Everline Studio Ireland: Odor-Free Tennis Dresses Built on Built-In Antibacterial Masterbatch Yarn
Everline Studio is a Ireland-based activewear label whose tennis dresses programme sells directly to consumers and through selected retail partners. The team asked us to rebuild the fabric from scratch because the garment smelled stale after a single session even straight out of the wash. The target was a fabric that stayed neutral through repeated wear between washes.
Everline Studio: odour-control swatch set for the tennis dresses programme
The challenge
The smell built up at the built-in short and the chest band, where sweat sits longest during a session. The previous fabric was a standard synthetic knit with no odour strategy, so bacteria broke the sweat down on the fabric and the smell became permanent after a few weeks. Rising returns with smell listed as the stated reason made the problem urgent: the brand needed a fix before the next bulk booking, not a new supplier search.
The fabric solution
We built the programme around Built-In Antibacterial Masterbatch Yarn on a polyester filament knit base. The mechanism matters: the active agent is locked inside the fibre so it cannot be washed off the surface. Keeping the base at bonded knit with inner shorts and 210 GSM meant the hand, the stretch and the cover stayed exactly where the design team wanted them, because odour control changed the chemistry and the construction rather than the silhouette.
Wear trial and fit approval of the polyester filament knit fabric
Development and implementation
- Week 1: brief agreed, sweat zone mapped, target set as above 99% bacterial reduction retained after 50 washes by JIS L 1902.
- Week 2–3: laboratory knits produced and tested; add-on level adjusted until the target was met with margin.
- Week 4–5: wear trial on finished tennis dresses, assessed after eight hours of wear.
- Pre-production: wash durability confirmed at 50 washes or more, care wording written as standard laundering with no special requirement.
- Bulk: fixed recipe, consolidated dye lots, JIS L 1902 repeated on every lot.
Specification delivered
| Parameter | Value |
|---|---|
| Product | Tennis Dresses |
| Base construction | bonded knit with inner shorts, 210 GSM |
| Odour-control system | Built-In Antibacterial Masterbatch Yarn |
| Performance target | above 99% bacterial reduction retained after 50 washes |
| Test method | JIS L 1902 |
| Service life | 50 washes or more |
| Added cost | an 8% yarn premium |
| Certification | OEKO-TEX Standard 100, REACH compliant inputs |
Results
The fabric held its odour value through 30 home washes with no measurable drop, and care wording was updated on the hangtag to protect the value. The odour value was re-measured on bulk fabric rather than on the approval sample, so the result reflects what customers actually received. The programme is now on its third repeat with the same recipe.
“The fabric still smells clean at the end of a double training day. That is the comment we get most often now.” — Everline Studio Product Team
Inline inspection and packing before the tennis dresses shipment
Key takeaway
Sustainability and performance were not in conflict here. Choosing the right mechanism satisfied the compliance team without asking the customer to accept less protection. For Everline Studio, that turned a recurring complaint into a feature the brand could sell.
