The Rise of Sustainable Materials in Outdoor Gear

The Rise of Sustainable Materials in Outdoor Gear

What are sustainable materials?

Sustainable materials are made from resources that can be produced or used without depleting natural resources or harming the environment. Often coming from renewable, recyclable, biodegradable, to lower environmental impact.

There have been many innovations in the sustainable materials genre over the years. Including the use of recycled materials like polyester, nylon, and wool/cotton. Natural and Renewable fibers like organic cotton, hemp, bamboo, and merino.

One of the key characteristics of sustainable materials is the renewable sources that they come from. The Minimal impact on the environment during production. The products are made with a long lifespan in mind to reduce the need for frequent replacements. The use of nontoxicity during production as well as reduced water and energy consumption with efficient manufacturing processes.

Timeline of relevance in outdoor gear

Sustainable materials made their introduction into the market in the 1970s. Patagonia was founded in 1973 with a focus on environmental responsibility and began to set the stage for the future of sustainability efforts within the outdoor industry. Patagonia committed itself to using organic materials as an early move toward sustainable materials

In 1989 several outdoor companies including Patagonia created the Conservation Alliance to support environmental organizations. In 1983 Patagonia introduced fleece material that was made from plastic bottles. This is one of the first cases of recycled materials in outdoor gear.

In 1996 Patagonia committed to using fully organic cotton in their entire product line. This highlighted a significant switch in the industry to a total commitment to sustainability. The design standard was launched in 2000 and became an industry standard that promoted safe and sustainable textile production practices. 

Prana partnered with Fair Trade USA in 2005 to focus on fair wages and safe working conditions for brands across the industry. Two years prior Patagonia started a recycling program that allowed customers to turn used clothing for repairs or turns.

The Higg index was created in 2010 by the Sustainable Apparel Coalition to measure environmental and social impacts. The next year Patagonia introduced the “Don’t Buy This Jacket” campaign, to raise awareness about consumerism and the environmental impacts of overconsumption. In the years to follow many brands such as North Face, Columbia, Adidas, and Arc’teryx launched sustainability programs.

Arc’teryx launched a used gear program in 2019 to promote a circular economy. Programs like this were replicated by brands across the industry, including companies like Patagonia and REI. In 2021 All Birds launched a plant leather, which is an alternative to traditional made from agricultural byproducts. In 2024 Salomon introduced the Index 2.0 which is a fully recycled running shoe. 

Importance of sustainable materials

Sustainable materials have become an important part of the outdoor gear community. Every brand in the space plays a crucial role in reducing environmental impact, conserving resources, and promoting health and safety standards. These practices have offered new ways of economic benefits when it comes to cost savings, and market differentiation through innovation. 

Sustainable products often have less energy and fewer resources to produce, recycled polyester uses up to 50% less energy than virgin polyester. Companies can use less nonrenewable resources like petroleum, by using natural resources like organic cotton, bamboo, and hemp.

In recent years there has been a growing market and demand for eco-friendly products. Consumers are likely to pay more and continue to support brands that come out with sustainability initiatives. This has led to many innovative products in the recycled goods space while each brand is trying to compete in a crowded eco-conscious market. 

Governments and International bodies have begun to implement strict regulations regarding environmental outputs and sustainability standards. Companies that have begun to adopt these policies. These practices have become essential in the outdoor gear industry, with many other industries seeing similar impacts. 

Key Sustainable Materials

There have been many sustainable materials that have been introduced to the industry over the past 30 years.  Popular materials include recycled polyester and nylon, regenerative cotton, plant-based alternatives like Tencel and hemp, and biodegradable synthetic materials all play a crucial role in reducing the environmental footprint of outdoor gear.

Recycled polyester and nylon

Recycled materials often come from plastic bottles, fishing nets, carpets, and other industrial waste. Some benefits of this are the reduced reliance on petroleum and the use of less energy and water consumption compared to virgin polyester. The use of recycled materials also diverse plastic waste from oceans and landfills which can be used on a wide variety of outdoor gear like jackets, tents, and backpacks. 

