiles.
The market is still a long way from that. According to Textile Exchange, less than 1% of the fibers produced worldwide come from recycled used textiles.
This shows that giving plastic a second life makes sense. However, this does not yet constitute a closed-loop textile cycle.
Recycled polyester or cotton: Which is better for clothing?
From our daily consultations, we’ve identified a common request: Many customers want T-shirts and sweatshirts that are comfortably soft while also retaining their shape and color as much as possible even after many washes. This is exactly where adding polyester can offer functional benefits. Polyester is durable, easy to care for, and quick-drying.
For companies that want to consistently focus on natural fibers, however, we are happy to recommend high-quality organic cotton. However, it would be too simplistic to make a blanket statement that every natural fiber is automatically more sustainable in every application. Raw material extraction, processing, dyeing, transportation, lifespan, and actual use must also be taken into account.
Our recommendation is therefore: Choose materials based on their intended use, and don’t use polyester simply because the label says “recycled.” When it comes to T-shirts and sweatshirts, it’s especially important to balance the desired feel and colorfastness against the goal of creating a collection based as much as possible on natural fibers.
What are the advantages of recycled polyester over virgin polyester?
When functional requirements call for polyester, recycled polyester is generally a better option than newly produced, fossil-based polyester. Existing plastic is reused as a raw material instead of relying exclusively on new raw materials derived from fossil sources.
When it comes to procuring corporate fashion, the differences can be categorized as follows:
| Criterion | New Polyester | Recycled polyester | Organic cotton |
|---|---|---|---|
| Raw materials | predominantly fossil-based | Existing PET/recycled material | renewable raw material |
| Microfibers | possible | possible | No plastic microfibers |
| Recyclability | limited | Depends on the recycling route | depends on the material |
| Features | Durable, easy to care for | Durable, easy to care for | comfortable, breathable |
| Use | Functional Clothing | Functional clothing made with recycled materials | Many shirts, sweatshirts, and basics |
For companies, therefore, the fabric name alone should not be the deciding factor. What matters most is what properties the garment actually needs for everyday work and how long it can be used.
From the Ocean to a Shirt? Where Recycled Polyester Actually Comes From
Images of plastic waste in the ocean quickly give the impression that recycled polyester clothing primarily removes waste from the oceans. The actual material flows look different. According to Textile Exchange, about 98% of recycled polyester currently comes from PET bottles.
This is an important distinction. PET bottles already have established recycling streams and can be processed back into bottles. If they are processed into textiles instead, this does not automatically result in a closed-loop textile cycle.
At the same time, the issue of microplastics remains relevant. A scientific study from 2024 confirms that microplastic fibers are released when synthetic textiles are washed. In this study, recycled polyester actually released more microfibers than the virgin polyester that was tested.
Therefore, the statement “made from plastic waste” should not be the sole sustainability criterion in procurement. Origin, processing, durability, and future recycling options should also be included in the assessment.
A Second Life for Plastic—But What Happens After That?
Recycling makes sense when existing materials remain in the cycle for as long as possible. That’s exactly why we take a nuanced view of recycled polyester. Turning plastic waste into a usable material can make more sense than producing new polyester exclusively from fossil-based raw materials. What matters most, however, is what happens after this second life.
Blended fabrics, in particular, can make subsequent recycling more difficult. While cotton and polyester together meet functional requirements, they must be separable again to enable high-quality fiber-to-fiber recycling.
For durable corporate fashion, we therefore recommend asking four questions right from the design phase:
- Do we even need polyester for this function?
- Is there a suitable solution made from natural fibers?
- If polyester is required: Is certified recycled material available?
- How durable and truly recyclable is the finished garment?
Our corporate hoodies made of cotton and blended fabrics also demonstrate just how varied the material requirements for corporate fashion can be.
GRS: How can recycled polyester be verified?
Companies should not rely solely on product descriptions when it comes to recycled textiles. The Global Recycled Standard (GRS) enables independent verification of recycled materials and their journey through the supply chain. In addition, the standard includes requirements for social and environmental criteria as well as restrictions on the use of chemicals.
We are GRS-certified and can offer companies textiles that are certified accordingly. For natural fibers, we also work with GOTS-certified products. This allows for much more transparent documentation of material choices than using general terms such as “eco,” “green,” or “made from recycled materials.”
Additional sources include the Materials Market Report from Textile Exchange, information from the European Environment Agency on microplastics from textiles, and information from Textile Exchange on the Global Recycled Standard.
FAQs About Recycled Polyester
Is recycled polyester sustainable?
Compared to new fossil-based polyester, recycling offers advantages because existing material is reused. Therefore, rPET is not fully sustainable. It remains a synthetic plastic and can release microfibers during washing.
Is recycled polyester better than cotton?
There’s no one-size-fits-all answer. Material production, use, and lifespan must all be considered together. For T-shirts and sweatshirts made from natural fibers, we prefer high-quality organic cotton. For certain functional requirements, recycled polyester can be a good choice.
Is recycled polyester of lower quality?
Not necessarily. Recycled polyester can achieve properties that make it suitable for durable and low-maintenance garments.
Does washing recycled polyester release microplastics?
Yes. Recycled polyester is also a synthetic fiber. Microfibers can be released during washing. Recycling does not solve this problem.
Sustainable corporate fashion starts with choosing the right materials
In our view, sustainable workwear isn’t simply created by replacing conventional polyester with a version labeled as recycled. What matters most is determining which material is truly needed for the specific application and how long the garment can be used.
For T-shirts, polos, hoodies, and sweatshirts, we therefore work with our customers to determine whether natural fibers or organic cotton are the best choice, or whether functional requirements call for a blend that includes recycled polyester fibers. In doing so, we also take into account finishes, wash performance, availability for future orders, and certifications.
As a GOTS- and GRS-certified company, we combine this material consulting with our own textile printing and embroidery facilities, as well as custom textile production.
Are you planning sustainable corporate fashion and want to know which material is right for your application? Then talk to us about your corporate fashion. We’ll provide project-specific advice on organic cotton, natural fibers, and certified recycled materials.
