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04.02.2025

Sustainable Textiles – The Way Forward

High dependence on fossil carbon, associated high carbon footprint, low recycling rates and microplastics: several solutions are emerging.

The evolution of the demand for textile fibres from 1960 to the present day shows how the textile industry found itself in this dilemma. In 1960, around 95% of textile fibres were of natural origin, from bio-based carbon, and there was no problem with microplastics, all fibres were biodegradable.

High dependence on fossil carbon, associated high carbon footprint, low recycling rates and microplastics: several solutions are emerging.

The evolution of the demand for textile fibres from 1960 to the present day shows how the textile industry found itself in this dilemma. In 1960, around 95% of textile fibres were of natural origin, from bio-based carbon, and there was no problem with microplastics, all fibres were biodegradable.

The explosion in demand – 650% between 1960 and 2023 – could only be met by synthetic fibres from the chemical and plastics industries. Their share grew from 3% in 1960 to 68% in 2023 and from less than 700,000 tonnes to 85 million tonnes/year (The Fiber Year 2024). The new fibres covered a wide range of properties, could even achieve previously unknown properties and, above all, thanks to a powerful and innovative chemical and plastics industry, production volumes could be rapidly increased and comparatively low prices realised.
 
At the same time, sustainability has declined, the carbon footprint of the textiles has increased significantly and the issue of microplastics requires solutions.

The first step would be to significantly increase the proportion of renewable fibres, as this is the only way to reduce dependence on fossil carbon, especially in the form of crude oil, and thus reduce the carbon footprint. But how can this be done? As defined by the Renewable Carbon Initiative, renewable carbon comes from biomass, CO2 and recycling: From carbon above ground. This addresses the core problem of climate change, which is extracting and using additional fossil carbon from the ground that will end up in the atmosphere.
 
What can cotton, bast fibres and wool contribute?
Cotton fibre production can hardly be increased, it is stagnating between 20 and max. 25 million tonnes/year. Cultivated areas can hardly be expanded, and existing areas are salinized by the irrigation required. With the exception of about 1% organic cotton, significant amounts of pesticides are used. The market share of “preferred” cotton – defined by a list of recognized programmes – will fall from 27% of total cotton production in 2019/20 to 24% in 2020/21, after years of growth. (Textile Exchange, October 2022: Preferred Fiber & Materials Market Report) Bast fibres such as jute (75%), flax, hemp, ramie or kenaf would require a huge boost in technology development and capacity investment and will nevertheless probably remain more expensive than cotton, simply because bast fibres are much more complicated to process, e.g. separating the fibre from the stalk, which is not necessary for cotton as a fruit fibre. As a source of cellulose fibre, bast fibres will remain more expensive than wood.

Although bast fibres are more sustainable than many other fibres, there is unlikely to be a major change – unless China focuses on bast fibres as a substitute for cotton. Plans to do so have been put on hold due to technological problems.

The importance of man-made cellulosic fibres (MMCFs) or simply cellulose fibres
Cellulose fibre production has been growing steadily over the last decades, reaching an all-time high of nearly 8 million tonnes in 2023, and is expected to grow further to 11 million tonnes in 2030. Cellulosic fibres are the only bio-based and biodegradable fibres that cover a wider range of properties and applications and can rapidly increase their capacity. The raw materials can be virgin wood as well as all types of cellulosic waste streams from forestry, agriculture, cotton processing waste, textile waste and paper waste. Increasing the share of cellulosic fibres will therefore play a crucial role in solving the sustainability challenges of the textile industry.

The production of MMCFs includes viscose, lyocell, modal, acetate and cupro. The market share of FSC and/or PEFC certified MMCF increased from 55–60% in 2020 to 60–65% of all MMCF in 2021. The market share of “recycled MMCFs” increased to an estimated share of 0.5%. Much research and development is underway. As a result, the volumes of recycled MMCFs are expected to increase significantly in the coming years. (Textile Exchange, October 2022: Preferred Fiber & Materials Market Report)

The CEPI study “Forest-Based Biorefineries: Innovative Bio-Based Products for a Clean Transition” (renewable-carbon.eu/publications/product/innovative-bio-based-products-for-a-clean-transition-pdf/) identified 143 biorefineries in Europe, of which 126 are operational and 17 are planned. Most of them are based on chemical pulping (67%) – the precursor of cellulose fibres. Most biorefineries are located in Sweden, Finland, Germany, Portugal and Austria. But there are already biorefineries in operation or planned in 18 different European countries.

The global report “Is there enough biomass to defossilise the Chemicals and Derived Materials Sector by 2050?” (upcoming publication end of February 2025, available here: renewablecarbon.eu/publications) shows particularly high growth in dissolving/chemical pulp (from 9 in 2020 to 44 million tonnes in 2050; growth of 406%), cellulose fibres (from 7 in 2020 to 38 million tonnes in 2050; growth of 447%) and cellulose derivatives (from 2 in 2020 to 6 million tonnes in 2050; growth of 190%).

