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How it works

So, you’re probably wondering how plastic bottles turn into super soft leggings and bras?
That’s a fair question - we’ll break it down for ya!

01

The bottles are sorted and cleaned.

Shower-time! 💧

Bottles have a lot of different categories based on their material. Six to be precise! Our products are made from plastic type #1 - Polyethylene Terephthalate, which you may know as PET plastic. It’s that #1 code labeled at the bottom of your iced tea bottles, peanut butter containers, and cleaning products!

When they arrive at the facility, they are weighed, logged, and steam washed. This process removes bottle caps and labels. They are then sorted by color - the clear bottles make up your clothes! How cool is that?!

02

The bottles are chipped into little pieces.

Shred baby shred!

This is when we shred the PET materials into little flakes!
We take a last look for any sneaky foreign materials that may have found their way through.

Then, we wash the flakes with disinfectants and cleaning agents, before rinsing and drying them to get them squeaky-clean!

03

The chips are melted into pellets.

Now things are really heating up! 🔥

The chips get melted down into long strings (if you’re envisioning what playdough spaghetti looks like in your head right now, that’s pretty accurate). Then they are chipped into little pellets that look like those cute little melt-in-your-mouth mints. (But you can’t eat these!)

04

The yarn is knit into fabric.

Things are getting reel - the yarn is knit. 🧵

The pellets then get reheated and extruded to make silk-thin threads. These threads get spun into our exclusive, super soft yarn (named Reluna), which is packaged and sent to our knitting facility!

Fun fact: Reluna fibers are thinner than traditional nylon AND it’s a double-knit fabric making it super lightweight while still durable and stable.
Another fun fact? OK, you twisted our arm. Our state of the art machine knits enough Reluna fabric to make 250 leggings per day. 😲

05

The fabric is dyed.

We want ALL the colors. 🎨

FINALLY! Dyeing can be detrimental to the environment, so we made sure Reluna was certified by the Global Recycle Standard AND chose to work with an award winning mill (Best Water Performer by the Sweden Textile Water Initiative).

Some fast facts? You know we love facts.
100% of wastewater is treated on site, just feet away from the machines.

The remainder of the water is purified and reused by the factory for production or local irrigation!

Leftover sludge (😖) and dye mud is compressed and reused for construction materials.
No waste, big wins!

Darker colored fabrics can often be less soft and less stretchy. We worked to minimize this and adjusted our technique to create consistency in softness + stretch across ALL Reluna colors (yes, even black). We’re alllll about the comfort.