Merino wool is often hailed as one of nature’s greatest gifts to the textile industry, offering a unique blend of comfort, performance, functionality, and sustainability.
It has become a top choice for creating sportswear due to its impressive properties, such as moisture management, breathability, and natural odour resistance.
At Blue associates Sportswear we love Merino Wool and have worked with this fibre for the last 20+ years. We have developed many different kinds of sportswear using this natural fibre and also blended it with other fibres to add different performance attributes.
We even designed and developed the kit for the Nissan Formula E team because the fibre would help them perform and feel more comfortable that synthetic fibres.
This blog will take you through the process of crafting merino wool sportswear, the benefits of this extraordinary sustainable fiber, and why it’s a real game-changer for activewear.
Why Merino Wool?
Merino wool, sourced from Merino sheep, is a natural fibre renowned for its fineness and softness. Unlike traditional wool, which can be scratchy, merino wool is silky and gentle on the skin, making it suitable for sportswear. Its ability to wick moisture, regulate temperature, and resist odors makes it an ideal material for athletes and outdoor enthusiasts alike.
Because Merino wool is antimicrobial, garment don’t need to be washed as regular as typical synthetic sportswqear that attracts bacteria and starts to smell after wearing. This makes Merino wool much more sustainable as the garments will last longer and uses less power and water to care for.
History of Merino Wool
The history of Merino wool can be traced back to the 12th century. Although its origins still remain a subject of debate, Morocco and Spain are believed to be the regions where it first originated in flocks. The material was closely guarded in the old times and its export was punishable by death in Spain until around the 18th century. Australia, the top producer of the wool, had banned the export of Merino sheep until 1986.
Genetic studies suggest that merino sheep were developed by cross-breeding churro ewes with other breeds, including during the Roman times with Italian rams, in the mediaeval period with northern African rams and in the 15th century with English rams.
Merino wool is part of the Woolmark brand. If you want to find out more about the history of Merino Wool, read this.
Key Properties of Merino Wool
- Moisture-Wicking
Merino wool absorbs sweat and releases it into the air, keeping you dry during intense physical activity. - Temperature Regulation
This fiber keeps you warm in cold conditions and cool in hot environments, offering year-round comfort. Merino wool will keep you far cooler than nylon of polyester in warm conditions. - Odor Resistance
Its natural antimicrobial properties prevent the growth of odor-causing bacteria. This means you don’t emit those nasty stale smells synthetic fibres do. - Softness
Unlike traditional wool, merino fibers are much finer, offering unmatched comfort without irritation. - Durability
When treated correctly, merino wool can withstand rigorous wear and tear, perfect for active lifestyles. The Merino wool doesn’t need to be washes as much as synthetic fibres and this will prolong the life of Merino garments. - Eco-Friendly
Merino wool is biodegradable and renewable, making it a sustainable choice for environmentally conscious consumers. We have done a study at Blue Associates Sportswear where we have buried a Merino T shirt and a syntheitc T shitrt (polyester) and dug them up after 6 months. The Merino T shirt had almost degraded to nothing, where the polyester T shirt was still in perfect condition!
Types of Merino Sheep
Australian Merino wool does not refer to a particular breed of merino. It refers to a number of strains of different sheep. The four types of Australian merino sheep, which are the ancestors of the vast majority of other sheep are as follows (Source: Australian Association of Stud Merino Breeders):
Peppin Merino
Around 70% of all wool coming from Australia is extracted from the descendants of Peppin Merino Sheep. With a diameter of 20-23 microns, it has a medium finesses level. It’s so common in Australia that people there usually think of merino wool as either Peppin merino or non-peppin merino.
Also known as the Wanganella stud, Peepin brothers established it in 1861, possibly a cross-breed between Spanish and French sheep. Peppin sheep thrive in drier regions and have fleece that is heavy with greater wool grease content. Today’s Peppin sheep can produce up to 18 Kg wool each year (with about 10kg on average).
South Australian Merino
The South Australian Merino sheep produce heavier, longer and thicker wool than other types of merino sheep. That’s mainly because they have been bred this way in order to thrive in the arid pastoral conditions of the South and to provide greater economic return. It’s also the largest Australian merino sheep. The wool is the thickest and the strongest and loaded with natural grease. These sheep are also found in New South Wales, Queensland and Western Australia.
Spanish Merino
Closest to the original Spanish Merino Sheep, these Australian sheep are outnumbered by a large margin by other types. They are quite similar to Peppin Merino sheep and produce wool of a similar quality. These are also cross bred with Saxon Merino for extra-fine wool and a better wool coverage.
Saxon Merino
Although the smallest, Saxon merino sheep produce the finest merino wool and are exclusive to southern Australia in the higher rainfall county. However, compared to Peppin Merino sheep that can produce up to 18 KG wool/year, these only produce 3-6 kilos/sheep/year respectively, but that’s extra-fine wool and not some ordinary wool. The white, bright and soft wool with a diameter of 14-17.5 microns is more expensive and used in luxury clothing products.
The Poll Merino
Established in 1934, these are merino sheep without horns and scattered throughout Australia within different bloodlines of the aforementioned types. The fineness of the wool depends on the bloodline and can vary from one breed to another. Some studs produce medium strong, while others can produce fine wool.
Step-by-Step Guide to Making Merino Wool Sportswear
1. Sourcing the Merino Wool
The first step in crafting merino wool sportswear is sourcing high-quality wool. This typically involves:
- Sheep Selection: Merino sheep are bred specifically for their fine wool. Their fleece is sheared annually, ensuring the animals remain healthy and comfortable.
- Ethical Farming Practices: It’s essential to source wool from farms that practice humane treatment of animals and sustainable land management.
