Designing Ocean Pro: Offshore Sailing Protection

We sat down with Matteo, Head of Design, to understand the thinking behind Ocean Pro.

Ocean Pro represents the most technically advanced offshore system Henri-Lloyd has engineered to date. Developed over an extended innovation cycle and produced with one of Japan’s most specialised laminators, it delivers exceptional waterproof protection, controlled breathability, reduced weight and long-term stability.

We sat down with Matteo, Head of Design, to understand the thinking behind it.

Q: Let’s start with the fabric. What makes Ocean Pro different?

Matteo: Developing this fabric was like building a precision system. Every element influences the next. If you adjust one ingredient, everything changes.

Ocean Pro is built on a functional 4-layer construction. Technically there are five layers within the structure, but four perform the functional work.

The outer face fabric is made from recycled production waste. Beneath that sits a microporous hydrophobic coating that repels water. Combined with this is a hydrophilic membrane that absorbs moisture vapour from inside the garment and transports it outward.

I describe it as a two-engine system. One engine repels water. The other moves vapour away from the body.

That balance between repelling external water and managing internal moisture is what defines the fabric.

Q: Why move from a traditional 3-layer construction to 4 layers?

Matteo: Performance stability and breathability over time.

Pure microporous membranes can lose efficiency because pores become clogged by salt crystals or dirt. When that happens, both waterproofness and breathability decline.

By pairing a microporous hydrophobic layer with a protective hydrophilic membrane, we maintain both functions. The hydrophilic layer protects the pore structure while actively transporting vapour outward.

Ocean Pro achieves:

35,000mm hydrostatic head waterproofness
14,000g per square metre per 24 hours breathability

For context, our previous Elite system delivered 20,000mm waterproofness and 10,000g breathability. Ocean Pro significantly increases both.

Most importantly, the performance remains stable after washing, verified through SGS third party testing.

Q: Can you explain what breathability means in the context of offshore sailing?

Matteo: Breathability is critical offshore.

Sailors generate heat through movement, trimming and manoeuvres. If moisture vapour cannot escape, condensation builds inside the garment. That is when you feel damp even if the jacket is technically waterproof.

The 14,000g rating means the fabric allows 14,000 grams of moisture vapour per square metre to pass through in 24 hours. This level is high for a system delivering 35,000mm waterproofness.

The key is balance. Extreme waterproofness without breathability creates discomfort. High breathability without protection fails offshore. Ocean Pro is engineered to manage both.

Q: Offshore sailing gear is often heavy. How did you address weight?

Matteo: Lightweight construction was a core objective.

The Japanese lamination process allows us to maintain softness while reducing bulk. Panels are laser cut and bonded to remove unnecessary seam weight. Modular elements mean sailors only wear what is needed.

Many testers immediately comment that the jacket feels lighter than expected for a 35,000mm system.

Protection does not have to feel heavy.

Q: You mentioned five layers technically. Where does the fifth layer sit?

Matteo: Between the outer face and the microporous coating.

During development we observed slight internal material migration over time. To solve that without compromising sustainability or performance, we introduced a thin stabilising barrier.

It is not a waterproof layer, so we describe the fabric as 4 layer. But technically there are five structural layers working together.

Q: How does sustainability fit into this system?

Matteo: The membrane is produced without solvent based chemistry and without harmful PFAS in its formation process.

The Smart Therm mid layers use certified recycled ocean sourced polyester insulation.

Sustainability was integrated at the engineering stage, not added later.

Q: Beyond fabric metrics, what defines Ocean Pro as a system?

Matteo: Modularity, breathability management and obsessive refinement.

The jacket includes:

Detachable face mask
Removable storm skirt
Detachable high storm collar
Multiple waist and hem adjustments

Critical areas are reinforced with stretch Cordura. Aquaseal YKK zips are used in key waterproof zones. The hood features a structured drainage channel to direct water away from the face.

The fleece lining uses an octagonal structure to retain warmth while allowing moisture to escape.

Everything works together to protect externally while managing internal climate.

Q: Waterproofness offshore is non-negotiable. How confident are you in Ocean Pro?

Matteo: Very confident.

35,000mm hydrostatic head exceeds many established offshore benchmarks. Combined with engineered seam construction, reinforced zones and premium zip technology, the system is built for sustained offshore pressure.

Waterproofness, breathability and lightweight construction must operate together. Ocean Pro was developed to deliver all three.

Q: The salopettes also evolved. What changed?

Matteo: Mobility and moisture management were priorities.

We reduced bulk in high movement areas. EVA knee pads are perforated to allow drainage and reduce pressure build up. Reinforced areas use stretch Cordura to maintain flexibility.

Pocket depth was increased while maintaining a clean silhouette. The shoulder straps use backpack inspired engineering to reduce pressure and improve airflow, enhancing comfort and breathability during long passages.

Q: If you had to summarise Ocean Pro’s core principles in a few minutes, what would they be?

Matteo:

Performance 35,000mm waterproofness. 14,000g breathability. Stable after washing. Engineered for sustained offshore conditions.
Breathability and Climate Control Dual membrane system managing moisture from inside while protecting from outside.
Lightweight Protection Soft lamination, reduced bulk and modular configuration. Maximum protection without unnecessary weight.
Sustainability Solvent free membrane production and recycled materials integrated from the start.
Detail Hundreds of refinements across seams, closures, reinforcements and articulation.

Ocean Pro is not simply an evolution. It is a recalibration of what offshore protection should deliver.