PrimaLoft, Inc. is increasing the use of post-consumer recycled content in its PrimaLoft Cross Core Series*, which now includes a stretch version for freedom of movement.

The Cross Core platform fuses existing PrimaLoft fibers with next-gen materials. The initial line of products uses Aerogel, a porous, lightweight structure developed by NASA scientists that acts as an insulator.

Beginning Fall 2021, products in the Cross Core Series will contain up to 90 percent PCR content.

“Our Relentlessly Responsible mission places equal focus on innovation, performance and sustainability,” said Mike Joyce, president and CEO of PrimaLoft. “Our Cross Core series of technologies includes some of our highest-performing products to date. We must marry that performance with an increased emphasis on the sustainability component. We’ve been able to include much higher ratios of recycled content and will continue to innovate on additional sustainable materials and processes.”

The current products in the PrimaLoft Cross Core Series use Aerogel for thermal performance. Silica Aerogel is composed of more than 95 percent air and “is the lightest solid material known to man and one of the most effective insulation materials,” said Primaloft.

PrimaLoft engineers integrate Aerogel material into the fibers, allowing PrimaLoft to develop apparel insulation to withstand outdoor garments’ extreme challenges. Fusing Aerogel with PrimaLoft Insulation provides a boost in warmth without increasing weight.

“When we first began experimenting with the idea of using aerogel in insulation fibers, our focus was on getting the formula right so that we were delivering a new level of thermal performance,” said Vanessa Mason, PrimaLoft SVP of engineering, insulation and polymers. “Once we became the first to crack that code, we knew we needed to continue to innovate on the sustainability side and find a way to use as much recycled content as possible while maintaining that performance. We’re excited with our progress and will continue to explore how we can introduce additional sustainable practices to this technology.”

Aerogel technology can be found in several PrimaLoft products including:

  • PrimaLoft Gold Insulation with Cross Core technology blends PrimaLoft Gold Insulation with Aerogel for lightweight warmth using 90 percent post-consumer recycled material, up from 35 percent in the previous version;
  • PrimaLoft Gold Insulation with Cross Core technology, now available in a stretch version, offers the same thermal performance characteristics with 5 percent stretch for greater freedom of movement. This version uses 70 percent post-consumer recycled content;
  • PrimaLoft Gold Insulation Hi-Loft Ultra with Cross Core has an accordion-like construction for loft and quick compression recovery for lightweight warmth. This product now offers 74 percent post-consumer recycled material; and
  • PrimaLoft Silver Insulation ThermoPlume with Cross Core Technology is PrimaLoft’s next level of warmth in loose-fill synthetic insulations. By blending individual plume fibers with Aerogel technology, the insulation delivers the aesthetic and performance of natural down with up to 12 percent more warmth compared to its previous ThermoPlume insulations, said the brand. The loose-fill insulation offers compressibility and a water-repellent finish.

*Products in the PrimaLoft Cross Core Series have been adopted by more than 50 brands including Maloja, Mammut, Vaude, Dynafit, La Sportiva, Millet, Bergans, Haglöfs, Norröna, Montane, Rab, L.L.Bean, Sitka, Black Diamond, Patagonia, and Strafe.  

Illustration courtesy PrimaLoft