For the first time in its more than 40-year history, insulation maker PrimaLoft is giving customers a circular option for synthetic insulation in outdoor apparel and accessories. The company has launched a new textile-to-textile recycling technology called ReRun, which takes pre- and post-consumer textile waste and reprocesses it into new insulation products.
PrimaLoft uses two different processes—mechanical and regenerative—to recycle textile material for new use. The mechanical process involves reclaiming and shredding pre-consumer footwear uppers in a closed-loop method to create ThermoPlume PrimaLoft ReRun material. ThermoPlume is a loose-fill insulation blend that creates a down-like silhouette. And while it’s made of 100 percent recycled content, 30 percent comes from the recycled pre-consumer footwear upper material.
Related Stories
The regenerative process strips impurities from recycled fiber content and breaks them down to the molecular level, turning fibers back into virgin-grade PET pellets used to create Silver PrimaLoft ReRun insulation. Silver—which is made with 100 percent recycled material, 50 percent of which is regenerative—boasts soft, fine fibers that provide thermal efficiency for lightweight warmth.
Along with ThermoPlume and ReRun, PrimaLoft recently introduced four additional insulation products—UltraPeak, a performance insulation; ThermaStretch, which boasts 30 percent more stretch and a 98 percent recovery rate compared to other insulations; HeatSphere, which reflects radiant body heat; and Rise Sleeping Bag insulation.
“The launch of six new product in 2025 is a direct result of the unprecedented momentum we’re experiencing at PrimaLoft, driven by our commitment to enabling outdoor enthusiasts to
perform at their peak,” said Anne Cavassa, president and CEO of PrimaLoft.
The new textile-to-textile recycled products come after PrimaLoft introduced its Produced Using Reduced Emissions (PURE) manufacturing method in 2019, which it said is environmentally superior to traditional processes. The proprietary process involves utilizing renewable energy sources and more efficient manufacturing equipment, which the company said reduces emissions by 50 percent or more..
PrimaLoft incorporated initially incorporated the PURE process in its flagship Gold Insulation production, and it also is used in producing 100 percent recycled UltraPeak performance insulation.
““PrimaLoft UltraPeak is the ultimate expression of this focus,” Cavassa said. “A result of decades of expertise, it’s built to deliver top performance, shaped by our community’s needs, and driven by our commitment to protecting the outdoors.”
PrimaLoft—which supplies insulation to brands such as Patagonia, Gap, Adidas, Moncler and Lululemon—said this latest development plays into its “Relentlessly Responsible” program dedicated to improving sustainability and decarbonization.
