How is Flex-Fill made?

Flex-Fill is a clustered fiber made from 100% recycled BPA-free plastic bottles.  When you buy one of our pillows, you can feel good knowing that you are helping keep numerous homeless plastic bottles out of our oceans and landfills.  For example: It takes 39 plastic bottles to make just one of our standard size pillows.  Talk about sleeping better!

Plastic flakes made from recycled plastic bottles used as raw material for Flex-Fill

The bottles are first sanitized, labels removed and then ground into pellets which are then mechanically processed into long threads.  From that point, the shorten strands are tumbled in a machine which forms the unique tiny clusters that give our pillows such wonderful support and squishiness.   

 Graphic of needle and thread by A Little Pillow Company

Clustered Flex-Fill fiber made from 100% recycled plastic bottles for A Little Pillow Company


The plastic bottles that are recycled for our fill are the same that are used in recycled food containers, garments and fabrics such as fleece, and even Rothy's shoes.  

Graphic of needle and thread by A Little Pillow Company 

DID YOU KNOW: These plastic bottles are made from a PET resin.  PET is a biologically inert material that doesn't react with foods or beverages and is resistant to attack by micro-organisms. It's been thoroughly reviewed and approved as safe for contact with foods and drinks by the FDA, Health Canada, the European Food Safety Authority and other health-safety agencies. It has also been used by consumers around the world for more than 30 years without any known adverse effects. Extensive testing of PET and PET packaging has repeatedly shown it to be safe. PET itself is biologically inert if ingested. (Source: