ROTHY’S: Design Out Waste by Knitting-to-Shape Technology and Targeting of Plastic Waste and Algal Blooms | Knowledge Hub | Circle Economy Foundation
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ROTHY’S: Design Out Waste by Knitting-to-Shape Technology and Targeting of Plastic Waste and Algal Blooms
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The majority of plastic products used nowadays are designed to be used only once and then disposed to the landfill. Plastic waste that gets into the waterways could also cause injuries and deaths of marine species upon injection. Another problem in many water bodies is the occurrence of algal blooms where the overgrowth of algae could obstruct the growth and survival of marine species by blocking out sunlight, competing for oxygen, and potentially releasing toxins. Concerning that, ROTHY'S collects single-use plastic bottles from landfills, plastic waste and algae from water bodies. Combined with other renewable materials it uses, they are used to produce ROTHY'S shoes, bags and accessories. ROTHY's also implements a knitting-to-shape strategy to minimise any waste produced during the manufacturing process. With that, it has repurposed millions of single-use plastic water bottles and over 200,000 pounds of ocean-bound marine plastic. The innovative knitting-to-shape strategy also helps reduce 30% material waste.

Problem

Plastic is deeply ingrained in human civilisation and serves its many purposes. According to UNEP, one million plastic drinking bottles are purchased every minute, and 5 trillion single-use plastic bags are used globally every year. However, more than half of all plastic products is designed to be used only once, and they are then thrown away. More than 60 million plastic bottles end up in the landfills and incinerators every day and 8 million metric tons of plastic end up in the oceans every year. According to the Ellen MacArthur Foundation, by 2050, there could be more plastic by weight in oceans than fish. Marine species could suffer from severe injuries and deaths upon injection of these plastic. 


Another problem happening worldwide is algal blooms, i.e. the overgrowth of algae in water, as a result of nutrient pollution from human activities. Occurrences of algal bloom and dead zones can produce dangerous toxins that can sicken or kill human beings and animals. In addition, aquatic life will find it hard to survive due to the overgrowth of algae blocking sunlight at the surface and competing for oxygen.

Solution

ROTHY'S diverts plastic bottles from landfills and plastic waste from water bodies within 30 miles of coastlines and marine environments. Meanwhile, it also harvests the harmful algae from waterways. These are then used to knit its shoes, bags and accessories. For instance, the uppers of its shoes are spun from plastic bottles, and the strobel boards (the green part of the shoes) are made from an algae-based foam. Committed to circularity, other 'better materials' ROTHY'S strives to use include renewable natural rubber, bio-based TPU made from corn, bio-based PU made from castor oil as 'a more eco-friendly plant source', hemp fiber, and merino wool.


ROTHY'S also leverages on its manufacturing technique. It knits its products to shape in order to minimise production waste by using knit machines that are programmed to precise size levels.

Outcome

According to ROTHY's, it has repurposed millions of single-use plastic water bottles and over 200,000 pounds of ocean-bound marine plastic into shoes, bags and accessories. By harvesting algae from waterway, it helps to minimise the impacts of algal blooms that could be detrimental to aquatic ecosystems. Its materials used also have additional advantages: Using algae as a material makes its shoes extra sturdy, while the bio-based TPU made from corn allows flexible and durable outsoles. ROTHY's programmed-to-size knitting techniques also has its advantages: It results in 30% less material waste than traditional cut-and-sew methods. As they are knit to shape, the final uppers are also seamless and more comfortable.

Additional information

ROTHY'S is committed to the continuous quest for circularity and improvement. It is also initiating a pilot recycling program and aspires to pursue zero-waste certifications in its workshops in 2022 so that it can expand its waste minimisation practices across all areas of the factory. 

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Tags

plastic waste

ocean plastic

design out waste

algal bloom