- The finest Merino: This is usually farmed in Austrailia with farmenrs managing to grow the finest merino due to the temperature, landscape and conditions, providing a happy environment for the sheep. Happy sheep grow the softest Merino wool.
2. Cleaning and Processing the Wool
Once sheared, the raw Merino wool undergoes several stages of cleaning and processing:
- Scouring: The wool is washed to remove dirt, grease, and impurities, leaving clean fibers.
- Carding: Fibers are separated and aligned into soft strands, creating a smooth base for spinning.
- Combing: This process further refines the fibers, removing shorter strands and ensuring uniformity.
3. Spinning the Merino Wool into Yarn
The prepared wool is spun into yarn. For sportswear, manufacturers often blend merino wool with other fibers like elastane or nylon to enhance durability and stretchability while maintaining the wool’s natural properties. There are also other sustainable fibres you can blend merino to to increase performance without lossing any of the sustainability or performance attributeds to the fibre.
If you are looking for Merino Wool blend, please see our Sustainable Fabric Guide here.
4. Knitting or Weaving the Fabric
Depending on the intended use, the yarn is knitted or woven into fabric:
- Knitted Fabric: Ideal for stretchy and comfortable activewear, such as base layers and leggings.
- Woven Fabric: Used for outer layers, offering more structure and wind resistance. Some woven fabrics are lamintaed to other fabrics with Merino being on the inner or outer surface.
5. Dyeing and Finishing
- Dyeing: The fabric is dyed using eco-friendly dyes to achieve vibrant, lasting colors.
- Finishing: This includes treatments like anti-pilling or water-repellent coatings to enhance the performance and longevity of the fabric.
6. Cutting and Sewing
Once the fabric is ready, it is cut into patterns and sewn into sportswear designs. Advanced sewing techniques are used to ensure minimal seams, reducing chafing during physical activity. Bonding is a great way to finish certain seams for merino as the Merino fibre has great bonding attributes.
Looking for a quality factory that specialises in Merino Wool. Check out our “FIND A FACTORY” Pack
7. Quality Testing
Before hitting the market, merino wool sportswear undergoes rigorous testing for:
- Durability
- Moisture-wicking capabilities
- Stretch and recovery
- Odor resistance
Types of Merino Wool Sportswear
Merino wool is versatile enough to create various sportswear items:
- Base Layers: Designed to be worn next to the skin, base layers are lightweight, breathable, and moisture-wicking.
- Mid Layers: Slightly thicker for insulation during colder weather, ideal for hiking or skiing.
- Socks: Merino wool socks offer comfort and blister prevention during long runs or hikes.
- Activewear Tops and Bottoms: Suitable for yoga, running, or gym sessions.
- Outerwear: Windproof and water-resistant jackets made with merino wool blends.
Advantages of Merino Wool in Sportswear
1. Performance in All Weather Conditions
Merino wool’s natural ability to adapt to temperature changes makes it suitable for diverse climates. Whether you’re running a marathon in summer or hiking in the snow, merino wool keeps you comfortable.
2. Lightweight and Packable
Despite its insulating properties, merino wool is incredibly lightweight, making it easy to pack for trips or outdoor adventures.
3. Low Maintenance
Merino wool is naturally resistant to wrinkles and odors, so it doesn’t require frequent washing, which extends its lifespan and saves water.
4. Sustainable and Biodegradable
Unlike synthetic fibers, merino wool decomposes naturally, reducing its environmental footprint. It’s a renewable resource, as sheep produce a new fleece annually.
5. Skin-Friendly
Thanks to its superfine fibers, merino wool is hypoallergenic and less likely to irritate sensitive skin, even during intense workouts.
Challenges and Solutions in Making Merino Wool Sportswear
- Cost
Merino wool is much more expensive than synthetic materials. However, its superior quality and longevity justify the investment. Most customers that have worn Merino wool will continue to buy it as they can feel the benefits the fibre gives them over stynthetic fibres. - Pilling
Over time, merino wool garments may develop pills. Blending wool with synthetic fibers or using advanced finishing techniques can minimize this issue. - Shrinkage
Improper washing can cause merino wool to shrink. Sportswear labels include clear care instructions to avoid this problem.
Caring for Merino Wool Sportswear
To maintain your merino wool garments:
- Wash in Cold Water: Use a gentle cycle with wool-specific detergent.
- Avoid Heat: Never tumble dry; lay flat to dry naturally.
- Store Properly: Keep garments in a cool, dry place to prevent moth damage.
Why Choose Merino Wool Sportswear?
Merino wool is not just a material; it’s an experience. Its unparalleled comfort, performance, and sustainability make it a standout choice for sportswear. Whether you’re hitting the trails, climbing mountains, or practicing yoga, merino wool sportswear supports your lifestyle while caring for the planet.
As demand for eco-friendly and high-performance textiles grows, merino wool is leading the charge, proving that nature truly knows best. By investing in merino wool sportswear, you’re choosing a product that aligns with modern values of quality, functionality, and environmental responsibility.
Making merino wool sportswear is a meticulous process that combines nature’s brilliance with human innovation. From sourcing ethical wool to crafting high-performance garments, each step ensures the final product meets the needs of active individuals. Merino wool’s exceptional properties make it a preferred choice for athletes, adventurers, and anyone seeking comfort and reliability.
As the world moves toward sustainability, merino wool remains a shining example of how natural fibers can outperform synthetics. By choosing merino wool sportswear, you’re not just wearing a garment; you’re embracing a legacy of quality, craftsmanship, and care for the planet.
If you are looking to produce Merino wool sportswear and need some advice, please get in touch.
