Why Synthetics Matter?

Towards Sustainable Synthetics – What material we use?

The industry has made significant progress and introduced several more sustainable synthetic alternatives. BETI is among the pioneers in recycled dyed yarns; we first presented them in 2014 at the Football World Championship in Brazil. Since then, more than ten years of experience with recycled polyamide and polyester have enabled us to deliver consistently high-performing recycled yarns. Moreover, BETI’s recycled yarns integrate seamlessly into almost all production processes where virgin polyamide or polyester would normally be used—such as socks, narrow weaving, yarn covering, circular and flat knitting, weaving, 3D knitting, seamless technologies, and more.

For a quick overview of BETI’s recycled and other sustainable yarns, users can simply apply the “Sustainable” filter in our yarn list.

Below is an outline of the most widely used alternatives:

1. Recycled Yarns

Recycled yarns reduce the need for virgin resources and, in addition, lower both energy consumption and greenhouse gas emissions compared to the production of conventional fibers.

Recycled Polyester (rPET):
The most common form comes from recycled PET bottles; however, post-consumer textile-to-textile recycled polyester is gradually entering the market. BETI already offers dyed recycled PET dtex 78/24 within our standard product range.

Recycled Nylon (rPA):
Most recycled nylon originates from industrial or post-industrial waste streams. Some producers also recover discarded fishing nets and transform them into high-quality yarns. BETI provides recycled dyed yarns alongside partner brands such as Q-Nova and Sensil Ecocare. The Econyl brand by Aquafil is another well-known example that uses a substantial share of post-consumer waste.

Furthermore, recycled synthetics often fall under the category of preferred materials within Textile Exchange guidelines, as they reduce dependence on fossil resources while diverting waste away from landfills and oceans.

2. Bio-Based Alternatives – Biosynthetics

Bio-polyester and bio-nylon come from renewable raw materials such as sugarcane, corn, or castor oil. Materials derived from commonly used edible crops are typically classified as first-generation biosynthetics. In contrast, non-food crops like castor or agricultural residues—including sugarcane bagasse, wheat straw, or orange peels—belong to the second-generation group. These bio-based synthetic alternatives reduce dependence on fossil fuels; however, they also require responsible land management and sustainable sourcing of feedstocks.

At BETI, we decided to take this development a step further. We introduced EVO by Fulgar, a 100% bio-based, ultralight, and quick-drying yarn, and enhanced it using algae dye—creating a truly bio-based alternative with significantly lower environmental impact.

Moreover, the growing availability of bio-based feedstocks offers a clear path toward decoupling synthetics from petroleum. For example, bio-nylon from castor oil and bio-polyesters from sugarcane both help reduce reliance on fossil resources. Nevertheless, designers and manufacturers must consider land use, biodiversity risks, and water footprint to avoid unintentionally shifting environmental burdens. According to Textile Exchange, preferred synthetics should not only minimize carbon impacts but also align with responsible agricultural and sourcing practices.

3. Other Non-Fossil Feedstock Alternatives

Innovative approaches in the textile industry now allow producers to transform end-of-life car tires into new synthetic yarns for apparel. Using a mass-balance method, manufacturers can replace 100% of the required raw materials with pyrolysis oil derived from discarded tires. As a result, this process enables the creation of high-quality fibers without relying on fossil-based inputs.

One example is Q-CYCLE by Fulgar, a PA 6.6 yarn that BETI also offers in dyed form. This alternative demonstrates how non-fossil feedstocks can open new pathways toward circularity and lower-impact materials in the textile sector.

4. Third-Generation Bio-Based Feedstock

The so-called third generation of bio-based feedstocks moves the industry truly beyond conventional synthetics. This category refers to lab-grown materials derived from microorganisms, such as microalgae. These innovative feedstocks represent a promising frontier, as they rely on regenerative biological processes rather than agricultural crops or fossil resources.

Although third-generation yarns have not yet reached industrial-scale production, research in this area is rapidly evolving. Several scientific studies—such as Green Synthesis of Bioplastic from Microalgae: A State-of-the-Art Review (Adetunji & Erasmus, Polymers, 2024)—highlight their potential to become viable low-impact alternatives in the future. Consequently, this emerging field may soon unlock entirely new pathways for sustainable textile innovation.

Towards Sustainable Synthetics – How We Use Them

By the end of 2025, BETI reached an important milestone: 30% of our production now relies on recycled materials. However, sustainability extends far beyond material choice; several additional design and production aspects play a crucial role.

1. Design for Extended Use and Recycling

Designing for extended use and recycling means integrating key sustainability principles at every stage of product development — from fiber selection and yarn engineering to fabric construction and end-of-life pathways. Only by connecting these phases can products achieve both long-lasting performance and circularity.

A comprehensive recipe for sustainable design includes several essential elements:

• High wear-resistant materials → These materials serve as an effective counterpoint to fast fashion, as they reduce the long-term use of energy and natural resources. Furthermore, BETI’s dyed yarns are known for exceptional durability, which can be further enhanced through our production processes.

• Mono-material garments → Single-fiber compositions recycle far more easily than blends, leading to higher-quality recycled outputs.

• Avoiding elastane → Minimizing elastane prevents major bottlenecks in textile-to-textile recycling systems.

