They say if you love something, let it go. In the case of Sean Satha, founder of Sydney-based eyewear brand Local Supply, it took three close calls at losing his favourite pair of designer sunglasses before he reached an epiphany of sorts when it came to dealing with the all-too-familiar struggle of misplaced eyewear.

“I actually lost and found that one pair [of sunglasses] three times before they finally went for good,” he laughs.

They also say that necessity is the mother of all invention. Resisting the urge to dash out and spend big on another pair that would burn a hole in his wallet (and his wardrobe, if he lost them again), the former investment banker and engineer took a step back to consider the gap in the market – eyewear that was affordable, with a classic design and a more sustainable production model.

Sean’s solution was Local Supply, a range of sunglasses ethically constructed and aesthetically timeless in silhouette that have been spotted on the likes of actor Arnold Schwarzenegger, singer Rita Ora and model Lara Worthington, who recently designed her own capsule collection with the brand.

“From a consumer perspective, at that time I felt like there wasn't a brand of sunglasses that were cool, good quality and affordable. I wanted a pair to just put on and walk outside, without thinking too much about them,” Sean explains.

Plant-based eyewear

This was in 2013, back when far fewer brands in the mainstream fashion industry were considering their impact on the environment.

When looking into different models for sustainable production, Sean says he decided against using recycled materials because “recycled plastic can only really be recycled once – it degrades.” Even bamboo, which was often touted as an alternative to acetate, wasn’t quite right.

The solution he eventually landed on was a plant-based resin derived from castor bean plants. Sean says he was immediately taken by the fact that the plants grow in semi-arid conditions, so they aren’t competing for land with food crops.

Saving the leftovers

Materials locked in, the next phase was to secure a manufacturer that could create the sunglasses with the smallest possible carbon footprint and minimal waste. This, says Sean, proved a little trickier.

“When we started…the factories hadn't actually worked with this material at all. So the whole process has been quite new,” he says.

Sean eventually found a manufacturer based out of Shenzhen, China, that was familiar with the resin. Collaborating on the best way to make his product with the smallest possible environmental impact, Sean helped develop a zero-waste injection method that feeds excess resin back into the moulding system. While this may sound like common sense, Sean says the leftovers from assemblage in eyewear production are surprisingly high.

“Even if you were to make a handmade pair [of sunglasses], you'd have a sheet of acetate. You'd put two eye holes in it, the nose bridge, and 90 to 95 per cent of that stuff is ending up on the factory floor, right? So it’s a problem even with handmade eyewear… this was something we had to work on with our factory,” Sean says.

Sustainable packaging solutions

Of course, sustainability in fashion goes well beyond just product construction. Shipping and packaging are two major contributors to carbon emissions and waste and Sean made it his mission to prove he could reduce the environmental footprint associated with delivering his product to the masses.

“We used to have everything individually boxed with an Italian company. They used German paper that was certified by the Forest Stewardship Council. But then we got the stuff sent over and they'd put each box into a plastic sleeve. And I was mortified.”

Sean’s solution was to devise a simpler, more streamlined presentation: “We made the decision to get rid of the boxes and use sleeves, and those sleeves are recyclable.”

But what about after the sunglasses have been created, delivered and put to good use? To make the product more sustainable at the end of its life, Local Supply partnered with TerraCycle, an innovative company that recycles the different components of the frames. The customer simply needs to return their frames to Local Supply to keep them out of landfill.

The insight that first inspired Sean to create his own solutions rather than simply repeating the mistakes of the past has also opened up further possibilities to expand within the accessory market.

“We're definitely looking at doing other plant-based lifestyle goods,” Sean says.

“The first to come off the rack, which I'm quite excited about, are hats. Tote bags as well. The caps will be made out of 55 per cent hemp and 45 per cent organic cotton and hopefully arriving in October in time for summer. So that's kind of a fun project.”

By Benjamen Judd