Sustainable Fashion Rides into Cycling: A Look at Eco-Friendly Jersey Brands and Green Textile Technology

Cycling is considered one of the most environmentally friendly modes of transportation, but the production process of cycling apparel is often not so “green.” Traditional polyester fibers come from petroleum, dyeing processes generate large amounts of wastewater, and fast fashion consumption patterns cause excessive waste. Fortunately, more and more cycling apparel brands are beginning to seriously address sustainability issues, driving green transformation across the board—from material sourcing to end-of-life products. This article introduces you to the brands and technologies leading this change.

The Environmental Footprint of Cycling Apparel

The Carbon Emissions of a Jersey

Manufacturing a typical polyester cycling jersey (approximately 150g) generates roughly 5-8 kg of CO₂ emissions, from crude oil extraction to finished product shipment. The main sources include:

• Raw material production (40%): Petroleum refining and polymerization
• Spinning and weaving (15%): Energy consumption of high-temperature processes
• Dyeing and finishing (25%): Chemicals and water usage for dyeing, printing, and functional treatments
• Sewing (5%): Usually completed in developing countries
• Transportation (15%): Logistics emissions from global supply chains

Water Consumption

The textile industry is the world’s second-largest water polluter. Traditional dyeing processes consume approximately 100-150 liters of water per kilogram of fabric, containing residual dyes and chemical auxiliaries not absorbed by the fibers. If this wastewater is discharged without proper treatment, it can have severe impacts on aquatic ecosystems.

The Microplastic Problem

Every time polyester clothing is washed, thousands of microplastic fibers are released into the water system. One study estimates that a polyester jersey releases approximately 1,500-3,000 microfibers per wash. These microplastics eventually flow into the ocean and enter the food chain.

Sustainable Material Technologies

Recycled Polyester (rPET)

Recycled polyester is currently the most mature and widely adopted sustainable fabric technology. The main sources of raw materials:

PET Bottle Recycling: Used PET bottles are washed, crushed, and re-melted into new fibers. Recycling 8-12 PET bottles can produce enough material for one jersey. Notable raw material suppliers include Taiwan’s Far Eastern New Century (FENC), whose TopGreen rPET fibers have been adopted by numerous international brands.

Fiber-to-Fiber Recycling: A more advanced technology that breaks down old garments back into polyester raw material for re-spinning. This holds greater significance for the circular economy than bottle recycling, but is also more technically challenging. Companies such as Renewcell and Worn Again Technologies are currently advancing commercialization.

Recycled polyester has approximately 30-50% lower carbon emissions than virgin polyester and reduces dependence on petroleum. In terms of performance, high-quality rPET fibers are nearly indistinguishable from virgin polyester—moisture wicking, strength, and dyeability all reach the same standard.

Bio-Based Fibers

Castor Oil-Based Nylon: Fulgar’s EVO series uses castor oil as a raw material to produce nylon fibers. Castor plants require no irrigation and do not compete with food crops for land, with a carbon footprint approximately 40% lower than petroleum-based nylon. Several cycling brands have already begun adopting it.

TENCEL / Lyocell: A cellulosic fiber made from wood pulp. The production process uses a closed-loop system with solvent recovery rates exceeding 99%. TENCEL offers excellent moisture absorption and a soft hand feel, and is often blended with polyester for casual-style cycling apparel.

SeaCell: Cellulosic fibers infused with seaweed extract. Seaweed cultivation requires no fresh water, pesticides, or fertilizers, resulting in an extremely low carbon footprint. It is currently mainly used in base layers and underwear.

Recycled Nylon

Econyl (Aquafil): The Econyl system developed by Italian company Aquafil recycles waste fishing nets, industrial plastics, and fabric offcuts into nylon 6 fibers. For every 10,000 tons of waste material recycled, approximately 70,000 tons of CO₂ emissions can be avoided. Econyl fibers are identical in quality to virgin nylon 6 and have been adopted by several high-end cycling brands.

Natural Rubber Alternatives

Chamois pads and anti-slip silicone grippers typically use synthetic rubber or silicone. Some brands are beginning to experiment with natural rubber or recycled silicone alternatives to reduce the use of petrochemical raw materials.

Green Process Technologies

Dope Dyeing / Solution Dyeing

Traditional dyeing involves submerging fibers or fabrics in a dye bath after they are produced. Solution dyeing, by contrast, adds color masterbatch to the molten polymer during the spinning stage, so the fibers are colored as they are formed.

The environmental benefits of solution dyeing are remarkable:

• Approximately 90% reduction in water usage
• Approximately 60% reduction in carbon emissions
• No dye-containing wastewater generated
• Excellent colorfastness (because the color is inside the fiber)

Taiwan’s textile manufacturers are globally leading in solution dyeing technology. Everest Textile’s solution-dyed polyester fibers have been supplied to numerous international brands.

