Brugnoli, The Lycra Company and Pissei Introduce Bio-Based PaceSetter Cycling Apparel

The collaboration combines Brugnoli’s Br4/E1 fabric with Renewable Lycra fibre, delivering 89% bio-based content in cycling shorts and reduced water and energy consumption during fabric processing.

Italian textile manufacturer Brugnoli, The Lycra Company and cycling apparel brand Pissei have launched PaceSetter, a project exploring the use of bio-based materials in high-performance cycling clothing. The collaboration combines renewable raw materials with advanced textile technologies to address performance requirements and reduce environmental impact.

Br4/E1 Fabric Combines Bio-Based Materials and Technical Performance

At the centre of PaceSetter is Brugnoli’s Br4/E1 fabric, which combines EVO bio-based polyamide from Fulgar with Renewable Lycra fibre. The fabric contains 89% bio-based materials and is designed to provide compression, muscle support, comfort and freedom of movement for demanding cycling applications.

Developed using Brugnoli’s internationally patented Br4 technology, the fabric is manufactured through a process that reduces water and energy consumption during dyeing and finishing by 20% compared with conventional methods.

EVO polyamide is derived entirely from renewable castor and corn feedstocks, while Renewable Lycra elastane contains 70% bio-derived content sourced from industrial corn. According to the companies, the materials offer the potential to reduce climate change impact by up to 45% compared with conventional alternatives.

The Renewable Lycra fibre used in the project is a bio-based version of Lycra Xtra Life, a technology recognised for durability and resistance to degradation. Its use in Brugnoli’s fabric is intended to increase renewable material content while retaining performance characteristics required for technical sportswear.

Brugnoli also reports that the fabric offers faster drying, breathability and odour control compared with traditional materials, alongside compression and comfort associated with its Explosive Technology.

Brugnoli Highlights Long-Term Focus on Performance and Sustainability

“For more than ten years we have worked to live up to our claim ‘Zero compromises between environment and performance’,” said Massimiliano Denna, CEO of Brugnoli Giovanni.

“The international Br4 patent was born from this commitment, and 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.”

Denna also identified Pissei as a natural partner for the project, citing its work with Brugnoli technologies over several years and its experience translating textile developments into garments for competitive cycling.

Pissei Develops Cycling Kit Using Bio-Based Fabrics

Pissei, which supplies cycling apparel to World Tour teams including UAE Team Emirates XRG and UAE Team ADQ, has developed a complete cycling kit incorporating the new materials.

The cycling shorts use Br4/E1 fabric with 89% bio-based content. Designed for performance, the shorts offer compression, muscle support, rapid drying, breathability and UV50+ protection. The fabric is also designed to resist degradation caused by heat and prolonged exposure to sunlight.

The accompanying ultralight, short-sleeved jersey uses Brugnoli’s Br4/02 CO PLUS fabric. Weighing 110 g/m², it contains 76% bio-based materials and incorporates Lycra fibre and Brugnoli’s patented Br4 technology.

Filippo Quagli, CEO of Pissei, said, “For Pissei, innovation means turning materials research into a concrete advantage for every cyclist,” said Filippo Quagli, CEO of Pissei.

“With Br4/E1 and the new Renewable Lycra fibre we can give shape to this vision, combining compression, comfort and freedom of movement with a more conscious choice of raw materials. This is the direction in which we want to take cycling apparel, from the demands of the World Tour to the passion of every cyclist.”

The Lycra Company Emphasises Commercial Potential

The Lycra Company views the collaboration as a demonstration of the commercial potential of Renewable Lycra technology, particularly for brands seeking to increase bio-based content without compromising durability, fit or performance.

“Brugnoli has consistently shown this spirit, turning innovative ideas, such as our new Renewable Lycra fibre, into fabrics capable of inspiring the most demanding brands,” said Ettore Manfrotto, Senior Strategic Account Manager, Brand & Retail at The Lycra Company.

“Together, we are helping to drive the next generation of increasingly sustainable high-performance apparel, through innovation that begins at the origin and creates value along the entire supply chain.”

Italian Textile Supply Chain Supports PaceSetter Development

The project also highlights the integrated textile and apparel manufacturing network in Italy. Brugnoli manufactures its fabrics entirely at its production facilities in Sacconago, near Busto Arsizio, while Pissei produces the finished garments at its headquarters in Agliana, Tuscany.

PaceSetter was presented at Performance Days in Munich on 13–14 October and is also scheduled to be showcased at Functional Fabric Fair in Portland, Oregon, on 27–28 October.

The collaboration brings together fibre innovation, knitting and finishing technologies, and garment development to explore the use of renewable raw materials in technical sportswear while addressing performance and environmental considerations.