Stage 1: Recycled bottles are taken to a recycling centre where they are shredded so that any liquid is removed. They are then boxed up to be shipped to stage 2.
Stage 2: The bottles are sorted into clear and coloured plastic, stickers, and bottle lids. They are put in a bath where the lids float to the top and can be cleared. Next, it’s bath number two in chemicals which help to remove the stickers.
Stage 3: After two chemical baths, the plastic bottles have now become a pile of soggy clear plastic shreds. So it’s time to dry it off. The plastic spends around 10 hours in what is effectively a slow cooker, rotating until it’s dry and ready for the next step in its journey to become activewear.
Stage 4: Next the mixture is sent through a rotating screw where it is heated to a whopping 270 degrees Celsius, which melts the plastic, and it is then dropped into large strings which are collected into a container below.
Stage 5: We now have large strings of thread, but it’s not strong enough for our activewear just yet. It is reheated and stretched to create stronger, binding fibres.
Stage 6: So what do we do with these new stronger fibres? We tear them apart again. Once they are torn apart, we’re left with a fluffy raw substance.
Stage 7: The fluff is sent off to another factory to be made into cloth. A machine lays the fibres into a rough cloth. This rough cloth is then spun into fibre and collected on giant bobbins.
Stage 8: The thread is now ready to be transformed into one of our wonderful Sundried designs.
So, what was once rubbish is now sweat-wicking, functional, and stylish activewear! It helps to conserve and protect the planet and contributes to combatting climate change.