In a pioneering step towards sustainable materials, PureCycle Technologies, based in Orlando, Florida, has made a significant breakthrough by selling nearly 500,000 pounds of its PureFive recycled polypropylene (PP) resin to Drake Extrusion, a leading producer of colored filament yarns and staple fibers. This move represents a major development in the production of eco-friendly continuous filament yarns, used in products such as rugs, upholstery, and apparel.

Drake Extrusion, headquartered in Ridgeway, Virginia, is renowned for its high-quality filament yarn production. The partnership with PureCycle follows successful trials where Drake used PureFive resin to produce continuous filaments. PureFive, produced at PureCycle’s Ironton, Ohio plant, is made entirely from 100% post-consumer recycled PP feedstock. The resin was then formulated into a specialized compound by PureCycle’s R&D team in Durham, North Carolina, enabling Drake to manufacture fibers for a variety of applications.

Drake’s CEO, John Parkinson, expressed his excitement about the partnership, saying, “We’ve been looking for a reliable source of post-consumer recycled PP that can be used to create sustainable fibers for our customers. After testing PureCycle’s material under various conditions, we produced several types of fiber that far exceeded our expectations. These fibers are now with customers for feedback, and we see this as a key growth opportunity.” This collaboration comes at a time when demand for sustainable materials is at an all-time high, particularly in industries focusing on circular economy principles.

Historically, approximately 20% of global virgin PP production has been used for fibers and yarns, but there has been no reliable recycling alternative until now due to the complexities of the fiber manufacturing process. Polypropylene fibers are favored for their lightweight, durability, and chemical resistance, making them critical in multiple industries. The PureCycle-Drake partnership aims to replace traditional virgin PP with recycled PP, which has previously been a challenge due to manufacturing limitations.

Dustin Olson, CEO of PureCycle Technologies, praised the collaboration, stating, “This achievement is a testament to our technology and the capabilities of our team. We’ve worked hard to create a compound that mimics the properties of virgin PP, enabling companies like Drake to integrate it seamlessly into their processes.” He also highlighted Drake’s deep industry expertise as crucial for expanding the reach of PureCycle’s recycled PP solution.

The companies conducted extensive trials to create filaments of varying thicknesses, ideal for diverse applications. Thicker fibers are well-suited for outdoor upholstery, while thinner fibers target the apparel market. Additionally, textured fibers offer added softness, enhancing their appeal for consumer products.

Looking ahead, PureCycle’s R&D team plans to refine its compounds further, aiming to increase recycled content and extend the use of recycled PP to industries like carpet manufacturing and automotive. This breakthrough not only strengthens the partnership between PureCycle and Drake but also signals a transformative shift toward sustainability in the global materials and textile industries.