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Pakafill

Pakafill insulation sheet / Source: Paka
Anti-MicrobialHypoallergenicLightweightMoisture BarrierNorth AmericaOdour ResistantPakafillSouth AmericaStrongTextilesWater RepellentWool

WHAT WE SAY:

The clothes we wear to enjoy nature can take a huge toll on it, as outdoor apparel brands fill their jackets with plastic to protect wearers against the elements. Not only is the insulation made from fossil fuels, but the thermal binding process needed to produce it is also fuelled by coal or liquid petroleum. Add in the microplastics that shed with each wash and you’ve got an environmental disaster on your hands.

You might choose down as a natural alternative, but welfare concerns and the fact that it can’t get wet rule it out for many, so where do you turn? Apparel company Paka hopes it will be towards Pakafill, a new insulation made from alpaca fibre. It’s early days for this patent-pending insulation, but the fact that it passed a field test at 17,913 feet altitude in the Andes Mountains is certainly a convincing debut. Outdoor brands should form an orderly queue.

Pakafill

WHAT IS PAKAFILL?

  • Created by Paka, Pakafill is said to be the "warmest ethical insulation on the market", designed as an alternative to both synthetic insulation and goose down.
  • Pakafill is made from alpaca fibre – it is soft, moisture wicking, antibacterial, odour resistant and hypoallergenic, with no lanolin. It is also naturally biodegradable.
  • A lightweight insulating material, it's half the volume of down but – unlike down – keeps the wearer warm when wet. Additionally, it thermoregulates between a wide range of temperatures to maintain a 'neutral comfort range'.
  • Paka claims testing has found Pakafill to be two times warmer than any synthetic currently on the market. The IDFL Laboratory and Institute gave it a 2.59 thermal CLO value.
  • The alpaca fibres used in Pakafill can be traced back to the farm in the Andes from which they are sourced, and all alpacas are allowed to roam freely. Paka financially supports high-quality humane shearing practices, and no animals are harmed during the manufacture of the material. 
  • The first use case of the insulation is in the Pakafill Lightweight Puffer, which became available for early bird and pre-order in November 2022. A limited batch of 600 units were delivered in December, with the rest delivered in January 2023.
  • In January 2023, Pakafill was made available to all outerwear companies to incorporate into their own products.

KEY PROPERTIES:

  • Anti-Microbial
  • Hypoallergenic
  • Lightweight
  • Moisture Barrier
  • Odour Resistant
  • Strong
  • Water Repellent

INDUSTRY:

  • Textiles

AVAILABILITY:

Commercially Available


DIVE DEEPER:

  • The two main options for outdoor apparel insulation are down and synthetics. Down is a natural fibre but stops insulating when wet, which can be deadly on a mountain. Synthetics remain insulating in the wet but are made from oil and can exist within the environment for hundreds of years.
  • Recycled synthetic alternatives exist, however most also require the fossil fuel-powered thermal binding process, and they still shed microplastics and pollute if they enter the natural environment. 
  • Pakafill is designed to combine the environmental benefits of natural fibres with the functionality of synthetics. It is made by Paka, a Peru-based apparel company which was founded in 2017. The first Paka sweater made from alpaca Wool was launched on Kickstarter and raised over USD 350,000 in 30 days.
  • Paka champions alpaca fibre because it can be transformed from fibre to garment by hand, meaning it doesn't consume many natural resources – it's simply sheared, sorted, spun into yarn, dyed if required, and woven or knitted.
  • Alpaca fibre has numerous beneficial qualities. Its tensile strength is 50 N/ktex, while Merino wool has a tensile strength in the range of 30-40 N/ktex. It has a water retention rate of 8% compared to 16-20% for most other wool, and it is three times lighter than sheep’s wool.
  • There are currently 3.6 million alpacas in Peru and they are intrinsic to the way of life in the Andes Mountains. As intermediaries have emerged, making the selling system more complex, producers can lose out financially at multiple points along the chain. To combat this, the fibre used within Pakafill is fully traceable according to the Traceable Alpaca programme.
  • The Pakafill Lightweight Puffer Jacket features the patent-pending Pakafill insulation, a PFAS-free, durable, water-repellent coating, an antibacterial Silvadur-infused outer membrane, and Bluesign approved textiles.
  • The jacket was field tested by Paka's founder and CEO Kris Cody during a summit of Yanapaccha in the Andes Mountains, which has an altitude of 17,913 feet. Peruvian mountaineer Jose Mostajo, who accompanied Cody, said: "The puffer was the only jacket I used… from the 2am freezing cold to the final ascent under a full sun, I didn’t need to add, remove, or switch layers."
  • While the first use case of Pakafill is a Paka jacket, the technology was never intended to be used solely by the brand. From 10 January 2023, the insulation was made available at Outdoor Retailer, an outdoor industry tradeshow based in Salt Lake City, US, to any retailers who wish to use it within their garments.
  • In December 2022, Pakafill was one of 29 finalists for the fifth annual Outdoor Retailer Innovation Awards, selected by an independent panel of expert judges based on four criteria: Spark, Desire, Function, and Impact.
  • Paka’s knowledge and use of alpaca fibre comes from the indigenous Quechua people of Peru, with whom the company has worked since its launch. In 2021, the legendary Quechua weaver Nilda Callañaupa was brought on board to oversee the teams of women textile weavers.
  • Paka is a founding member of The Good Ocean and is a certified B Corp. It was named Best for the World in 2021 and 2022, reaching a 124.4 impact score most recently.
Pakafill Lightweight Puffer / Source: Paka
Alpaca fibres / Source: Paka

KEY FACTS:

3x

Alpaca fibre is three times lighter than sheep's wool

3.6mn

There are 3.6 million alpacas in Peru

8%

Alpaca fibre has a water retention rate of 8% compared to 16-20% for most other wool


Key Questions to Ask:

Can Pakafill reach price parity with synthetic insulation materials?

The Pakafill Lightweight Puffer retails at USD 330, suggesting that Pakafill is not a cheap material. It is best used for investment pieces designed for longevity, which may not pose a problem for customers of outdoor brands who are used to paying more for quality. Mass market brands, however, are unlikely to invest in this material, but there are other solutions that don't involve plastic, including the Nudown's innovative use of air pockets for insulation. 

Can you convey functionality to maximise uptake?

Given how lightweight Pakafill is, consumers may not consider it suitable for sub-zero temperatures based on appearance alone. Paka overcame this with its field test and accompanying marketing, and while you may not wish to scale a mountain, communicating its capacity for multiple weather types will be crucial for uptake.

How can you keep your final product plastic free?

A natural insulation inside a plastic shell could undermine progress away from synthetics. Can you explore plastic-free outdoor materials such as Bananatex for your shell?

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