US yarn marker Unifi has partnered with headwear company New Era to develop the first official National Football League (NFL) cap made from Repreve recycled filament fibres.

Developed for the Denver Broncos American football team and available in multiple styles, including the 9FIFTY and 9TWENTY, each hat is made using four plastic bottles.

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“The synergy between Repreve and New Era Cap represents one of incredible quality, performance, and a commitment to eco-friendliness,” says Mark Maidment, vice president, creative for New Era Cap. “Not only does New Era Cap value environmental consciousness, but our consumers are also increasingly looking for products with a transparent sustainability story.”

The Repreve fibre was launched in 2005 and is today used by brands including Patagonia, Haggar, Levi’s and The North Face. Since inception, Unifi estimates more than 4bn plastic water bottles have been recycled into the yarn.

“We are excited to extend our relationship with New Era and the Broncos,” adds Jay Hertwig, vice president of global brand sales for Unifi Manufacturing, Inc, a wholly owned subsidiary of Unifi. “The collaboration will help us continue to spread the word that recycled plastic bottles can become high-performance products when they’re made with Repreve.”

The Repreve-based caps will be available to buy at the Broncos Team Store at Sports Authority Field at Mile High during Broncos games from 12 November, priced at US$34.99 for the 9FIFTY and $24.99 for the 9TWENTY silhouette.

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Unifi is also teaming up with the Denver Broncos to spread eco-friendly messaging prior to and during games. Repreve-focused messaging will run on stadium boards and on 12 November and 19 November, Unifi’s custom-designed, Repreve mobile tour will be at the stadium where fans can learn how recycled plastic bottles can be transformed into high-performing gear.