Our construction techniques

This video gives a good overview of our materials and construction methods, and a sneak peek at our factory.

Thread and needles

Twin needles are used on all seams. The thread used is a large, polyester-core, spun-cotton wrapped thread, giving it strength and waterproofness. Small needles are also used, resulting in smaller holes and even better waterproofing.

bindingBinding seams with canvas binding tape

All our canvas rucksacks use canvas binding. The seams are bound using twin needles, resulting in two lines of stitching (14 stitches per inch in total) for extra durability. Small needles are used, reducing the size of the holes, while the large polyester-core, spun-cotton wrapped thread is strong and also swells when wet, filling any remaining gaps.

The binding process required the development of special sewing machines – built in Australia – as well as needle guides to stabilise the needle, reducing needle damage and making the process consistent and even.

Our synthetic packs use synthetic binding tape.

bar-tackBar tacking

Bar tacks are a special stitch used to give massive strength to high-stress areas. (These stitches are used on rockclimbing slings, a testament to their strength.) Bar tacks are used as reinforcement in key areas on One Planet rucksacks: in fact, the Exact Fit harness uses roughly 50 of these. Our bar tacks consist of 42 or 28 individual stitches, depending on the application, done on a special machine.

Frames and endcaps

Our frames are made from high-grade aluminium and are shaped by hand to ensure they meet our exacting standards.

Also, we know it’s only a small thing, but it’s important to us; all frames are finished with high-quality, non-crack endcaps to protect the surrounding fabric.

Buckles, webbing and zips

The buckles used on One Planet packs are made from non-crack nylon for strength and reliability. Most of our competitors use acetyl buckles: these are strong, but if subject to force they will break rather than bend. (The most common damage comes from standing on them!) We prefer to be able to bend our buckles back into shape and continue on our merry way!

Non-slip webbing is used in high-wear areas such as the shoulder strap and hipbelt adjustments: straps that grow mysteriously are a thing of the past. This non-slip webbing can be identified by a tension-weave edge.

The zips on all One Planet pack are the genuine YKK article, because the last thing you need is a busted zip. The slider on YKK zips is made from a soft alloy so that it will wear out before the zip teeth – good news, as the slider is easy to replace, while the teeth aren’t!