Fit for the Planet

Millions of workouts are making the environment unfit. New stretchable corn-based apparel produced using vacuum from BUSCH will keep Mother Earth in good shape.


Elastane, otherwise known as Lycra or Spandex, is great for workout. But production of elastane is petroleum-based. It contains microplastics and is non-biodegradable. What feels good in the gym, feels bad on the planet. Companies have been looking seriously at stretchable alternatives, including those made from corn.

A great opportunity

Between 5% and 10% of corn is wasted after each harvest. Inedible stems and leaves that represent a great opportunity. In 2014, an elastane product with two-thirds of its content derived from industrial corn waste was created. More recently an elastane substitute has been produced using vacuum, called PO3G (Polyoxytrimethylene Glycol). It is a bio polyol made of fermented corn starch. Polyols react with diisocyanates to produce polyurethanes, which are the basis for stretch fibers like Spandex.

Better elasticity

Vacuum is used to dry the corn waste in the PO3G production process. It draws water vapor from it in an evaporator. Vacuum boosters are then employed in a distillation tower. This ensures that the materials that did not react during PO3G production, and therefore are surplus to requirements, are recovered. These include nitrogen and air. When compared to conventional petroleum-based polyol production, PO3G production cuts greenhouse gases by 40%. PO3G also meets stringent plastics regulations. Products made with PO3G using vacuum technology from BUSCH are actually smoother, with better elasticity and resistance to abrasion over existing elastane products. Mother Nature would no doubt wear them if she went to the gym.