When we think about the amount of plastic waste that "inhabits" the oceans, the image is usually bleak. However, at ANTARA OCEAN we have decided to change our perspective. We don't just see trash; we see a poorly managed resource with great potential.
When we say that our swimsuits are born from the ocean, we are not referring to a poetic metaphor, but to a rigorous industrial process capable of converting a polluting waste into a high-performance fabric.
It's not magic, it's science applied to sustainability. Below, we tell you about the journey plastic takes to become your second skin for those days of sun and sand.
Phase 1: selective collection and sorting🗑️
As you know, PET plastic (the material used in most beverage bottles) is a serious problem, especially for the ocean. Millions of bottles end up floating away, polluting and endangering marine life. But here's the good news: PET is 100% recyclable.
The process begins with the collection of these bottles and other plastic debris made of PET. They come from:
- Landfills
- Recycling systems
- Cleaning of coasts and the sea.
To obtain a high-quality fabric, the sorting phase is crucial. PET bottles are separated from other types of plastics (such as PVC or HDPE) and sorted by color. For the textile industry, clear PET is the most valuable, as it allows for more precise and vibrant subsequent coloring, essential for our marine prints.
Phase 2: From bottle to flake (crushing and washing)🧼
Here comes the most amazing part: the physical transformation. The clean bottles are shredded at high speed. The result? Hundreds of miles of tiny pieces, like grains of rice or plastic flakes. These are called "PET flakes."
These flakes are the essential raw material. If you looked closely, you'd see that the plastic that was once a bottle is now a shower of tiny fragments ready for the next stage.
Did you know that...:The use of recycled PET flakes consumes significantly less energy than the production of virgin polyester (derived from petroleum), reducing the carbon footprint of the base material by between 30 and 60%.
Phase 3: Thermal alchemy (extrusion and spinning)🧵
PET scales melt. Yes, they melt at high temperatures until they become a dense, viscous liquid. This liquid is nothing other than molten polymer.
Now, this polymer passes through something called a spinneret, which is like a showerhead with many tiny, fine holes. As it exits these holes, the polymer cools and solidifies immediately, creating threads similar to fishing line, but much thinner. These threads are recycled polyester (rPET). This process is called extrusion.
Phase 4: local weaving, printing and sewing👙
Once the rPET yarns are ready and wound onto large spools, the final act begins. These yarns are taken to textile factories where, by adding a percentage of elastane (Lycra), the fabric is woven that will later become a swimsuit.
The result is a durable, breathable, and resistant fabric with the same (or better!) properties as virgin polyester, but with one giant difference: no new petroleum was used in the process.
To bring our designs to life, we use digital printing with certified eco-friendly inks. This technique, free of toxic chemicals, reduces water consumption compared to traditional dyeing. This allows us to achieve vibrant, sun-resistant colors that are completely safe for your skin and respectful of the marine ecosystem.
A conscious decision
Understanding this process allows us to appreciate each garment not only for its aesthetics, but also for the innovation it represents. By choosing a swimsuit made from recycled polyester, we are validating a technology that gives a second life to materials that would otherwise take centuries to decompose in our marine ecosystems.
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