Organic and regenerative cotton

Organic cotton is used in t-shirts, pants, jackets, and other clothing items. The cotton was grown without synthetic pesticides, fertilizers, or any other genetically modified organisms (GMOs). The benefits of this growth method are that it is safer for the farmers and surrounding communities because of the lack of chemicals. As well as the use of less water compared to traditional growth methods with a reduced impact on soil quality. 

Regenerative cotton has similar uses to organic cotton and can be used in a variety of apparel and gear. The benefits of regenerative cotton are that it promotes biodiversity improves water retention in soil and enhances soil fertility, increasing carbon sequestration. They are grown using regenerative agricultural practices that restore soil health and biodiversity.  

Plant-based alternatives 

Tencel is made from sustainably sourced wood pulp, primarily eucalyptus, beech, and spruce trees. That can be used in base layers like t-shirts and underwear. The benefits of Tencel are that it is made from biodegradable and compostable materials, soft and breathable with highly absorbent material making it comfortable for outdoor apparel. It's produced in a closed-loop process that recycles water and solvents. 

Recently hemp has become a popular material in items like clothing, backpacks, and footwear. Some of the benefits are that Hemp requires no pesticides and minimal water, with soil that can be grown in a variety of climates, that is strong, durable, and that are naturally resistant to UV light. The hemp comes from the stalks of the plant.

Biodegradable synthetics

Biodegradable materials were created from renewable sources like corn, sugarcane, and other plant materials. These materials can be used for apparel, outdoor gear, and accessories. The benefits of biodegradable materials are that they reduce environmental impact as well as they can be composted at the end of their life cycle. 

The outdoor industry continues to set goals to lower its impact on the environment. They have innovated constantly with their product design and supply chain to implement these sustainable materials and strategies. In the years to come the use of the materials is likely to expand in the use and the overall health of the planet.  

Innovative Companies 

Several companies have been known to embrace sustainability at rapid speeds that have driven consumer wants and needs for sustainable products. Patagonia, Arc’teryx, Osprey, and Icebreaker are known leaders in the outdoor industry to embrace technological advancements in their products. These innovations showcase how brands are balancing performance, durability, and eco-friendliness. 

Patagonia's Recycled Materials Initiative

Patagonia started using recycled materials across its product lines, from its jackets to backpacks. They were the first company to start using recycled plastic polyester from plastic water bottles. Also starting a Repair and Worn Wear program that encourages their customers to either get their products repaired or buy used gear, to extend the gears product lifespan. 

Patagonia has committed to net zero emission goals and 100% recycled material use within its supply chain. Patagonia has also deceived private transparent reporting on all their supply chain and environmental impact. 

Arc'teryx is committed to using sustainable materials

Arc’teryx is one of several brands that created a program for their customers to upcycle and resell their gear, this promotes a circle economy. They have also committed to using BlueSign-approved fabrics across their product lines, these fabrics meet high environmental and safety standards. 

Arc’teryx has developed a PFC-Free treatment for their apparel that is water repellent and avoids harmful polyfluorinated chemicals. They are continuing to explore the use of biobased materials in their technical apparel. 

Osprey's recycled fabrics in backpacks

Osprey has begun to offer repair programs to its customers, hoping this will extend the customer's life and product life span. They have also started to offer more sustainable alternatives to what their customers offer and are exploring more sustainable products for the future. Since 2022 they have been committed to PFC-Free water repellent treatments on all their products.

An increasing amount of Ospreys products are made from recycled material like in their pack bodies and other components. Osprey has focused on creating highly sustainable products that are also very durable and long-lasting to reduce waste. 

Icebreaker's commitment to natural fibers

Icebreakers have committed to creating products with natural fibers. They have focused on merino wool which is a renewable and biodegradable fiber that they use in their apparel. Tencel can also be combined with merino wool creating strong and more sustainable products. 

They have begun to remove all plastic from their packaging. Also developing new natural fibers to improve performance. Similar to Patagonia they have committed themselves to publishing annual reports derailing their sustainable progress, challenges, and future goals. 

These initiatives by Patagonia, Arc'teryx, Osprey, and Icebreaker demonstrate the outdoor industry's commitment to sustainability. By focusing on innovative materials, repair, and reuse programs, and transparent supply chains, these brands are setting new standards for environmental responsibility.

