EKOFOM: a new technology from INGENITEX for producing bra cups with recycled foam
Most bra cups are made from flexible polyurethane foam. They provide a soft and comfortable fit but to date have always been made from virgin foams. Recycled foams were simply not suitable.
To add to the less than sparkly picture, both the scraps produced during the manufacturing process and old bras generally end up going to landfill as flexible polyurethane foam can only be recycled if it is not attached to another substance. Padded bras therefore have always been unrecycled and unrecyclable.
EKOFOM is a new technology developed by INGENITEX as part of a project running until next June. It makes the padded bra manufacturing process more sustainable by producing bra cups using recycled foams which are of comparable quality and performance to virgin foam products.
The project may be expanded to other apparel products that use foam pads, such as sports bras, shapewear and swimwear, and they can be integrated into garments with other recycled and sustainable materials. This will definitely contribute to a more sustainable approach to fashion.
- Phase 1 (Completed): R&D to develop methods for recycling flexible foams into recyclates which can be used to manufacture bra cups.
- Phase 2 (Completed): Design and engineering to develop machines and manufacturing processes to integrate the recyclate foams into the manufacturing of bra cups.
- Phase 3 (Ongoing): Testing to optimise product performance in cost effective, sustainable and ecofriendly ways, while ensuring that the final product meets all safety and quality standards.
- Phase 4: Establish the circularity process to recycle flexible foams by integrating them into manufacturing processes suitable for mass production. This will yield cost-effective solutions that can eventually enable all brands and retailers to adapt the technology.