Why Elastane (Spandex) Is a Recycling “Killer Fiber”

Elastane (commonly known by brands like Lycra® or Spandex) is prized in activewear because just 2–5% added to a fabric blend delivers stretch, comfort, and shape retention. However, that same stretch makes elastane one of the hardest fibers to recover at the end of life—and a major barrier to textile recycling.

1. Even small amounts block recycling machinery

A recent study from TU Wien (Vienna University of Technology) found that fabrics containing elastane, even at low levels, cause major problems in textile recycling facilities. Elastane’s high elasticity leads to clogging, clumping, and jamming of shredders and fibre-separation machines, making mechanical recycling inefficient or impossible. Phys.org+2textile-platform.eu+2

2. Mixed-fibre blends are far harder to recycle

Most textile recycling systems are designed for mono-fibre materials (100% cotton, 100% wool, 100% polyester). When elastane is blended with cotton, polyamide, polyester or other fibres, those mixed fabrics must be chemically or biologically separated before recycling. That separation is complex, energy-intensive, and often not cost-effective. MDPI+2ResearchGate+2

3. Chemical recycling is emerging—but still experimental

Researchers are developing solvent-based or chemical methods to selectively dissolve or degrade elastane, freeing the other fibres for reuse. For example:

• TU Wien have developed new elastane quantification tools and identified gentler solvents that can dissolve elastane without damaging companion fibers. Phys.org+2ScienceDirect+2

• A research team in Denmark created a process that breaks down elastane chains using heat and alcohol, allowing separation from Nylon, although cotton remains a tougher challenge. World Economic Forum

• McKinsey estimates that, despite advances, fibre-to-fibre recycling including elastane blends will only reach 18–26% of global textile waste by 2030—assuming significant improvements in sorting and processing technology. International Fiber Journal+1

4. Even recycled elastane can reduce the quality of the final material

During recycling, residual elastane can degrade the quality and elasticity of reused fabrics. In some cases, fabrics with more than 5% elastane are downcycled—turned into insulation, stuffing, or lower-grade textile applications—rather than being remade into new wearable garments. International Fiber Journal+2inwink+2

5. Alternatives are improving—because the need is urgent

Because elastane is such a barrier to circular textiles, textile innovators are now offering alternatives:

• Elastomeric yarns that are easier to depolymerise or recycle (e.g., new “stretch without elastane” fibres). International Fiber Journal+1

• Developing recycled nylon systems (e.g. Econyl) that can separate or tolerate small stretch fibre components more effectively. Wikipedia+2World Economic Forum+2

• Brands are increasingly seeking plant-based or mechanical stretch fibers that don’t require synthetic elastane, especially in sustainable or “plastic-free” fashion lines. textile-platform.eu+2Wikipedia+2

What This Means for Activewear Consumers & Brands

If your clothing—or your brand’s clothing—relies on elastane for stretch and fit, here are a few practical takeaways:

• Look for mono-fibre stretch solutions or blends that avoid elastane totally, or reduce it to ultra-low levels (under 1–2%).

• Demand clarity on fibre composition and recyclability: ask for “stretch without spandex” alternatives or innovative fibre blends designed for circularity.

• When your elastane-blend garments are worn out, try to recycle them through systems that support chemical recycling or fabric recovery—not just traditional mechanical shredding or landfill.

• If you’re designing for sustainable fashion, explore newer “stretch without elastane” textile innovations or actively support apparel that commits to easier-to-recycle blends.

In short: elastane may make clothing feel amazing, but until recycling methods improve significantly, it increasingly feels like an unsustainable compromise. If we want activewear that truly supports circular fashion, we may need to rethink that stretch fiber—either using much smarter alternatives or eliminating it altogether.