The Problem

The overwhelming scale of plastic production and its subsequent impact on our environment is deeply confronting.
Did you know that globally, an incredible 380 millon tonnes of plastic is produced every year? However, what exacerbates the situation even further is that only 9% of this vast plastic production is recycled.

As you know, this now presents a massive global issue.

The Repercussions

The repercussions of such low recycling rates are far-reaching and have significant consequences for our planet. The remaining 91% (345 millon tonnes) of plastic waste is left to find its way into landfills, incineration facilities, or even worse, into the natural environment, including our precious oceans.

It is estimated that approximately 8,000,000 metric tons of plastic enters our oceans every year.

That’s 8 billion kilograms. For context, if you turned 8b kg of plastic into liquid, it would fill over 2,000 olympic swimming pools

The Problem

The overwhelming scale of plastic production and its subsequent impact on our environment is deeply confronting.
Did you know that globally, an incredible 380 millon tonnes of plastic is produced every year? However, what exacerbates the situation even further is that only 9% of this vast plastic production is recycled.

As you know, this now presents a massive global issue.

The Repercussions

The repercussions of such low recycling rates are far-reaching and have significant consequences for our planet. The remaining 91% (345 millon tonnes) of plastic waste is left to find its way into landfills, incineration facilities, or even worse, into the natural environment, including our precious oceans.

It is estimated that approximately 8,000,000 metric tons of plastic enters our oceans every year.

That’s 8 billion kilograms. For context, if you turned 8b kg of plastic into liquid, it would fill over 2,000 olympic swimming pools

A Solution.

To stop adding to the problem and help combat this issue, we created DreamGreen.

Instead of creating MORE plastic to use as microfibre fill in our bedding like most manufactures do, we’ve perfected the use of plastic which is recycled from drinking bottles.

This is how is happens.

1: Source and Sort

Plastic bottles are sourced from a variety of places, including recycling centers, waste management facilities, and municipal recycling programs. Once gathered, these bottles undergo a comprehensive sorting procedure to eliminate contaminants and non-recyclable items.


During the sorting process, each item is carefully examined by trained personnel and/or automated systems to ensure its suitability for recycling. Non-recyclable items (i.e. bottle caps) are separated from the bottles and following processes.

2: Clean and Shred

Next, the plastic bottles undergo a thorough cleaning and sterilisation process to remove any impurities. This cleaning stage is to ensure all recycled plastic achieves a very high level of purity.


After cleaning, the bottles are subjected to shredding, where they are transformed into small chips or flakes. This shredding process serves multiple purposes. Firstly, it increases the surface area of the plastic, making it more accessible for subsequent processing steps, while it also ensures consistent quality and properties throughout the recycled batch.

3: Chips to Thread

The next step involves using controlled temperatures to melt down the small flakes into a molten plastic which is then passed through a extrusion tool called a spinneret. The plastic is forced through the spinneret under pressure which shapes the molten plastic into long, continuous strands which are known as filaments


Following this is a process called Drawing. This involves stretching the filaments to improve the thread’s strength and give it a finer diameter. This results in a fine fibre, commonly known as microfiber.

4: Fiber to Fluff

Next the microfiber is processed through a specialised machine that ‘crimps and cuts’ the fiber. This introduces waves or bends into the fiber which adds volume and resilience to the fibers, ensuring they can provide adequate loft and support when used as fill.


After crimping, the fibers are cut into shorter lengths, typically ranging from a few centimeters to a few inches, depending on the desired characteristics of the final product. The cutting process ensures that the fibers are of uniform length, enabling consistent quality and feel within the end product. These are then baled and prepped for carding.

5: Carding

The crimped fibers undergo a crucial step called carding. Carding is a process that aligns the fibers in a parallel manner while removing any remaining tangles or irregularities. This uniformity results in better quality and performance of the final product.


The aligned and carded fibers are now processed to form a thin and continuous web or mat. This web is gradually built up as the fibers are transferred from one carding roller to the next. Once the web is formed, it is compressed and consolidated to increase its thickness.

6: Combining to Quilting

After carding, the web is trimmed to the correct size and is combined with outer fabrics – now the final product starts to take shape.


The whole piece is now quilted. Quilting involves stitching the layers of fabric together with the fiber fillings in between, creating a patterned or quilted effect. This process adds strength, stability, and aesthetic appeal to the final product.

7: Binding & Finishing

Once the quilting is complete, binding is added to the edges of the quilt. Binding is a fabric strip that is folded in half and sewn along the raw edges of the quilt to enclose the edges and provide a finished look.


Labeling adds the finishing touches: Quilts have varying labels attached to identify the brand, size, care instructions etc. Additionally, some custom product may receive additional finishing touches such as embroidery work.

8: QC and Packaging

The finished luxury pillows undergo rigorous quality control (QC) checks to ensure they meet our standard in terms of appearance, comfort, and durability. During this phase we will inspect area such as stitching and seam quality, size and the distribution of filling, plus much more.


Once approved, the product is compressed using a vacuum sealing machine, resulting in a compact and space-saving package. This also protect the item from dust, moisture, and insects during transportation and storage. When the package is opened, the item will regain its original shape.

The Impact

Bottles

Since we launched the DreamGreen bedding initiative in 2016, this is the ever growing number of plastic bottles we’ve recycled:

19,347,592



It is all thanks to the unwavering support of our valued customers. The tremendous positive impact your purchasing decisions have had on the environment is truly remarkable!

We are deeply grateful for the unwavering support of our valued customers, as it is thanks to you that this remarkable result has been achieved. To our clients, your purchasing decisions have had a tremendous positive impact on the environment, and we are truly inspired by this accomplishment.

Distance

If we took every bottle recycled to date through the DreamGreen program, and laid them end to end, they would stretch this many kilometers:

3,863



For context, this would stretch from Sydney to Darwin, or from Brisbane to Kalgoorlie or if we head over the Pacific, from Hobart to Queenstown AND back!
Did you know that we can live-track exactly how many bottles you have recycled through your purchases of DreamGreen? This is captured on your account which you can check anytime, and promote through your social media channels or inhouse to your guests!

Bottles

Since we launched the DreamGreen bedding initiative in 2016, this is the ever growing number of plastic bottles we’ve recycled:

19,347,592



It is all thanks to the unwavering support of our valued customers. The tremendous positive impact your purchasing decisions have had on the environment is truly remarkable!

We are deeply grateful for the unwavering support of our valued customers, as it is thanks to you that this remarkable result has been achieved. To our clients, your purchasing decisions have had a tremendous positive impact on the environment, and we are truly inspired by this accomplishment.

Distance

If we took every bottle recycled to date through the DreamGreen program, and laid them end to end, they would stretch this many kilometers:

3,863



For context, this would stretch from Sydney to Darwin, or from Brisbane to Kalgoorlie or if we head over the Pacific, from Hobart to Queenstown AND back!
Did you know that we can live-track exactly how many bottles you have recycled through your purchases of DreamGreen? This is captured on your account which you can check anytime, and promote through your social media channels or inhouse to your guests!

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