Recycling old futons into Vintage Cotton for sustainable bedding

Japanese bedding company Yayoi Delight is transforming old cotton futons into sustainable products. The company is launching “Vintage Cotton,” a new material made from 40% recycled cotton and 60% organic cotton, aiming to address the growing waste crisis in the bedding industry.

Yayoi Delight developed Vintage Cotton by recycling high-quality cotton from used futons, blending it with Turkish organic cotton to ensure both strength and softness. By focusing on small-lot orders, Yayoi Delight aims to curb overproduction and reduce waste. The new material will be available for order starting October 15, is aimed at advancing a circular economy while preserving traditional Japanese values. The estimated lead time for production is around three months, with fabric samples already available for prospective buyers.

The bedding industry in Japan faces significant environmental challenges, including waste from overproduction and the reliance on synthetic fibers, which are difficult to recycle and do not decompose. In 2023, only 2% of bedding was recycled, largely due to the challenges of recycling synthetic fibers and the lack of established collection systems. Yayoi Delight aims to increase that number to 20% by 2028.

The company is responding to changes in consumer behavior as well. Japan’s population decline has led to a decrease in bedding demand, as smaller household sizes and fewer family members mean less need for multiple sets of futons compared to previous generations. This shift has resulted in overproduction and a subsequent waste problem. Yayoi Delight addresses these issues through small-scale production.

“Mass production might be efficient, but it often results in surplus and eventually waste,” Yayoi Delight shared. “By focusing on smaller production lots, we can supply exactly what is needed, helping reduce unnecessary waste and resource depletion.”

Yayoi Delight’s initiative also targets the water-intensive cotton production process. By recycling cotton from used futons, the company aims to reduce the consumption of new resources. The organic cotton used in Vintage Cotton is certified by the Organic Content Standard (OCS), which verifies the presence and amount of organic material in a final product, ensuring quality and adherence to environmental standards. In addition, the company supports fair trade practices, benefiting cotton producers and minimizing environmental impacts during the production process.

The recycled cotton collected by Yayoi Delight undergoes processing stages like carding, combing, and spinning, maintaining its traditional texture while meeting modern quality standards by combining it with organic cotton.

Yayoi Delight respects traditional Japanese cultural practices, such as wedding futons symbolizing family bonds and parental love. The company hopes to preserve this tradition for future generations by combining heritage with modern environmental consciousness.