For decades, the fashion industry has treated carbon dioxide as a problem to be reduced, taxed, or offset. In 2026, that thinking is changing. Carbon is no longer viewed only as waste. It is increasingly being treated as a raw material.
A growing number of textile innovators are turning industrial emissions and even atmospheric carbon into feedstock for polyester. This shift marks the rise of an “air-to-closet” supply chain, where the carbon released from factories becomes the base ingredient for synthetic fibers used in apparel, footwear, and performance textiles.
For sourcing and sustainability teams, this is not a distant experiment. It is already entering commercial supply chains.
From Emissions to Fiber: How Carbon Capture Becomes Polyester
Sourcing managers do not need to master chemistry, but understanding the basic flow of Carbon Capture and Transformation helps assess supplier readiness.
The first step is capture. Specialized systems extract carbon dioxide from steel plants, waste-to-energy facilities, or directly from the air. Instead of releasing emissions into the atmosphere, they are isolated as a usable input.
Next comes fermentation. This stage resembles a microbial brewery. Engineered bacteria consume the captured carbon and convert it into ethanol. This biological process replaces fossil-based feedstocks with emissions-based inputs.
The ethanol is then converted into monoethylene glycol, or MEG. MEG is one of the two essential components used to make PET polyester. Once produced, this MEG behaves exactly like its petroleum-derived counterpart.
Finally, the material is polymerized and spun into yarn. The resulting polyester is identical in performance, strength, and durability to virgin polyester. From a mill or garment factory perspective, it runs on existing equipment with no change in handling.
Why Air-Mined Polyester Goes Beyond rPET
Recycled polyester made from plastic bottles has been the industry benchmark for more than a decade. While rPET remains important, it has clear structural limits.
The first issue is scale. There are not enough post-consumer plastic bottles to meet fashion’s growing demand for polyester. As packaging recycling improves, bottles are increasingly diverted back into bottle-to-bottle systems, reducing availability for textiles.
Air-mined polyester does not face this constraint. Industrial emissions are continuous and abundant. As long as factories operate, carbon feedstock exists.
The second difference is environmental impact. rPET addresses solid waste. Carbon capture materials address atmospheric emissions. This directly links textile production to climate mitigation rather than waste management alone.
The third advantage is quality. Mechanically recycled polyester degrades over multiple recycling cycles. Carbon-derived polyester is virgin-equivalent and can be recycled repeatedly without loss of performance.
Who Is Already Using Captured Carbon
This technology is no longer confined to pilot labs.
LanzaTech has been one of the pioneers in carbon recycling, working with industrial partners to convert emissions into ethanol at scale.
Zara has launched Carbon Circle collections using fabrics derived from captured carbon, signaling mass-market viability.
On Running uses CleanCloud foam made from carbon emissions in its performance footwear, proving suitability for high-stress applications.
Lululemon has developed leggings using carbon-derived materials, demonstrating that stretch, comfort, and durability are not compromised.
These examples show that air-mined materials are moving beyond concept stories into repeatable supply chains.
The Business Case for Sourcing Teams
Carbon regulations are tightening globally. Carbon taxes, emissions disclosure, and Scope 3 reporting are becoming unavoidable.
Using captured carbon materials can help brands lower reported emissions intensity. In some markets, it may also support eligibility for carbon credits or regulatory incentives, depending on policy design.
Cost remains higher than conventional polyester, but the gap is closing. As carbon capture plants scale in regions like China and the United States, unit economics are improving. Early adoption allows brands to learn before regulation forces rapid change.
For sourcing leaders, this is about future-proofing material strategies rather than chasing short-term marketing claims.
Questions Sourcing Leaders Should Ask Now
To move beyond recycled bottles, sourcing teams should start with better questions.
What percentage of polyester supplied is carbon capture based versus rPET?
Which mills have active partnerships with carbon capture technology providers?
Is it possible to pilot a capsule collection using zero virgin fossil-based polyester?
These conversations help identify suppliers preparing for the next phase of material regulation and climate accountability.
Looking Up Instead of Digging Down
For decades, the fashion industry has relied on oil extracted from the ground to make synthetic fibers. In 2026, the most forward-looking sourcing strategies are shifting direction.
Carbon is no longer only something to reduce. It is something to redesign into value. The sky is no longer the limit. It is becoming the warehouse.