Waterless Dyeing

Supercritical CO₂ Dyeing (ScCO₂): Uses supercritical carbon dioxide instead of water as the dye carrier. In its supercritical state (above 31.1°C and 73.8 atm), CO₂ possesses liquid-like dissolving power and gas-like permeability, allowing it to carry dyes into the fiber interior. After the process, the CO₂ is recovered and reused—the entire process uses no water and produces no wastewater.

Digital Inkjet Printing: Compared to traditional roller printing and screen printing, digital inkjet printing dramatically reduces ink waste (ink is only applied where needed) and water usage. An increasing number of jersey designs are produced using digital printing technology.

A Tour of Leading Brands

Rapha

British brand Rapha’s efforts in sustainability are commendable. Its 2025 sustainability commitments include: all products using at least 50% recycled or organic materials, 100% recyclable packaging, and full carbon neutrality across the supply chain. Rapha’s Core line already makes extensive use of recycled polyester, and the brand has launched a garment take-back program. Furthermore, Rapha’s high-durability positioning is itself a sustainability strategy—one jersey worn for five years is far more environmentally friendly than five jerseys each worn for one year.

MAAP

Australian brand MAAP represents a new generation of sustainable cycling brands. Its flagship product lines make extensive use of REPREVE recycled polyester and Bluesign-certified fabrics. MAAP’s packaging uses FSC-certified paper and soy-based inks, reducing petrochemical usage. The brand also actively participates in ocean cleanup initiatives, funding a certain area of ocean cleanup for every product sold.

Pas Normal Studios

Danish brand PNS embraces Nordic sustainable design principles. Its Mechanism line uses recycled polyester and Bluesign-certified fabrics, and production is carried out in small batches in Europe to reduce transportation emissions. PNS’s minimalist design philosophy—fewer premium pieces rather than mass-market volume—is itself a critique of fast fashion.

7mesh

Canadian brand 7mesh is known for its technology-driven sustainability strategy. Its products make extensive use of Bluesign-certified fabrics and recycled materials, and the brand offers a lifetime repair service—if a garment is damaged, 7mesh will repair it whenever possible rather than recommending a new purchase. This “repair over replace” philosophy is the core spirit of the circular economy.

Velocio

American brand Velocio is one of the pioneers of sustainable cycling apparel. Its Signature line uses 100% recycled polyester, and the Ultralight line uses Econyl recycled nylon. Velocio is a member of 1% for the Planet, donating 1% of revenue to environmental protection organizations.

The Role of Taiwanese Brands

While Taiwan’s cycling apparel brands may not have the international recognition of their European and American counterparts, the country plays a critical role in the sustainable textile supply chain. Taiwanese companies such as Far Eastern New Century (TopGreen rPET), Everest Textile (solution dyeing), and Makalot Industrial (high-performance fabrics) serve as the technological backbone behind numerous sustainable cycling brands worldwide.

What Can Consumers Do?

Choose Sustainable Products

Look for the following certifications and labels:

• Bluesign: Certification for chemical safety and environmental management in fabrics
• OEKO-TEX Standard 100: Certification for testing of harmful substances
• Global Recycled Standard (GRS): Verification of recycled material content
• Fair Trade: Fair trade certification

Extend Product Lifespan

The most sustainable jersey is the one you already own. Proper care can significantly extend garment life:

• Reduce washing frequency (not every wear requires a wash)
• Use cold water and low spin speed
• Avoid tumble drying
• Repair minor damage promptly before it worsens

Use a Laundry Bag to Filter Microplastics

Using a microfiber-filtering laundry bag such as Guppyfriend can capture over 90% of microplastic fibers released during washing. This is currently the most practical measure for reducing microplastic pollution.

Participate in Garment Take-Back Programs

An increasing number of brands are launching garment take-back programs. Rapha’s Trade In program, Patagonia’s Worn Wear, and others offer old clothing a better fate than the trash bin.

Looking Ahead

The sustainability transformation of the cycling apparel industry is still in its early stages. A fully circular economy—where garments can be infinitely recycled into new clothing—still faces technical challenges. But the trend is clear: rising consumer awareness, tightening regulations, and technological progress are three forces accelerating the entire industry toward sustainability.

As riders, one of our original motivations for choosing a bicycle is to reduce our impact on the environment. Let our jersey choices carry on that intention—every purchase is a vote, cast for the future we want.

Related Reading

• Environmental Sustainability and Cycling: How Riding Becomes Climate Action
• Sustainable Riding: 10 Eco-Friendly Cycling Brands and Gear Worth Watching
• Cycling Environmental Advocacy: The Eco-Consciousness of Taiwan’s Cycling Community
• The Environmental Awareness of Bicycles: Calculating the Carbon Footprint of Two-Wheeled Commuting