• Digital IDs and fiber tracing → These tools enable accurate sorting and help ensure that garments are reprocessed effectively at the end of their life.

• Certifications such as the GRS – Global Recycled Standard → A must-have for synthetics, as it guarantees verified recycled content, full traceability, and consistent quality.

We integrated all these principles into the DISKO5 project, where we designed sustainable, 100% Slovenian underwear pieces that demonstrate how circular design can significantly reduce environmental impact.

2. Durability as a Sustainability Lever

High-quality synthetics often outperform natural fibers in abrasion resistance, colorfastness, and elasticity. Because of these advantages, they are exceptionally well suited for sportswear, swimwear, hosiery, and various industrial applications. Moreover, durable garments need to be replaced far less frequently, which directly reduces overall material consumption and resource use.

When durability is combined with good recyclability, synthetics can generate substantial sustainability benefits. Consequently, products made from long-lasting and recyclable materials keep their value longer and can re-enter the production cycle more effectively — a key principle of circular design.

3. Green Chemistry as Part of Sustainable Design

Green chemistry plays a crucial role in making synthetic textiles more sustainable. While OEKO-TEX® remains the industry’s “gold standard” for chemical safety, many brands are already moving beyond its requirements due to growing consumer expectations and emerging regulatory trends. As a result, stricter limits on hazardous substances are becoming increasingly common.

In recent years, substances such as PFAS and bisphenols (BPA, BPF, BPS) have received heightened attention because of their environmental persistence and potential health effects. Consequently, textile producers face the challenge of maintaining high performance while transitioning to cleaner, more responsible chemistry.

At BETI, we actively address this challenge. In 2024, we introduced ZERO-bisphenol yarns, and by December 2025, nearly 90% of our production already operates with low-bisphenol formulations. These improvements demonstrate how targeted chemical innovation can meaningfully reduce environmental impact without compromising product quality.

4.Low Impact Production Technologies: DyeCare 

The company’s DyeCare 1.0™ line represents a breakthrough in sustainable yarn dyeing — all polyamide and polyester yarns are processed through an optimized dyeing method that significantly reduces resource use and emissions.

The process was developed in-house and in cooperation with research partners, ensuring careful control over both technology and material quality.

Compared to conventional dyeing, DyeCare yarns use over 50% less water, 21% less electricity, and emit 34% fewer CO₂ emissions.

Many of the DyeCare yarns are made from 100% recycled materials — for example recycled polyester derived from PET bottles — combining sustainability with high performance. The end product is soft, elastic, durable yarn that meets strict standards: the yarns are certified under OEKO‑TEX® Standard 100 and Global Recycled Standard (GRS), and the environmental savings are verified by an independent auditor.

The company’s commitment to innovation and sustainable practices through DyeCare 1.0™ has been recognized with awards, underlining its role as a pioneer in sustainable textile production.

The Road Ahead for Sustainable Synthetics

Discussions about sustainability often oversimplify materials into “good” and “bad” categories. However, the reality is far more nuanced—especially when it comes to synthetics. Although their fossil-based origins raise concerns, synthetics offer unique advantages for building a circular textile economy when manufacturers, brands, and consumers use them responsibly.

Moreover, sustainability extends well beyond material selection and production practices. Brands, consumers, recycling companies, and governments all play essential roles in shaping a more circular system. Understanding how these stakeholders contribute is key to unlocking the full potential of sustainable synthetics.

Consumer and Brand Responsibility

Sustainability is never determined solely at the fiber level. Brands must design products with recycling in mind, choose certified fibers such as GRS, OEKO-TEX®, or Textile Exchange Preferred Materials, and communicate transparently with consumers. In addition, consumers can make a meaningful difference by purchasing long-lasting products and caring for them responsibly—for instance, washing garments at lower temperatures, using microfiber filters, and extending their use.

End-of-Life Considerations and Scaling Recycling Solutions

Although synthetics are not biodegradable, they excel in recyclability when kept pure. Therefore, the industry must prioritize the development of collection systems, invest in recycling infrastructure, and educate consumers about proper textile disposal. Without systemic change, even the most advanced sustainable fibers risk ending up as waste.

Well-designed collection systems help ensure that end-of-life textiles return to reprocessing rather than landfills. This requires building consumer awareness, introducing take-back programs, and creating partnerships across the value chain. Meanwhile, some brands are already testing garment take-back schemes or collaborating directly with recyclers. Governments are also stepping in by implementing Extended Producer Responsibility (EPR) for textiles, which holds brands financially accountable for post-consumer waste. Together, these initiatives transform end-of-life challenges into opportunities for circularity.

From Contradiction to Opportunity

Synthetics will continue to play a central role in the textile industry. The true challenge lies in moving from a linear take–make–waste model to a system where synthetics are designed for circularity. When manufacturers combine renewable energy, low-impact production technologies, advanced recycling methods, and robust standards, synthetics evolve from a perceived environmental contradiction into a powerful driver of innovation across the textile value chain.

🌍Towards a New Generation of Synthetics

Sustainable synthetics are not a contradiction—they are a necessary evolution.
With recycled inputs, bio-based innovations, advanced dyeing technologies, and circular design principles, synthetics can shift from an environmental burden to a cornerstone of a more responsible textile future. Instead of rejecting them outright, the industry must adopt innovation, transparency, and systems thinking to fully unlock their sustainable potential.