Stowe firm upcycles 50,000 pounds of ski gear

Winter clothing often ends up in landfills due to minor damage, but a Stowe-based company is converting that waste into new products. BirdieBlue operates a sustainable workshop focused on reducing, reusing, and upcycling unused ski and snowboarding gear. The business transforms scrap fabric and broken equipment into accessories designed for a second life.

Founder Kate Harvey describes the process as a way to keep gear out of landfills. The team washes incoming items and breaks them down into usable remnant fabrics. Workers then cut these materials into sewing packs. These packs are distributed to a network of home sewers who assemble the final products. Harvey stated, “We’re truly putting to action what our mission is all about and keeping that gear out of the landfills.”

The company began in 2022 after a personal incident. Harvey was riding a chairlift at Okemo Mountain with her son when her ski pants ripped open. She had worn the pants for 20 years and did not want to discard them. The family took the pants apart and used her grandmother's sewing machine to create zip wallets. These wallets became one of the company's popular products.

Since its inception, BirdieBlue has expanded beyond a one-person studio. The firm now employs a team and operates in new manufacturing space in Stowe. The operation handles a larger volume of clothing waste than before. Harvey noted that the business is “busting at the seams a bit” but continues to accept gear regardless of its condition. The company estimates it has saved approximately 50,000 pounds of gear through upcycling efforts.

BirdieBlue partners with various manufacturers and local ski resorts. Harvey listed partners including Burton, Turtle Fur, Sugarbush, Killington, and Stratton. These collaborations help the company secure a steady supply of materials. The variety of incoming items ensures that no two products are identical. Marlaina Hunter, a member of the BirdieBlue team, said, “It’s so exciting because you never know what the day is going to bring.”

The company aims to become the primary upcycling partner for the outdoor gear industry. Harvey described the current scale as just the beginning of their potential. The business seeks to corner the market in sustainable upcycling by offering a reliable service for other brands. This strategy allows manufacturers to manage their own end-of-life products through BirdieBlue's network.

BirdieBlue also addresses the scraps left over from the upcycling process. The company does not discard small pieces of fabric that are too small to be used for new accessories. Instead, they work with a downcycling partner. This partner chops the remaining materials into shoddy, which is then used to create home insulation. Harvey explained that this step ensures the company tries not to throw anything out.

The final products include fanny packs, scrunchies, and bags of various sizes. Each item is made from previously used winter gear. The process extends the life of materials that might otherwise be discarded. BirdieBlue continues to take in gear from customers and partners in Stowe.