Vermont workshop diverts 50,000 pounds of ski gear from landfills

As the cold season approaches, a Stowe, Vermont, company is intercepting damaged winter gear before it reaches the trash. BirdieBlue upcycles used ski and snowboard equipment into new products, aiming to keep textiles out of landfills through a reduce, reuse, and upcycle model.

Founder Kate Harvey started the business in 2022 after a pair of twenty-year-old ski pants ripped open on a chairlift at Okemo Mountain. Rather than discard the worn garment, Harvey took it apart and used a family sewing machine to create small zip wallets. Those initial items became one of the company's popular products, prompting her to formalize the process.

The workshop now processes a steady stream of fabric waste. Harvey described the workflow as washing the items, breaking them down into usable remnants, and cutting the material into sewing packs. These packs are then distributed to a home sew network of volunteers and employees who assemble the final goods. The company produces a variety of items, including fanny packs, scrunchies, and bags of various sizes.

Since the last news cycle, the operation has moved beyond a one-person studio. BirdieBlue now employs a team of workers in a new manufacturing space in Stowe. Harvey stated that the company is currently handling a volume of material that stretches their capacity, though they remain open to accepting more gear regardless of its condition. She estimated that the company has saved approximately 50,000 pounds of gear from landfills to date.

The firm has broadened its supply chain by partnering with several major entities in the industry. Harvey listed ski mountains and Vermont gear companies as key collaborators. Specific partners mentioned include Burton, Turtle Fur, Sugarbush, Killington, and Stratton. These collaborations provide a consistent flow of damaged or surplus inventory for the upcycling process.

Marlaina Hunter, a member of the BirdieBlue team, noted that the variety of incoming materials creates a unique production environment. She said the unpredictability of the daily intake keeps the work engaging. The company also handles the final scraps from the upcycling process by sending them to a downcycling partner. That partner chops the remaining material to create shoddy, which is used in home insulation.

Harvey outlined the company's long-term goal to become the primary upcycling partner for the winter sports industry. She characterized the current scale as just the beginning of their potential. The business continues to accept donations and partnerships as it works to maximize the utility of every piece of fabric that enters the facility.