Conner Hats transforms post-consumer plastic bottles into premium outdoor hats using certified recycled polyester. Each recycled hat diverts approximately 5-7 plastic bottles from landfills and waterways while delivering the performance you need for hiking, boating, and sun protection.
Our recycled material hats are crafted from Repreve recycled polyester and post-consumer PET plastic. Compared to virgin polyester production, our recycled materials deliver measurable environmental benefits:
Tens of billions of plastic bottles are discarded every year, and most are never recycled. At Conner Hats, we intercept this waste stream and transform single-use plastic into durable, handmade hats you'll wear for years.
Founded by Will Conner, Conner Hats continues a 50-year family tradition of hat craftsmanship started by his father Bill Conner in Byron Bay, Australia. We've committed to incorporating sustainable materials—including organic cotton, hemp, and recycled plastic composites—since our founding, running our original St. Augustine warehouse on 100% solar power and prioritizing ethical production at every stage. We still maintain our company food forest at the site and have created a hub there for other small businesses to use the location.
Our recycled hats are made from certified recycled polyester (rPET) sourced from post-consumer plastic bottles. We partner with Repreve, a traceable recycled fiber manufacturer, to ensure 100% recycled content. Each hat contains material from approximately 5-7 recycled plastic bottles. The fabric is then handmade into hats at our production facilities, with organic cotton sweatbands (GOTS certified) and shipped from our warehouse in American Fork, Utah.
Each Conner recycled hat diverts approximately 5-7 post-consumer plastic bottles from landfills and waterways. Tens of billions of plastic bottles are discarded every year, and most are never recycled. By choosing recycled material hats, you're helping transform single-use waste into durable outdoor gear that lasts for years.
Yes. Recycled polyester delivers the same performance as virgin polyester—waterproof, quick-drying, fade-resistant, and durable—while taking less energy and producing fewer CO₂ emissions to manufacture. Our recycled hats are backed by a limited lifetime guarantee against defects in materials and workmanship, demonstrating our confidence in their durability.
Yes. Most Conner recycled hats feature UPF 50+ rated fabrics, blocking at least 98% of harmful UVA and UVB rays. This is the highest sun protection rating available and is critical for outdoor activities, as UV exposure increases about 2% (EPA) for every 1,000 feet of elevation gain during hiking.
Recycled polyester hats are easy to care for. Hand wash with mild soap and cool water, then air dry. The material is naturally quick-drying and won't shrink or fade. For crushable/packable styles, you can fold them into your backpack without losing shape. Avoid machine washing or high heat, which can damage the organic cotton sweatband.
Conner Hats uses certified Repreve recycled polyester, which is fully traceable and verified. Compared to virgin polyester, our recycled materials cut energy use, CO₂ emissions and water use. Our original St. Augustine warehouse runs on 100% solar power, and we use biodegradable string instead of plastic hang tags, and ship hats on flat cardboard instead of plastic bags. Our woven labels are made from recycled PET plastic. We're transparent about our materials and processes—sustainability isn't a marketing claim, it's our company policy.
Our recycled material collection includes boater hats, bucket hats, outback styles, and hiking hats. Popular models include the Airflow Lightweight Recycled Outdoor Hat, Tarpon Springs Recycled Floating Sailing Hat, Aztec Boater Recycled Hat, Mojave Boater Hat, and Sunblocker Lightweight Recycled Outdoor Hat. Many feature crushable, packable designs ideal for backpacking and travel.
Yes, select styles float on water. The Tarpon Springs Recycled Floating Sailing Hat and Mojave Boater Hat are specifically designed to float, making them ideal for boating, kayaking, and water sports. Check individual product descriptions for floatability features.
Conner Hats is a family-owned business with handmade hat craftsmanship dating to 1969. Unlike mass-produced hats, ours are hand-cut and sewn by artisans, shipped from our warehouse in American Fork, Utah, and backed by a limited lifetime guarantee. We use certified Repreve recycled polyester (fully traceable), GOTS organic cotton sweatbands, and biodegradable packaging materials. Our founder Will Conner learned hat-making in his father's Byron Bay factory and has prioritized sustainable materials since launching Conner Hats.
Both materials have benefits. Organic cotton is largely rain-fed and biodegradable, while recycled polyester avoids virgin petroleum and uses less water to produce. For waterproof, quick-drying performance needed in outdoor and water activities, recycled polyester outperforms cotton while diverting plastic waste from landfills. Conner Hats uses both materials strategically—recycled polyester for performance hats and organic cotton for breathable, natural-fiber styles.
