Our focus on materials extends beyond our garments, we consider everything from the coffee cups we use in our Untouched World Kitchen to the packaging we use for our orders. We aim to reduce, or eliminate, waste wherever possible, so a couple of years ago we took a closer look at our packaging to see what positive changes we could make. This research process involved an extensive, three-year deep dive, drawing upon expert insight from the government agency Callaghan Innovation, alongside many other sources of expertise in the fields of plastic and Life Cycle Assessment (LCA). Polybags stood out as a key area where we could make improvements, so we set out to investigate our options.

What are polybags?

Polybags are the thin, see-through plastic bags that are used to protect garments as they’re shipped between factories, warehouses, and stores. When you order clothing online, it’s very likely you’ll receive it in a polybag.

Why do we use polybags?

As cutting down plastic waste is such an important topic and very much in the limelight, we understand that many people would ask why we use polybags at all. Can’t we just do away with them? Polybags could be described as a necessary evil. They are a single-use plastic product, but they are absolutely crucial for protecting garments while in transit, so they don’t get dirty or damaged.

To investigate ways to reduce the amount of packaging waste they produced, Patagonia conducted a series of tests in one of its distribution centres. When they ran their shipping system without polybags, around 30% of the garments became damaged beyond the point of being sellable.

That level of product and textile waste just isn’t sustainable. We also need to protect our garments from moths, as they love our natural fibres, particularly wool. No one wants to buy a moth-eaten sweater!

Can’t we just switch to paper?

The experiment at Patagonia’s distribution centre included paper bags too, but the paper packaging was too easily damaged, and dirt and dust could then get into the packaging via holes made.

Paper isn’t a great option when it gets wet either, explains our Development Manager Fiona Bretherton, as it can simply disintegrate. In addition, the packaging being clear is a must because when the dispatch team cannot see the products, the error rate in the warehouse goes up. This means return rates increase which in turn increases the amount of shipping and the associated impact. After exploring paper, we also looked at compostable options, but again they just didn’t pass muster and meet our needs.

“We really grappled with what we need from our packaging, and worked with a plastics specialist within Callaghan Innovation to look at our options. We’ve looked at the full life-cycle of packaging and compared plastics, paper, compostables and the novel newcomers like stone,” says Bretherton. “There is a lot more to consider than meets the eye!”

Making the switch

Previously, we were using virgin plastic polybags. After extensive research we realised that the biggest problem with them was that they came from a non-renewable resource and the end-of-life infrastructure to reuse them simply didn’t exist in New Zealand. However, after exploring all the options, plastics actually came out as the top choice from the point of view of emissions. But rather than simply sticking with the option we had, which we weren’t entirely happy with, we decided to find something which performed better environmentally.

That’s when we discovered that Better Packaging Co. had launched POLLAST!C polybags, made from 100% Ocean Bound Plastic pollution, answering a lot of the requirements we had.

“First, it is made from recycled plastic so it’s not using any virgin materials. Also, the prevention of ocean plastics is massive for us - it’s the reason we make garments using natural fibres, so we’re not contributing to the problem. We love that it’s made from waste likely to have ended up in the ocean,” says Bretherton. The cherry on top is that Better Packaging Co. which is headquarted in New Zealand, is a BCorp which supports its community, pays fair wages, and works towards the UN’s Sustainable Development Goals, as we do.

A further clever feature of the POLLAST!C polybags is that they’re resealable. To make the most of each bag we have a programme in place with our stores where they keep all the bags and send them back to head office for reuse. Once a bag can no longer be reused we can count the number of barcode stickers on the bag (each new one is stuck over the old) to see how many cycles we kept it in use.

Even the most seemingly simple of switches takes a lot of research, development, and consideration, but they are, without fail, worth the effort. In this case, we’re diverting plastic pollution from the ocean, working with a fellow local BCorp, and reusing what already exists, all while ensuring our garments are protected so they arrive at their destination in perfect condition.

To learn about more ways in which we’re improving the finer details of our brand from a social and sustainability standpoint, read our journal entry on our 2024 goals, and head over to our 2023 Impact Report to see what we’ve already achieved.