The cycling industry has a new benchmark for sustainable performance. Santini Cycling and Polartec, a Milliken & Company brand, jointly launched the AERO RACE jersey on April 14, 2026 — the first commercial application of recycled carbon fabric technology in the global apparel market.
Santini is now the only cycling brand in Europe and North America to adopt Polartec® Power Dry™ with Recycled Carbon. This first-mover position underscores the strategic depth of the Santini–Polartec partnership and its commitment to responsible textile innovation.
Carbon Capture Technology Behind the Fabric
At the heart of the AERO RACE jersey is Polartec® Power Dry™ with Recycled Carbon, engineered through a proprietary carbon capture process. Industrial CO₂ emissions are intercepted before atmospheric release and chemically converted into recycled polyester fibers, which are then knitted into Polartec's performance fabric.
The resulting material carries 91% recycled carbon content by weight at a construction of 128 g/m². Compared to virgin polyester equivalents, the AERO RACE jersey achieves a carbon footprint reduction of up to 66%. This calculation is based on CO₂ savings from captured carbon polyester fiber versus virgin polyester at a fabric weight of 128 g/m², 175 cm wide, and a yield of 1.75 yards per unit, with recycled carbon yarn accounting for 91% of fiber content by weight.
This technology transforms greenhouse gases into functional textile — not merely offsetting emissions but physically converting captured CO₂ into wearable, high-performance gear. It supports a future economy where industrial emissions become the feedstock for elite apparel.
Aerodynamic Design and Technical Specifications
Every element of the AERO RACE jersey's construction was tested and refined in a wind tunnel. Strategically placed rear panels deliver a second-skin fit that minimizes aerodynamic drag. The sleeves incorporate a specialized striped structure built around Vortex Generation technology, which actively enhances airflow around the arm to reduce resistance at speed.
The lightweight 128 g/m² Polartec® Power Dry™ fabric efficiently manages moisture during intense efforts, ensuring breathability and thermoregulation throughout each ride. Key construction details include:
- Full elastic hem with silicone grip for ride stability
- Raw-cut sleeves for comfort and unrestricted movement
- Three rear pockets for practical on-bike storage
- Unisex fit available in three colorways
Industry Voices and B2B Implications
Ramesh Kesh, SVP of Polartec and Apparel Innovation, explained the broader vision: "Our ability to transform captured carbon into performance-driven Polartec® fabrics shows how we can reimagine materials to reduce impact while empowering athletes to perform without distraction."
Fergus Niland, Creative Director at Santini, emphasized real-world validation: "The AERO RACE jersey has been tested by professionals, built for cyclists, and designed to deliver on performance, comfort, and a new standard of responsibility."
For textile manufacturers and B2B procurement professionals tracking textile news, this launch delivers a concrete data point: a 66% carbon footprint reduction is achievable in technical performance apparel without compromising durability or precision. As global emissions regulations tighten, carbon capture–derived fibers will transition from niche innovation to mainstream sourcing consideration across multiple apparel categories.
Frequently Asked Questions
What is Polartec® Power Dry™ with Recycled Carbon?
It is a performance fabric engineered through a carbon capture process that intercepts industrial CO₂ emissions and converts them into recycled polyester fibers. Constructed at 128 g/m² with yarns containing 91% recycled carbon content by weight, the fabric delivers elite breathability and moisture management during high-output activities.
How significant is the AERO RACE jersey's carbon footprint reduction?
The AERO RACE jersey reduces its carbon footprint by up to 66% compared to equivalent garments made from virgin polyester. This figure is based on CO₂ savings from captured carbon polyester fiber versus standard virgin polyester at a fabric weight of 128 g/m², 175 cm wide, and a yield of 1.75 yards per unit.
Is Santini the only brand currently using this fabric technology?
As of 2026, Santini Cycling is the first and only cycling brand in Europe and North America to adopt Polartec® Power Dry™ with Recycled Carbon. The AERO RACE jersey represents the first commercial application of this fabric technology across all global apparel categories.
