Cycling jerseys - making circularity a reality

Aanleiding

The fashion industry accounts for 10% of global carbon emissions. On average, Europeans purchase nearly 26 kilos of textiles and discard about 11 kilos annually. Textile purchases generated approximately 270 kg of CO2 emissions per person in 2020, according to the European Environment Agency (Source: Circular economy for textiles (europa.eu)).

Specifically, an estimated 10 million cycling jerseys are discarded and incinerated each year, because of the current lack of recycling options. Velor addresses this issue by converting discarded jerseys into new apparel without any loss of quality. In 2024, Velor successfully demonstrated a world-first proof of principle (on a 20kg scale) that cycling jerseys could be recycled into new high-quality jerseys.

With this proven success, Velor now aims to take the next step by recycling:

• 500 kg (batch #1 in this proposal)
• 1,000 kg (batch #2 in this proposal)

Ultimately, by 2029, Velor aims to produce uitsluitend fully circular cycling jerseys. Fully circular value chains are essential to achieving climate objectives, making this project a critical step in reducing waste, CO2 emissions, and the overall environmental impact of the textile industry.

Doelstelling

The purpose of this project is to validate in a first step a technique to recycle 500 kg of discarded cycling jerseys (at least 90% polyester) in a continuous process; and 1,000 kg in a second step. These validations are a crucial final step before large-scale industrial implementation.

Throughout the execution of this project, we can demonstrate that a circular economy is possible in the fashion and more specifically in the sportswear industry, which currently lacks solutions – not only technical solutions but also operational solutions for the collection of old jerseys.

While creating a fully circular economy for cyclewear, we'll also drastically reduce CO2 emissions in comparison with the more traditional, linear economy which uses fossil-based products, made in low-cost countries with a non-favorable energy mix. The process that Velor aims to establish will prevent all of these emissions, contributing to a healthier living environment and a more sustainable and circular future.

Korte omschrijving

Velor will lead the project and manage the collection of old jerseys through various channels:

• Directly from consumers
• Partnerships with cycling teams and shops
• Events
• Collaborations with textile collection and sorting companies like Rd4

Once collection is completed, the discarded cycling jerseys will be sent to GR3N, Italy, for recycling. GR3N will use its proprietary technology (chemical de-polymerization of complex PET/Polyester waste products). The resulting virgin-like polyester pellets will be sent to Antex (Spain) for melt-spinning and texturizing.

SPW Argentona (Spain) will perform circular knitting to create high-quality fabric for new garments. The fabrics will be tested in an independent lab to verify quality. Finally, ForGo Sports in The Netherlands will be responsible for manufacturing the new garments, which Velor will test on a large scale.

Velor will be responsible for:

1. The collection of the old jerseys
2. Setting and verifying all specifications between the different steps
3. Testing of the fabrics and the jerseys
4. Connecting the whole value chain
5. Overseeing the budget and overall project management

Resultaat

This project aims to prove that circularity in the textile industry, particularly in sportswear using polyester and elastane, is achievable. By the end of the project, semi-industrial production of fully circular cycling jerseys is validated, paving the way for upscaling to full-scale production.