South Korea’s Hyosung TNC has switched on a fully integrated bio-spandex production system in Vietnam, backed by $1 billion in investment, as the world’s largest spandex maker moves to cut its reliance on fossil-fuel-based raw materials.
The company said on Monday it has begun commercial operation of a 50,000-ton-per-year Bio-BDO (bio-butanediol) plant in Ho Chi Minh City, with infrastructure in place to scale capacity to 200,000 tons annually as demand grows. Bio-BDO, traditionally derived from petrochemical sources such as coal, is instead fermented from sugarcane sugars at the new facility, with sourcing traceability verified through the VIVE Sustainable Program.
The plant feeds directly into Hyosung’s existing operations at Dong Nai, where Bio-BDO is converted into PTMG, a core polymer input for spandex, before flowing into mass production of the company’s “regen Bio” spandex line at the same site. The result, Hyosung said, is a single vertically integrated chain running from sugarcane-derived feedstock to finished fiber, reducing exposure to raw-material supply disruptions while lowering carbon emissions across the production cycle.
Chairman Hyun-Joon Cho, who has overseen the project, said the bio business would become “a core pillar for Hyosung’s next 100 years,” adding that the company intends to expand its global market position and strengthen its premium brand on the back of the integrated system.
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Beyond spandex, Hyosung noted that BDO has applications spanning automotive interior materials, biodegradable plastics known as PBAT, footwear soles and industrial compounds, positioning the Vietnam site as a broader platform for circular bio-materials rather than a single-product facility.
The move comes as global apparel brands face mounting pressure to decarbonize supply chains and meet tightening environmental regulations in key markets including the European Union and the United States.
Bio-spandex, used widely in sportswear, swimwear and denim, is designed to match the elasticity and durability of conventional petrochemical-based spandex while offering brands a lower-carbon alternative backed by traceable sourcing. Hyosung said the integrated system also allows it to adjust production speeds quickly in response to shifting market demand, a capability it expects will help it fulfil rapid turnaround requests from global fashion clients operating on tight seasonal timelines.
Hyosung TNC is one of the world’s top producers of spandex fiber, and the Vietnam facility marks its most significant push yet into bio-based textile inputs, as competitors across the synthetic fiber industry pursue similar investments to meet demand from luxury and sportswear brands seeking supply chains aligned with their sustainability commitments.