Patagonia
CASE STUDY
Created by Redress
Patagonia
Patagonia is an outdoor clothing company with a mission to “build the best product, cause no unnecessary harm, use business to inspire and implement solutions to the environmental crisis.”
With this mantra, they incorporate sustainability through many parts of their business, but for AW2014, Patagonia launched a ‘Truth to Materials’ capsule collection showcasing radical new approaches to manufacturing, and haven't looked back since. The capsule contained seven styles, with each piece made from reclaimed or alternatively sourced fabrics like un-dyed cashmere, and reclaimed cotton, wool and down.
In this case study, learn how partnership along the supply chain can upcycle waste from within. Group together and map out other waste hotspots that are waiting to be discovered. Plus, explore how you, as designers, can find ways to upcycle waste into new products.
Image credit: Patagonia
Image credit: Patagonia
Image credit: Patagonia
“Truth to Materials is about discovering the origin of a material and staying as true to that as possible during every step of the design and manufacturing process,” explained John Rapp, Patagonia Product Designer and Tester.
In the development of this collection, they worked with a number of different partners to explore manufacturing methods that could create garments with a reduced need for dyeing and processing, using fewer virgin resources and focused on craftsmanship.
One example of these partnerships was with TAL Group, a large-scale manufacturer based in China and Vietnam, where they worked closely together towards closed-loop production. Historically, cotton remnants that dropped to the floor during the cutting process were discarded, meaning that the invested resources in growing, spinning and weaving of the fabric were wasted.
Through this collaboration, TAL now collects the cotton remnants, categorises them by colour and then sends the materials to a remnant recycler. Here, the materials are re-spun and delivered as new yarn to the fabric mill for fabric production.
This is then used in Patagonia’s products, such as their reclaimed cotton hoodie. Just one hoodie contains the leftover materials from the production of 16 virgin cotton shirts. In the process of recycling, the reclaimed cotton is neither bleached nor dyed before it is blended with virgin organic cotton. At present, Patagonia blends with virgin materials in order to meet fabric quality and performance standards of their products, but they continue to push the boundaries to improve fibres.