Hyosung starts 50,000-tonne bio-BDO production in Vietnam

Hyosung TNC has started commercial production of bio-based 1,4-butanediol (bio-BDO) in Vietnam, with an initial annual capacity of 50,000 tonnes and a phased expansion target of 200,000 tonnes. The plant anchors a planned US$1 billion investment by the South Korean group.

For sourcing teams buying stretch fibres, the significance is structural: this is the first fully integrated chain linking sugarcane-derived feedstock to finished bio-based elastane at industrial scale. The bio-BDO from the new Vietnamese facility feeds Hyosung's operations in Dong Nai, southern Vietnam, where it converts into polytetramethylene ether glycol (PTMG), the key intermediate for elastane, and then into regen BIO spandex.

What does the change mean for buyers?

Hyosung says the bio-BDO is chemically identical to its fossil-derived equivalent, so elastane made from it retains the stretch, recovery and quality specs textile manufacturers already work to. On paper, that removes the usual trade-off between renewable content and performance in stretch fibres.

Chairman Hyun-Joon Cho said: "We have established an integrated production system that connects bio-based raw materials with finished spandex fibre. This will be a core pillar of Hyosung's next century."

He added: "Building on our pioneering work in bio-based fibres, we aim to lead the development of this market and strengthen Hyosung's position in premium textiles worldwide."

The company commercialised corn-based regen BIO spandex in 2022 and already runs recycled fibre lines using PET bottles and discarded fishing nets. Cho has flagged bio-based materials as a strategic growth area for the group.

How is the chain organised?

The Vietnam facility produces bio-BDO through fermentation of sugarcane-derived sugars, replacing fossil feedstocks used in conventional BDO manufacture. By integrating fermentation, PTMG conversion and spandex spinning within Vietnam, Hyosung aims to improve supply reliability, raise production efficiency and cut transport movements between tiers.

The finished regen BIO spandex targets sportswear, intimate apparel, swimwear and denim applications.

What sits behind the sustainability claims?

Two compliance anchors apply. Sugarcane sourcing and traceability are verified through the VIVE Sustainable Program, and bio-based content is certified under SGS's Environmentally Evaluated Product Scheme (EEPS). Brands needing documentary evidence for renewable-content claims should request both credentials.

The scope extends beyond textiles. Hyosung plans to supply bio-based chemical intermediates for thermoplastic polyurethane (TPU) in automotive interiors and polybutylene adipate terephthalate (PBAT), a polymer used in biodegradable plastics.

Where can you see it?

Hyosung is promoting the development at the Textile Exchange Conference in Vancouver and Performance Days in Munich, both in October, followed by Functional Fabric Fair in Portland, Oregon, on 27–28 October.

Hyosung TNC, one of the world's leading elastane producers, supplies stretch fibres under its Creora and regen brands plus speciality nylon and polyester. The practical decision for sourcing teams: bio-based elastane is now available at verified 50,000-tonne scale with certification in place — spec writers can move it from pilot to programme.