The Hurdles of Apparel Recycling: Overcoming Plastics, Zippers, and Mixed Synthetics
The fashion industry produces over 92 million tons of textile waste annually, with only a small fraction of clothing actually being recycled. While many consumers donate or discard old clothing with the assumption that it will be reused or repurposed, the reality is far more complex.
One of the biggest hurdles? Apparel is difficult to recycle due to the presence of heavy plastics, zippers, buttons, and mixed synthetic fabrics. These challenges make it costly, labor-intensive, and inefficient for recyclers to process textiles in a truly sustainable way.
1. Heavy Plastics in Apparel
Plastics are deeply embedded in the apparel industry, often in ways that consumers don’t realize. Many clothing items contain plastic-based materials such as:
Polyester, nylon, and spandex fibers – Found in everything from athletic wear to swimwear, these fabrics are derived from petroleum and are not biodegradable.
Coatings and waterproof finishes – Jackets, backpacks, and outerwear often have plastic-based waterproof coatings, which make them difficult to recycle.
Shoes and accessories – Many shoes contain rubber soles, plastic reinforcements, and synthetic fabrics, making separation and recycling nearly impossible.
Since these plastic-based textiles do not break down naturally, they persist in landfills for centuries if not properly recycled.
2. The Zipper & Button Problem
Apparel recycling isn’t as simple as just shredding old clothes into reusable fibers. One of the biggest bottlenecks in the process is removing non-textile components like zippers, buttons, and fasteners.
Zippers are often made of a mix of plastic and metal, requiring manual removal before recycling.
Buttons can be made from plastic, metal, or wood, which all need to be sorted separately.
Metal rivets and embellishments (such as on denim) add further complexity, increasing the labor needed before textiles can be processed.
Since automated sorting systems are not advanced enough to efficiently separate these materials, much of this work still needs to be done manually, adding cost and time to the recycling process.
3. The Mixed Synthetic Fiber Challenge
Most clothing today is made from blended fabrics, such as:
Poly-cotton blends (commonly found in t-shirts)
Spandex-infused leggings and athletic wear
Wool blends with synthetic fibers for durability
While natural fibers like cotton and wool can be mechanically recycled or composted, synthetic fibers cannot be easily separated from these blends.
Traditional textile recycling relies on shredding, which results in a lower-quality recycled material that cannot be reused for high-quality garments.
Chemical recycling methods for breaking down synthetic fibers exist but are expensive and not widely available.
Contaminated or poor-quality fibers often mean blended fabrics are rejected from recycling streams, ultimately being downcycled or landfilled.
What Are the Solutions?
Despite these challenges, innovative approaches are emerging to improve apparel recycling:
1️⃣ Advanced Sorting & Deconstruction Technologies – New AI and robotic systems are being developed to automate the removal of zippers, buttons, and non-textile components, making the recycling process more efficient.
2️⃣ Chemical Recycling for Synthetics – Some companies are pioneering chemical processes that break down polyester and nylon into reusable raw materials, though these solutions are still costly.
3️⃣ Designing for Circularity – Brands are beginning to redesign apparel with end-of-life recycling in mind, using mono-material fabrics, removable fasteners, and compostable materials.
4️⃣ Closed-Loop Recycling Programs – Some companies are taking responsibility for their own waste, offering take-back programs that turn old clothing into new garments.
How EOL Stewards Can Help
At EOL Stewards, we specialize in sustainable solutions for apparel recycling, helping brands and businesses navigate the challenges of textile waste.
We provide responsible destruction services for unsellable apparel.
We connect companies with downcycling and upcycling partners to keep textiles out of landfills.
We help brands explore circular economy strategies to reduce their overall waste footprint.
📢 Want to make apparel waste more sustainable? Contact EOL Stewards today to learn how we can help you recycle textiles more effectively. Let’s rethink fashion waste together!
