Raw Materials
Fleece is a type of polyester, which is made from ethylene glycol and terephthalic acid. Both of these are petroleum products and are therefore non-renewable. Most polyester is polyethylene teraphthalate, the same material used to make plastic bottles. Some companies, most notably Patagonia, have begun to manufacture fleece from recycled plastic bottles and from recycled fleece garments. This minimizes the petroleum needed for the manufacture of fleece, lowering its environment impact.
Manufacturing Process
According to "The New York Times," manufacturing a polyester shirt uses more than twice the energy it takes to manufacture a cotton shirt. The manufacture of fleece is an energy-intensive process. The chemicals must be heated, autoclaved and forced through tiny holes to make the polyester threads. Large quantities of water are used for cooling, and lubricants and bleach are emitted in the process.
Care and Wear
Once manufactured, fleece garments can actually have a positive environmental impact. Fleece is very durable and can last longer than most other fabrics, allowing wearers to reduce consumption. It can be washed at a lower temperature than cotton clothing and hang-dries quickly, reducing the need for energy-hungry tumble dryers.
Disposal
Fleece may last longer than cotton, but when it does wear out, it's non-biodegradable and, like PET bottles, can leach chemicals into the ground. Some companies now accept worn-out fleece clothing for recycling, saving them from the landfill and reducing the environmental impact from start to finish.