Let's get bio-technical!

How is bio-textile made?

With support from the Biosolutions Zealand we are currently testing bio-textile from Pond Biomaterials on our thermo wear. Thermo is one of our largest product groups, and if it succeeds, we will be able to offer plant-based outerwear on a large scale.

Here you get an insight into the innovative material Pond Cycle®, which might be able to replace our current recycled polyester in the future.

🌱 The main ingredient comes from sugarcane (from Thailand, where the humid climate means no artificial irrigation is needed).

🦠 The sugar goes through a fermentation process with lactic acid bacteria, which convert the sugar into lactic acid.

📿 The lactic acid is extracted, and its molecules are bound together in chains – each chain can consist of up to 2,000 molecules, like beads on a string. This is called PLA, Poly Lactic Acid.

💡 In a reactor, Pond produces other molecular chains, which are mixed with PLA – the main component of the material – and turned into granulate (pictured above).

🧶 The granulate is sent to a spinning mill. The spinning process is similar to that of polyester: the granulate is melted and pressed through a fine-meshed sieve to form thin fibres. PLA is spun at 210–215°C, while polyester requires 270–280°C = energy savings.

The spun yarn is wound up and sent to a knitting mill, where it is turned into fabric.

The result is Pond Cycle®, a bio-based textile that is:

✅ Verified 100% plant-based (ASTM 6866)
✅ Certified biodegradable by DIN CERTCO according to ISO 14855
✅ Free from fossil-based carbon

Composting is not the goal of bio-textiles. The goal is to phase out fossil resources and reduce the product's overall footprint – throughout its entire life cycle. The most innovative feature of Pond Cycle® is that the textile can be recycled back into pure granulate. That could mean goodbye to the need for new raw materials!

We are really excited to see if it succeeds. We will update when there is news.