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    Recycled Plastic Bottle Hats

    We use 50 billion plastic bottles per year. That is crazy! Only 20% are recycled and the rest are thrown away filling up landfills and polluting our waterways. At Conner Hats, we want to help clean those up by turning a single use item into a more valuable and beautiful recycled hat that you will get years of use from. Our hats made out of recycled items are strong but soft to the touch, waterproof, and lightweight. They won’t shrink or fade and also dry very quickly. We hope you love your new recycled hat!

    Hats

    Made from Recycled Plastic Bottles

    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.

    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:

    The Problem We're Solving

    Globally, 50 billion plastic bottles are used each year, but only 20% are recycled. The remaining 40 billion bottles end up in landfills and pollute waterways. 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: Our artisans hand-cut and sew each hat in our production facilities, ensuring quality control at every step
    • Food Forest give back : Check out our Food Forest permaculture project in St. Augustine, Florida. Possible because of you!

     Performance Features

    • Waterproof & 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
    • UPF 50+ Sun Protection: Blocks 98% of harmful UVA/UVB rays
    • 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 in 2014, 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, operating from a 100% solar-powered warehouse and prioritizing ethical production at every stage.

    Frequently Asked Questions: Recycled Material Hats

    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 solar-powered warehouse in Utah.

    Each Conner recycled hat diverts approximately 5-7 post-consumer plastic bottles from landfills and waterways. Globally, 50 billion plastic bottles are used annually, but only 20% are 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 using 59% less energy and producing 55% fewer CO₂ emissions during manufacturing. Our recycled hats are backed by a lifetime warranty 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 approximately 4-5% 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 reduce energy consumption by 59%, CO₂ emissions by 55%, and water usage by 68%. We've operated from a 100% solar-powered warehouse since our founding, 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 since 2014.

    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 a 50-year heritage of handmade hat craftsmanship. Unlike mass-produced hats, ours are hand-cut and sewn by artisans, shipped from a 100% solar-powered warehouse, and backed by a lifetime warranty. 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 in 2014.

    Both materials have benefits. Organic cotton uses 71% less water than conventional cotton and is biodegradable, but recycled polyester has a 50% lower carbon footprint than organic cotton and uses 90% less water than virgin polyester production. 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.