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Hats Made from Recycled Materials
Americans throw away tens of billions of plastic bottles every year. At Conner Hats, we turn some of that waste into hats that can last for decades with proper care.
Hats
Made from Recycled Plastic Bottles
Conner Hats transforms post-consumer plastic bottles into premium outdoor hats using recycled polyester. Each recycled hat diverts about five plastic bottles from landfills and waterways while delivering the performance you need for hiking, boating, and sun protection.
Why Recycled Polyester Outperforms Virgin Materials
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:
- Lower energy consumption during manufacturing (Stockholm Environment Institute)
- Lower CO₂ emissions compared to virgin polyester production (Stockholm Environment Institute)
- Reduced water use versus conventional polyester fabric (Qian et al., 2021)
- Wide-brim shade for the face, ears and neck: hats with open mesh, vents or brims under 2.5 inches are not UPF-rated.
The Problem We're Solving
Some of our hats are made with recycled plastic bottles. At Conner Hats, we intercept this waste stream and transform single-use plastic into durable, handmade hats you'll wear for years.
From Bottle to Hat: Our Process
- Collection: Post-consumer plastic bottles are collected and sorted
- Cleaning & Shredding: Bottles are cleaned, shredded into flakes, and melted
- Fiber Creation: Molten plastic is extruded into recycled polyester thread
- Handmade Craftsmanship: Each hat is handmade with care
- Food Forest give back : Check out our Food Forest permaculture project in St. Augustine, Florida. Possible because of you!
Performance Features
- Water-Resistant & Quick-Drying: Recycled polyester naturally repels water and dries faster than cotton
- Lightweight & Packable: Crushable designs fold into backpacks without losing shape
- Floatable Designs: Select styles (like the Tarpon Springs and Mojave Boater) float on water
- Sun protection: Wide brims shade face, ears and neck; hats with open mesh, vents or brims under 2.5 inches carry no UPF rating
- Durable & Fade-Resistant: Won't shrink, fade, or deteriorate like natural fibers
- GOTS Organic Cotton Sweatbands: Interior comfort meets sustainability standards
Family-Owned, Sustainability-Driven
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. Across our wider range, we've committed to incorporating sustainable materials—including organic cotton, hemp, and recycled plastic—since 2014, running our original St. Augustine warehouse on 100% solar power (orders now ship from American Fork, Utah) 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.
Frequently Asked Questions: Recycled Material Hats
Our recycled hats are made from recycled plastic bottles. Several styles use Repreve fabric, and some have organic cotton inner bands. The hats are handmade and shipped from our warehouse in American Fork, Utah.
Our recycled hats are made from recycled plastic bottles and other single-use plastics. Each hat uses about five plastic bottles, helping transform waste into durable outdoor gear.
Yes. Recycled polyester is durable and delivers the same performance as virgin polyester, including water resistance, quick drying, and fade resistance. Our Limited Lifetime Guarantee (50% off if lost or stolen) covers workmanship failure on purchases from connerhats.com: during the first 12 months, it provides a free replacement of the same style, size, and color, with shipping paid. After 12 months, it provides 40% off a replacement, with shipping not included. Material degradation from use is eligible for a 30% off code.
Some recycled material hats are UPF rated; check each product page for its rating. Hats with open mesh or vents, or brims under 2.5 inches, are not UPF rated.
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.
Several hats in this collection use Repreve, a bluesign®-approved material made from plastic bottles and other single-use plastics. Recycled polyester uses about 45–59% less energy than virgin polyester. Our original St. Augustine warehouse runs on 100% solar power, and orders now ship from American Fork, Utah. We use biodegradable string to attach tags, and our packaging uses biodegradable and recyclable materials. Our woven labels are made from GOTS-certified organic cotton with vegetable dyes. We share specific materials and practices rather than claiming our hats have no environmental impact.
Current recycled-material styles include the Airflow Lightweight Recycled Outdoor, Aztec Boater Recycled Hat, Boat Yard Outdoor Recycled Fedora, Mojave Recycled Floating Sailing, Sun Shield Recycled Boater Hat, Sunblocker Lightweight Recycled Outdoor, Tarpon Springs Recycled Floating Sailing, and Way Outback Recycled Hiking Hat.
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 family-run, with over 50 years of hatmaking in the family. 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. The guarantee also includes a 50% off code to replace the same hat if yours is ever lost or stolen. Several hats in this collection use Repreve recycled polyester, and some have organic cotton sweatbands. 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 environmental benefits. About 70–80% of organic cotton is rain-fed, and organic cotton hat bodies are biodegradable. Recycled polyester is made from plastic bottles and other single-use plastics, and uses about 45–59% less energy than virgin polyester. Conner Hats uses recycled polyester in some hats and organic cotton for some sweatbands.