Polyester yarns producer Unifi, has announced it will invest in the backward integration of its Repreve supply chain to improve the availability of recycled raw materials and increase the company’s product capabilities.

In addition to providing greater control over the production of the recycled chip that is used to make Repreve polyester fibres, Unifi says the new state-of-the-art recycling technology will provide opportunities for the company to recycle post-consumer and post industrial fabric waste back into Repreve. Scheduled start-up for the new capabilities is February 2011.

Unifi says that for more than a decade, it has continued to raise its commitment to sustainable practices, recycling everything from paper tubes, pallets and corrugated boxes to donating biosolids to area farmers.  In the mid 2000’s, Unifi developed Repreve recycled polyester to provide customers and consumers with an eco-friendly, 100% recycled product that performs like virgin fibres and conserves natural resources. Since then, Repreve has evolved from one product into a family of recycled fibres.

 “Bringing the extrusion process in-house is a natural next step for us,” said Roger Berrier, executive vice president for Unifi.  “Being more vertically integrated will significantly increase our product development capabilities and capacity.”

Unifi also announced that it has purchased a 40% interest in a biomass feedstock company.  The new joint venture, which will be called Repreve Renewables, will focus on the direct sales of Freedom  Giant Miscanthus to farmers, who in turn will supply the product to bioenergy and biofuel operations in the U.S. and E.U.  According to Unifi Freedom Giant Miscanthus is non-invasive and is the highest-yielding crop available on a commercial scale. Giant Miscanthus is a perennial C4 grass that is extremely efficient in converting sunlight to biomass energy.  

 “We are continually looking for innovative, sustainable initiatives, and we are very excited about participating in this renewable energy opportunity,” said Bill Jasper, Unifi’s CEO and president. “Both of these initiatives will support our strategy to grow the Repreve brand and product portfolio, and will add to our commitment in being a global leader in sustainability efforts.”