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Manufacturing process of Nike Forward drastically reduces carbon footprint compared to traditional knit fleece
September 8, 2022
By: Tara Olivo
Associate Editor at Nonwovens Industry
Athletes around the world have shared that climate change is a barrier to sport. Nike Forward, the company’s most significant apparel innovation since Dri-Fit, responds to that concern by re-setting the way we think about fleece. Moving away from traditional knit and woven processes, Nike Forward revolutionizes apparel creation by hacking punch-needle machines for the purpose of making premium, sustainability-minded product. “Nike Forward feels different because it is different. It is not a traditional knit or woven, but a completely new material that drastically reduces its carbon footprint,” says Carmen Zolman, VP Innovation Apparel Design, Nike, Inc. Over five years of research went into the development of Nike Forward. The innovation, shifting from knit or woven, simplifies the process of material fabrication by reducing steps. Rather than follow a multistage (spin yarn, knit, cut, sew and more) creation cycle, Nike Forward turns fiber directly to textile through needlepunch. Fewer steps means less energy consumption, contributing to an average of 75% reduction in the carbon footprint for this first generation material compared to traditional knit fleece. Nike Forward material also has a lighter density than traditional knit fleece, which is crucial to reaching 75% carbon reduction, and the finished product is comprised of 70% recycled content by weight.
In keeping with its sustainable ethos, the hoodie forgoes embellishments and dyes, favoring raw cut pockets and zero water usage.
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