Meet the Maker: Flotsam Flo

Meet the designer behind our unique new partnership, turning discarded Royal Mail trolley sleeves into fashionable bags.

In November of 2024, we partnered with Cornwall based eco-fashion brand Flotsam Flo to create a range of bags made from Royal Mail trolley sleeves. Without repurposing, these materials would often end up in incineration or, in some areas, landfill.

Founder Kate sorts through the old Royal Mail red trolley sleeves.

We chatted to Flotsam Flo founder Kate to find out more about her business and how it came to be.

Hi Kate, Can you tell us a bit about yourself and what inspired you to set up Flotsam Flo?

Flotsam Flo launched in 2021, inspired by my love for sewing, upcycling and repurposing. I use materials that can’t easily be recycled such as life jackets, wetsuits and banners and turn them into amazing products such as bags, pouches and more.

The journey towards creating Flotsam Flo was shaped by several pivotal moments. Five years ago, I experienced a life-changing brain haemorrhage that led me to re-evaluate everything. My experience made me realise that tomorrow is never promised so I took a leap of faith and followed my dream. At the end of 2021, I left teaching and started Flotsam Flo, named after my Granny Florence, who was always a big inspiration to me.

How has the brand grown since the launch, and where can we find your upcycled products?

Flotsam Flo began on a small scale, working from my mum’s kitchen table, exploring creative ways to upcycle and repurpose and selling online.

Helping others is at the heart of everything Flotsam Flo stands for. For example, during the pandemic, the vaccination tent at my local GP surgery was vandalised. They had taped the damage but it was an eyesore in the community. I cut out heart and hand shapes from broken plastics (representing the support in the community) and stitched them together, adhering them onto the vandalised areas.

In July 2022 a very close friend of mine suddenly died of cancer at a Hospice in Cornwall. In support of the Hospice that looked after her, a bag was made and subsequently donated for them to use to raise money from. They have since donated all of their banners for me to use, avoiding landfill or incineration. These will be turned into future products; true sustainable circular economy

Since those early days, Flotsam Flo has grown in ways I couldn’t have imagined. A key turning point was securing a workspace from Biffa, along with a grant to invest in industrial sewing machines, which allowed me to expand production. Today, I’ve had the privilege of collaborating with larger organisations like Royal Mail and The Postal Museum. It’s amazing to think that just a few years ago, Flotsam Flo was an idea and now it’s a full-time business!

An assortment of items, including Christmas decorations, made by Flotsam Flo using old Biffa materials.

Our products are now available through our website and select retail locations, and our reach continues to grow. In addition to creating these items, I also give talks, lead workshops, and engage with schools, spreading awareness about plastic pollution and the endless potential of repurposing and upcycling.

Can you talk us through the process for sourcing materials and how they come to be fashion items?

At Flotsam Flo, sourcing and transforming materials is a thoughtful, hands-on process. Most of our materials are donated by local communities and organisations, each piece with its own story.

When I receive these materials, I start by assessing their durability and potential, imagining what each item could become. This can include items like decommissioned life jackets, banners, or wetsuits. Working with such diverse materials keeps me adaptable, as each piece presents its own unique challenges and opportunities.

Once the materials are prepared and cleaned, I experiment with colours and designs to create cohesive, stylish pieces. Using industrial sewing machines, I then transform these reclaimed materials into fashion accessories that are not only functional but also serve as reminders of the importance of sustainable design. Each product is made with care and is a one-of-a-kind piece that encourages people to rethink what might be considered waste.

Can you tell us a bit more about the designs you have been creating in partnership with The Postal Museum and Royal Mail? What does the project mean to you?

This partnership is incredibly meaningful to me. I can’t actually believe it. I’m just a girl from Cornwall who wants to use as much material as possible that is often destined for waste. To be able to work with such amazing organisations like this is just incredible.

Upcycling trolley sleeves into functional, handmade bags is a perfect extension of what Flotsam Flo stands for. These sleeves were once integral to the postal system, so transforming them into stylish, durable bags rather than seeing them discarded aligns perfectly with our mission of reducing waste and embracing creativity.

Royal Mail disused Trolley Sleeves ready to be repurposed.

More than just a sustainable project, it’s about storytelling. Each bag holds a piece of postal history, now repurposed for a new purpose, creating a connection between the past and future. It’s a privilege to bring this history to life while supporting UK craftsmanship. This project embodies our shared vision for a sustainable future and reinforces that beauty and utility can come from the most unexpected materials. I just can’t believe it and I am so grateful to be a part of this.

What change were you seeking to inspire in the fashion industry? What do you think the future holds for sustainable fashion?

Through Flotsam Flo, I hope to challenge the disposable nature of fast fashion and encourage a more thoughtful approach to materials and design. I want to show that waste doesn’t have to be waste—it can be reimagined as something unique, practical, and beautiful.

I believe the future of sustainable fashion looks bright, but it will require significant changes in both production and consumption habits. We’re already seeing a growing demand for sustainable products, but moving towards a circular economy is crucial. This could mean more investment in practices where materials are reused and products are designed to last longer. Smaller, eco-conscious brands will play a crucial role in this change, as they are often able to innovate and challenge norms quickly.

Ultimately, I hope sustainable fashion becomes the industry standard, with both brands and consumers embracing slower, more mindful choices that respect the environment and future generations.

What would you like someone in the future who discovers your upcycled bags in The Postal Museum’s collection to know about them?

I would want them to see it as more than just a fashion item. The bags represent a commitment to sustainability and a determination to rethink waste in the face of climate change. They also symbolise a shift in perspective: seeing utility in everyday materials and embracing the potential of reusing and upcycling. The Flotsam Flo story itself reflects that same mission.

I hope these bags inspire others to view waste differently, to recognise the value in the overlooked, and to remember that positive change is possible, even with the humblest materials. This project marks a moment in history where we recognised the importance of change—and through each upcycled bag, we contribute to a future where waste becomes opportunity.

For me, Flotsam Flo is about resilience and giving back. Through the brand, I aim to show people that even the smallest sustainable choices—like using upcycled products—can create a cleaner, greener world for future generations.