Production Processes

The outdoor industry has increasingly been focused on adopting innovative production practices that minimize their environmental impact. This quest for sustainability has been driven by consumer demand and regulatory and policy pressures. These practices include closed-loop manufacturing, water, and energy-saving techniques, and effective chemical management and reduction. These practices have led to new production standards across the industry. 

Closed-loop manufacturing

The goal of closed-loop manufacturing is to create a circular system where waste is minimized and resources can be used over time. Patagonia uses this with its recycling program producing new garments from old garments. This process can reduce energy by up to 75% while reducing community waste. 

Water and energy-saving techniques

There are several water-saving techniques within the company's supply chain. Including waterless dying, low water washing, water recycling, and solution dyeing. The waterless dyeing method with fabric is placed in a pressurized CO2 chamber with the dye. This process can conserve up to 25 liters of water, significantly reducing water consumption throughout the supply chain.

There are also low-water washing methods that use advanced washing machines that can clean fibers and textiles with less water. As well as water recycling methods that can treat and reuse wastewater within the manufacturing processes. The benefits of these methods are that they conserve and reduce water waste that is polluted in other areas. 

Companies also use renewable energy sources like solar, wind, or hydroelectric power for their manufacturing facilities. This benefits their carbon output and reduces their need and demand for fossil demands. Manufacturing facilities have now installed modern energy efficient machinery the benefits of these machines are the low energy usage and operational costs. 

Chemical management and reduction

There are many practices and industry standards that companies use when it comes to chemical management and reduction. The Bluesign System is an industry-wide standard that checks all the chemicals, optimizes processes to reduce resource consumption, and checks all production standards to ensure they meet safety standards. This benefits the workers, customers, and the environment. 

Companies will also set goals in place to eliminate hazardous chemicals in the textile and footwear industries. This ensured a safer production process within the company's manufacturing processes. They also have created safe water-repellent finishes that would minimize environmental and health risks associated with water-repellent finishes. 

The outdoor industry has stayed committed to sustainable production, these practices not only help the environment but allow brands to innovate to meet the growing demand for eco-friendly products. As these sustainable practices continue to evolve they will play crucial roles in the industry and how brands individually do their parts in preserving the natural landscape of the world.

Consumer Impact

For many years customers in the outdoor industry have demanded sustainable products from companies. Consumers have increasingly been interested in the lifecycle, duration, and sustainable methods used to create the product. It has been critical for brands to take these factors into account when working in the outdoor gear and apparel industry. 

Changing preferences and awareness

Over the years consumers have become more informed about environmental issues like climate change, pollution, and resource depletion. These issues have significantly influenced consumer purchasing habits with a large percentage of customers willing to pay more for products from brands that promote sustainability and policies that align with their values. 

Customers have been evaluating the lifecycle impact of their purchases from its production to how it is disposed of. Brands are also educating their customers through advertising campaigns and publishing transparency reports. There is still a large gap between actual implementation and talking about doing so. 

Price considerations

When sustainable products instantly hit the market they were often priced higher than traditional products. This was because of the significant investments that were required to create these new products. Customers did show willingness to pay higher prices for the sustainably made products. 

Sustainable products often were designed to be more durable and long-lasting, reducing the need for replacement. Emphasizing long-term savings through durability introduces the concept of total cost of ownership, shifting the focus from upfront costs to long-term value.

Performance comparisons with traditional materials

With the advancement in sustainable materials, customers have sought out products with these innovations like the PFC-free treatments for waterproofing gear and recycled fibers that maintain high manufacturing standards. Customers want products that are built with high standards ensuring that performance is not compromised. 

Brands that have successfully transitioned to sustainable products have built stronger trust with their customers than other brands. Customers with positive experiences with sustainable products are more likely to recommend the products to others as well as repeat the purchase. This loop of positive feedback fuels the accelerated adoption of sustainable products more than one marketing campaign can do. 

This evolution of sustainability within our purchasing habits not only benefits the environment but also our relationships between brands and customers, as customers continue to buy from brands with similar values to themselves.

Challenges

The outdoor industry continues to make progress towards sustainability and total net zero emissions. These goals involve constant challenges related to scalability, cost of research and development, and maintaining industry performance standards. 

