THE PROCESS
Reengineered from the ground up using 100% Grade 1 recycled polyester and milled under solar power, the Aero Zeroº fabric allows us to make a massive reduction in our fabric footprint.
STEP 1: Melt
We use a high grade of polyester that is sourced from Japan. Sorting is an energy intensive process, but Japanese recycling protocols minimize incinerated waste by separating recycling into multiple streams. Clear PET bottles have their own stream, which ensures we’re able source 100% Grade 1 Recycled Plastic without contamination.
STEP 2: Extrude
Recycled PET bottles are ground into chips and are extruded under heated pressure through a nozzle with a bi-component shape that gives the fiber a helical structure creating it’s elasticity.
STEP 3: Spin & Twist
The filament is a long continuous fiber that is spun onto spools and into intricate multi-tone patterns that are individually dyed. The twisting and spinning process also contributes to the strength, softness and stretch of Aero Zeroº
STEP 4: Weave
Aero Zeroº fabric is milled under 12.2 acres of solar power at Shinkong’s Dashi fabric mill - one of the most energy efficient mills on the planet. The fabric is woven on the Belgian Piconal Optimax weaving machine - the most energy efficient weaving machine in the industry.