Brugnoli Hits 89% Bio-Based Content in Technical Cycling Fabric

Brugnoli, The Lycra Company and Italian cycling apparel maker Pissei have produced a technical cycling fabric containing 89% bio-based content, according to a joint pilot project unveiled this month. The figure marks a new ceiling for renewable raw material share in a fabric engineered for competitive cycling, where compression and durability specifications have historically limited bio-based inputs.

The PaceSetter project has delivered a kit comprising shorts and a jersey made from fabrics developed by Brugnoli. The shorts use the new Br4/E1 material, which combines two fibres:

• EVO bio-based polyamide from Italian manufacturer Fulgar, derived from castor beans and corn
• Renewable Lycra elastane from The Lycra Company, containing 70% bio-derived content sourced from industrial corn

Together, the two fibres give Brugnoli the 89% bio-based content in a fabric designed to meet the performance requirements of competitive cycling.

What does the fabric actually deliver?

Br4/E1 is the latest development of Brugnoli's patented Br4 technology, introduced more than a decade ago to combine high-performance stretch fabrics with reduced environmental impact. The company reports that its proprietary dyeing and finishing technology cuts water and energy consumption by 20% compared to conventional production methods — a claim that relates to the mill's own process rather than third-party verification.

Brugnoli also states that the bio-based raw materials reduce climate change impact by up to 45% compared to conventional fibres. The company itself qualifies this figure: it applies to the materials, not the complete finished garment. Buyers weighing the claim for their own product carbon accounting should treat it accordingly.

On performance, the fabric is engineered to provide high compression, muscle support and freedom of movement, alongside improved breathability and odour control, building on Brugnoli's existing Explosive Technology platform. The Renewable Lycra fibre incorporated into Br4/E1 is a bio-based version of Lycra Xtra Life, designed for enhanced durability and resistance to degradation.

What did the partners say?

Massimiliano Denna, CEO of Brugnoli, framed the launch as the payoff of a decade-long positioning: "For more than ten years we have worked to live up to our claim of zero compromises between environment and performance. With the collaboration of The Lycra Company and its latest innovation, Renewable Lycra fibre, we can now present Br4/E1 and reach a level of bio-based content that a few years ago seemed unthinkable in a high-performance technical fabric, without giving up anything in terms of compression, muscle support and comfort."

Denna added that Pissei was a natural partner, having worked with Brugnoli's technologies for several years and developed cycling apparel meeting the requirements of professional competition, including the World Tour.

Ettore Manfrotto, senior strategic account manager for brand and retail at The Lycra Company, said: "Brugnoli has consistently shown this spirit, turning new raw materials into fabrics capable of inspiring the most demanding brands. Together, we are helping to drive the next generation of increasingly sustainable high-performance apparel."

Pissei CEO Filippo Quagli positioned the project in practical terms: "Innovation means turning materials research into a concrete advantage for every cyclist. With Br4/E1 and the new renewable Lycra fibre we can combine compression, comfort and freedom of movement with a more conscious choice of raw materials."

Where is it being shown?

The PaceSetter concept was presented at Performance Days in Munich on October 13–14 and is being showcased at Functional Fabric Fair in Portland, Oregon, on October 27–28. The three partners say the project demonstrates the potential to raise renewable raw material content in premium performance apparel without compromising the technical properties required by professional athletes — an intention that now moves to commercial-scale validation as brands assess the fabric for future seasons.