Lululemon plans to make leggings from plants

Folks world wide have swapped their denims and khakis for comfortable leggings and joggers—however activewear, which is basically made from petroleum-based supplies like nylon and polyester, damages the planet. It doesn’t biodegrade, however quite breaks into tiny fragments that find yourself in oceans and the meals chain. And the method of extracting oil and manufacturing these fibers spews greenhouse gases into the environment, fueling local weather change.

Because the world confronts international warming, Lululemon is working to discover extra sustainable supplies for its merchandise. The $4.4 million big proclaims right now that it has made an undisclosed funding within the bioengineering firm Genomatica to produce nylon that’s made from plants quite than petroleum. Lululemon says that this bio-based nylon can simply be plugged into its provide chain, so the model can begin utilizing it instantly with the aim of switching fully to renewable or recycled nylon over the subsequent 9 years.

It’s a part of a broader pattern within the trend world of transferring away from petroleum to plant-based merchandise. However whereas that is an enchancment over the established order, it’s not essentially a clear-cut win for the planet: Bio-based plastics are sometimes not biodegradable, and extra work wants to be executed to quantify their environmental affect.

[Photo: Courtesy of Lululemon]

Why we love nylon

The DuPont Co. invented nylon in 1938. Since then, varied types of the artificial fiber have discovered their means into nearly each side of contemporary life. It’s present in carpets, automobile interiors, toothbrushes, surgical sutures, and, in fact, clothes. It’s a very helpful material in activewear as a result of it’s moisture wicking and could be made to stretch and provide compression.


Whereas many trend and activewear manufacturers have a tendency to use plenty of polyester, which is cheaper and barely much less sturdy than nylon, Lululemon has tried to set itself aside as a premium model within the activewear class, so it makes use of extra nylon than its counterparts. Presently, nylon makes up round half of all of the supplies that Lululemon makes use of. (Its second most closely used materials is polyester.)

“So as to get the type of long-lasting efficiency we’re on the lookout for, and to create the type of materials that really feel good to the contact, we rely closely on nylon,” says Calvin McDonald, Lululemon’s CEO. “That’s why it was so vital for us to discover a extra sustainable different to nylon, particularly.”

Within the realm of artificial supplies, nylon is worse for the surroundings than different fibers when you think about its complete life cycle. A report by the Global Fashion Agenda, a trend sustainability assume tank, says that nylon has the next environmental affect per kilogram of fabric than rayon, spandex, and polyester as a result of extra greenhouse gases are emitted throughout its manufacturing course of. In Lululemon’s 2020 Impact Agenda, the corporate stated that about 50% of its carbon impacts come from its materials. So switching to less-carbon-intensive supplies may go a good distance towards bettering the corporate’s general carbon footprint. Lululemon goals to scale back carbon emissions throughout its international provide chain by 60% by 2030 as a part of its broader sustainability targets.

[Photo: Courtesy of Lululemon]

Probably the most enticing elements of Genomatica’s nylon is that it will probably simply be swapped into Lululemon’s present provide chain. Typically, when a brand new materials is launched into the manufacturing course of, it requires designing fully new merchandise and coaching manufacturing unit companions on how to use it. That would take months or years for an organization the dimensions of Lululemon. With Genomatica’s nylon, Lululemon expects to begin incorporating the fabric into its mills this 12 months.

“It’s a drop-in substitute,” says Marc Hillmyer, an impartial knowledgeable in bio-based plastics on the College of Minnesota’s chemistry division. “That is usually simpler for corporations to handle as a result of the molecules are similar.”

The transfer to reduce nylon’s carbon footprint through the use of plant-based sources is a part of a broader pattern throughout many industries: Manufacturers at the moment are touting plant-based options to plastics in every part from sneakers to artificial grass. “Through the use of renewable, plant-based feedstock, we’re already considerably reducing the local weather affect of the nylon,” says Christophe Schilling, Genomatica’s CEO. “Plants sequester carbon from the environment, in order that they’re actively countering international warming. We’ve additionally labored to scale back the quantity of carbon emitted from the manufacturing course of.”

However some plants—like algae and bamboo—are much less resource-hungry than others whereas nonetheless successfully capturing carbon. Genomatica has not shared which plants it’s utilizing for the actual bio-based nylon it’s making with Lululemon (the businesses need to preserve the components proprietary for a while earlier than making it accessible to the remainder of the style trade). And whereas Schilling says it may slash nylon’s carbon footprint by 90% or extra, it has not but disclosed precisely how the carbon emissions of this bio-based nylon compares with petroleum-based nylon.


What’s extra, the plant-based nylon Genomatica has created is neither biodegradable nor compostable, because it has the identical molecular construction as nylon. Its fundamental promoting level is that it will probably scale back nylon’s reliance on fossil fuels. However corporations should nonetheless sort out the difficulty of what occurs to the nylon on the finish of its life.

On condition that many manufacturers at the moment are touting their use of plant-based plastics, Hillmyer, on the College of Minnesota, urges shoppers to be skeptical of a few of their advertising claims. For one factor, we are able to’t assume that plant-based plastics have a smaller affect on the planet than these derived from petroleum as a result of evaluating the environmental affect of supplies may be very difficult. As an example, in the event you’re utilizing plants as feedstock, you want to calculate how a lot vitality and environmental sources are used within the agricultural course of.

“You’ll have to do a full life-cycle evaluation research that integrates questions like how a lot fertilizer and water was used, how a lot vitality was concerned with trucking the crop to the manufacturing plant,” Hillmyer says. “All of this may be quantified, nevertheless it’s a fancy calculation.” When it comes to Genomatica’s nylon, a lot of the affect would rely upon what sorts of plants are getting used and the way they’re grown.

Then, in fact, there’s the truth that many plant-based plastics available on the market is not going to biodegrade. However Hillmyer says that there’s a lot of analysis at the moment occurring within the subject of chemistry, and scientists have developed bio-based plastics which can be in a position to break down underneath the warmth and strain of commercial compost amenities. He’s assured that over time, they will even develop biodegradable plastics.

“I consider there’ll come a time within the close to future once we will probably be in a position to create renewable, plant-based plastics which have a really low local weather affect, and greater than that, they are going to be absolutely recyclable and compostable,” he says. “We want to be doing the analysis now to get to that time.”

[Photo: Courtesy of Lululemon]

McDonald factors out that this Genomatic partnership is only one a part of a broader sustainability initiative. Like many corporations, together with Nike and Walmart, Lululemon plans to supply renewable vitality throughout its direct operations (although not in its companion factories), part out single-use plastic, and scale back water consumption. The corporate has additionally invested in Mylo, a plant-based materials derived from mushrooms that’s an alternate to conventional leather-based, and plans to begin together with it in merchandise this 12 months. “This isn’t a one-off challenge,” he says. “It’s a part of a a lot greater plan.”

It’s now clear that the style trade is actively accelerating local weather change. Specialists estimate that the sector is answerable for 10% of the world’s carbon emissions. Earlier this month, the United Nations released a report that made it clear that every one of those emissions are instantly answerable for the intense climate occasions we’re seeing world wide, and it’s already too late to cease temperatures from rising over the subsequent three many years. However the report identified that if the world aggressively and quickly cuts its emissions, we could have the ability to restrict temperatures from growing past 2050. In different phrases, corporations want to change their complete provide chains—and quick.

McDonald says he’s feeling the strain. “We’re actively exploring different sustainable supplies, together with pure, biodegradable ones,” he says. “However our partnership with Genomatica comes out of the belief that we are able to’t actually afford to wait. We want to make these quick enhancements whereas concurrently engaged on next-generation supplies.”