Macrocycle: Revolutionary Plastic Recycling at TechCrunch Disrupt 2025

The Challenge of Recycling Plastics and Textiles

Globally, plastic recycling rates are surprisingly low, with approximately 9% of all plastic waste being successfully recycled. This figure, however, pales in comparison to the recycling rate of textiles, which stands at a mere 0.5%.

A significant obstacle in textile recycling lies in the complex composition of most fabrics. Items like buttons and zippers present difficulties, but the inclusion of spandex and novel synthetic blends creates an even greater challenge, resulting in clothing that is comfortable to wear but exceptionally difficult to recycle.

MacroCycle's Innovative Approach

“The inherent unpredictability of waste streams poses a major hurdle to effective recycling,” explains Stwart Peña Feliz, co-founder and CEO of MacroCycle, in an interview with TechCrunch. “Each waste stream contains an infinite variety of contaminants.”

MacroCycle has developed a novel method aimed at achieving cost parity between recycled plastic and virgin material. The startup’s process selectively extracts desirable synthetic fibers from waste textiles, effectively isolating them from other materials. MacroCycle is currently a Top 20 finalist in the Startup Battlefield competition and will be showcasing its technology at TechCrunch Disrupt in San Francisco.

From Chemical Recycling to a New Solution

Peña Feliz is well-acquainted with the limitations of traditional plastic recycling methods. His prior experience at ExxonMobil involved operating a chemical recycling plant that utilized heat to break down plastic into its basic hydrocarbon components. While functional, this process proved to be energy-intensive and generated substantial carbon dioxide emissions.

“Having witnessed these drawbacks directly, I recognized the need for a different approach,” he stated.

Following his departure from ExxonMobil, Peña Feliz pursued an MBA at MIT. It was there he connected with Jan-Georg Rosenboom, a postdoctoral researcher who had pioneered a unique plastic recycling technique. “Upon seeing his technology, I initially found it almost unbelievable,” Peña Feliz remarked.

The pair began developing their technology into a viable business in the fall of 2022. Their efforts were further supported by a Breakthrough Energy Fellowship awarded the following spring. “We realized at that point that we needed to dedicate ourselves to this project full-time,” Peña Feliz said. MacroCycle subsequently secured a $6.5 million seed funding round earlier this year.

Understanding the Chemistry of Plastics

A foundational understanding of plastic chemistry is crucial to grasping the nuances of plastic recycling. Plastics are polymers – lengthy chains composed of repeating monomer units, or chemical building blocks. Conventional chemical recycling techniques typically involve breaking down these plastic polymers into smaller components, including monomers, which are then used to create new plastic materials indistinguishable from virgin plastic.

MacroCycle’s Polymer Looping Technology

MacroCycle distinguishes itself by avoiding the breakdown of polymers. Instead, its process involves looping the polymer chains back onto themselves, forming ring-shaped structures known as macrocycles. These macrocycles are then separated from contaminants through the use of different solvents, which can themselves be recycled. Subsequently, the rings are opened to reform the original polymer chain. “As these rings open, they readily combine, and in the case of polyester, longer polymer chains result in higher quality material,” Peña Feliz explained.

“By circumventing the need to retrace all the initial steps, we achieve a significantly more energy-efficient process,” he added. MacroCycle’s method requires 80% less energy compared to the production of virgin polyester, while other chemical recycling processes typically reduce energy consumption by 20% to 30%.

Scaling Up and Commercialization

The startup is currently establishing a larger reactor, boasting a capacity 2,000 times greater than their initial prototype used two and a half years ago, according to Peña Feliz. This expanded capacity will enable the production of 100 kilogram (220 pound) batches of material for potential customers to evaluate. MacroCycle is already generating revenue through collaborations with fashion brands interested in adopting the technology.

“We are confident in our ability to offer this material at price parity with virgin plastic once our first industrial facility is operational, a claim few, if any, public chemical recyclers can currently make,” Feliz Peña stated.

He firmly believes that this is the only viable path for recycled plastic to effectively compete with fossil fuels in the industry. “Economic incentives are a primary driver of innovation, and for companies like ExxonMobil to alter their practices, the economic advantages of adopting new solutions must be compelling,” he said. “Our goal is to develop a technology that is so economically attractive that the cost of inaction becomes prohibitively high for them.”

For those interested in learning more about MacroCycle’s work and exploring other innovative pitches, attending workshops, and building valuable connections, visit the TechCrunch Disrupt event website to learn more about this year’s conference, taking place October 27 to 29 in San Francisco.