Italian cycling apparel brand Santini Cycling and U.S.-based textile innovator Polartec have introduced a next-generation cycling jersey that converts industrial carbon emissions into high-performance fabric, marking a significant step forward in sustainable sportswear.
The newly launched Aero Race jersey features Polartec’s “Power Dry with Recycled Carbon” technology, which captures carbon dioxide emissions—primarily from steel mills—and transforms them into recycled polyester yarns.
This process represents a shift from traditional recycling methods, which rely on plastic waste, by instead utilizing airborne emissions as raw material. The resulting fabric contains up to 91% recycled carbon content and reduces the garment’s carbon footprint by approximately 66% compared to conventional polyester alternatives.
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The Aero Race jersey is the first commercial application of this carbon-capture textile technology, combining sustainability with performance. Designed for competitive cycling, the garment incorporates aerodynamic engineering, including a close “second-skin” fit and vortex-optimized sleeves to minimize drag.
Despite its environmental focus, the jersey maintains performance standards expected by professional athletes. The lightweight fabric enhances breathability, moisture management and thermoregulation during high-intensity activity.
Industry experts view the innovation as part of a broader shift toward decarbonizing synthetic textiles. By transforming greenhouse gas emissions into functional materials, manufacturers aim to reduce reliance on fossil-fuel-based inputs without compromising product quality.
Santini said the technology could eventually be scaled across a wider range of cycling apparel, signaling potential for broader adoption in the sportswear sector as brands respond to tightening environmental regulations and consumer demand for sustainable products.