Scalability issues

The industry faces several issues when it comes to scalability when it comes to producing its sustainable products: supply chain limitations, new manufacturing processes, quality control, and infrastructure gaps. 

Sustainable materials often are limited in availability, along with retool facilities to be fitted for the new materials can be complex and expensive taking some time to employ, and may lack the quality control they are used to producing.   

Cost of research and development

Creating and testing new materials has required sustainable R&D investment investments. This process has involved lots of innovations in manufacturing processes. For brands to ensure materials meet industry standards and certifications. 

Not all research and development projects have worked, and this has led to lengthy R&D efforts which are costly. Ongoing research is necessary to stay on top of the competition when it comes to new product innovation as well as meeting sustainability emission goals. 

Maintaining performance standards

Sustainable materials have to match or exceed customer expectations when it comes to their performance against traditional materials or non-sustainability-made gear. Balancing long-lasting products with biodegradability has been a challenge for the industry to tackle. Also, weight considerations, with sustainable materials often being heavier can be a problem because low-weight gear is critical. 

Despite these obstacles, the industry has continued its efforts in ongoing innovations. Addressing sustainability and maintaining performance standards outdoor gear and apparel companies are paving the way to a more sustainable future. 

Future Trends

The focus on sustainability has been changing the outdoor gear and apparel industry for the past several years, pressured by regulatory pressures and pushed by eco-conscious customers. The aim has been to produce top-tier materials and technologies with sustainable materials, understanding these advancements is crucial for widespread adoption. 

Startups and large corporations are both aligned when it comes to creating new manufacturing techniques such as 3d printing could allow for on-demand printing, AI-driven design processes that will allow for more efficient processes, and multifunctional products that allow customers to acquire fewer products that have more purpose. This leads to an optimized and innovative experience for customers, allowing for a more personalized experience.  

Emerging materials and technologies

High-performance fabrics have begun to be made from nonrenewable resources like mycelium, algae, and other agricultural waste. These materials aim to replicate the quality and performance of traditional materials and fabrics that may have a more harmful creation process.

Smart textiles that can adapt to environmental conditions are being developed. These fabrics will be capable of regulating moisture and temperature. Plus nanotechnology textiles are being used to create ultra-lightweight, strong material, and water-repellent gear.    

Potential for industry-wide adoption

Many companies have banded together and have collaborated on industry-wide sustainability metrics that allow them to standardize quality and transparency across manufacturing. With the growing consumer awareness around sustainability, brands have almost been expected to participate in net zero programs with no thought to the economic outcomes only the net zero dreams. 

Industry-wide initiatives began to take place to educate and train designers, marketers, and engineers in sustainability practices and technologies. This education is required for critical innovation solutions when promoting the products that will drive the further adoption of sustainable products 

The future of sustainable innovation in the outdoor gear and apparel industry is constantly improving the emerging materials, technologies, and growing consumer demand for sustainably made products. The outdoor industry is well positioned to lead and create standards for other manufacturers to follow and create a more sustainable future.  

Conclusion

Sustainable materials and technologies will continue to play a major role in the outdoor gear and apparel industry, these advancements are not just fads but have become an essential component in company images and their supply chains. 

To fully transition to a net zero industry the industry must continue to invest in research and development for their products, manufacturing process, collaboration when creating sustainable policies across the industry, and educating customers. The support from customers is crucial during this process as they are a main driver when it comes to driving the market towards greater sustainability.  

Customers have continued to educate themselves about the sustainability practices of many brands as it has become one of the main drivers in their purchase decisions. Customers have opted in for products that cost more than non-eco-friendly products. Customers have demanded accountability from brands encouraging them to implement eco-friendly practices and policies throughout their company. 

Companies have dedicated resources to continue researching and developing sustainable materials and technologies. Brands have committed themselves to working with other industry players to develop and adhere to sustainability metrics and design principles. Several companies have committed themselves to maximizing transparency by opening their supply chain prices and environmental impacts by publishing reports and sharing them with the public. 

By working together, customers and companies have been able to drive the outdoor gear and apparel industry to a more sustainable future. Embracing sustainable materials and technologies will ensure that the industry continues to thrive, setting a powerful example for other sectors to follow. 

-

el fin.