Biosynthetics – Bio-based and CO2-based Synthetic Fibres
To further reduce the share of fossil-based synthetic fibres, bio-based polymer fibres (also called “biosynthetics”) are an excellent option because of their wide range of properties – only the implementation will take decades as the share today is only below 0.5%. There are many options, such as polyester fibres (PLA, PTT, PEF, PHA), polyolefin fibres (PE/PP), bio-based PA fibres from castor oil. PTT, for example, is well established in the US carpet market and PLA in the hygiene market. They are all bio-based, but only a few are also biodegradable (PLA, PHA).
 
Biosynthetics are one of many applications of bio-based polymers. In general, 17 bio-based polymers are currently commercially available with an installed capacity of over 4 million tonnes in 2023. Ten of these bio-based polymers are used as biosynthetics. resulting in the production of over one million tonnes of biosynthetics (nova report: Bio-based Building Blocks and Polymers – Global Capacities, Production and Trends 2023–2028, renewable-carbon.eu/publications/product/bio-based-buildingblocks-and-polymers-global-capacities-production-and-trends-2023-2028-short-version/).

In principle, many fibres can also be made from CO2, but here the technology and capacity needs to be developed, perhaps in parallel with the production of sustainable aviation fuels from CO2, which will become mandatory.

Circular Economy – Recycling of Textile Waste & Fibre-to-Fibre Recycling
The textile industry is at a pivotal moment, where sustainability is no longer an option but a necessity. As the environmental impact of textile production and disposal becomes increasingly clear, the pressure to adopt circular economy principles is growing.

One promising solution is fibre-to-fibre recycling, a process that converts used textiles into new, highquality fibres, effectively closing the waste loop. While significant progress has been made in the European Union, challenges remain, particularly in scaling up technologies, lack of collection systems and handling of mixed fibre textiles. Europe currently generates approximately 6.95 (1.25 + 5.7) million tonnes of textile waste per year, of which only 1.95 million tonnes is collected separately and 1.02 million tonnes is treated by recycling or backfilling.
 
The recycling of textiles reduces the demand for virgin fibres and the textile footprint. The share of recycled fibres increased slightly from 8.4% in 2020 to 8.9% in 2021, mainly due to an increase in bottlebased PET fibres. However, in 2021, less than 1% of the global fibre market will come from pre- and post-consumer recycled textiles (Textile Exchange, October 2022: Preferred Fiber & Materials Market Report). New regulations from Brussels for closed-loop recycling, especially bottle-to-bottle recycling, could threaten the use of bottle-based PET fibres in the textile industry. This would mean a reduction in recycling rates in the textile industry until the logistics and technologies are in place to recycle textiles on a large scale. This will be necessary to contribute to the circular economy. Several research projects are underway to find solutions and first pilot implementations are available.

The Future of Sustainable Textiles
The sustainable textile industry of the future will be built on a foundation of cotton fibres and fast-growing cellulose fibres, later strongly supported by bio- and CO2-based synthetic fibres (“biosynthetics”), and high recycling rates for all types of fibres. This combination can eventually replace most fossil-based synthetic fibres by 2050.

To get the latest information on cellulose fibres, the nova-Institute organises the “Cellulose Fibres Conference” every year, which will take place next time in Cologne on 12 and 13 March 2025 – this year for the first time with biosynthetics.

Source:

Michael Carus and Dr. Asta Partanen, nova-Institute (Germany)

Russell Holden, Pixabay
28.01.2025

Project explores possibilities for UK wetsuit recycling

The University of Plymouth will work with Circular Flow to examine the scope for developing a UK neoprene recycling facility. A plan to develop the UK’s first wetsuit recycling facility is among eight new projects funded by Future Fibres Network Plus.

Many wetsuits are made from neoprene – but the UK currently has no way of recycling them, meaning more than 380 tonnes is burned or landfilled each year. The neoprene recycling project is one of the eight mini projects newly funded by the network.

The University of Plymouth will work with Circular Flow to examine the scope for developing a UK neoprene recycling facility. A plan to develop the UK’s first wetsuit recycling facility is among eight new projects funded by Future Fibres Network Plus.

Many wetsuits are made from neoprene – but the UK currently has no way of recycling them, meaning more than 380 tonnes is burned or landfilled each year. The neoprene recycling project is one of the eight mini projects newly funded by the network.

Led by the University of Plymouth and working with industry partner Circular Flow Ltd, it will examine the scope for developing a UK neoprene recycling facility to help make the surfing and diving industry more circular or sustainable. Circular Flow already has a facility in Bulgaria, but establishing one in the UK – home to some of the world’s most popular surfing locations – would be a significant development.
Dr Kayleigh Wyles, Associate Professor in Psychology: “Our project will investigate the level of interest among UK businesses for returning end-of-life wetsuits and accessories to a UK facility where they can be turned into new and useful products. We also aim to understand consumers’ willingness to purchase and wear recycled neoprene products, and explore the logistics of developing a recycling facility.”

“Many of those who buy and wear wetsuits have a genuine interest in the environment, and therefore in the sustainability of these products. However, wetsuits are one of the hardest products to recycle and the possibility of opening a recycling facility in the UK is very exciting,” stated Emma Major-Mudge,
Head of Sales and Commercial Partnerships, Circular Flow
 
Dr Katie Major-Smith, a post-doctoral researcher involved in the project, added: Ultimately, we hope to promote circularity in the water sports industry and keep hundreds of tonnes of wetsuits out of landfill.

If the findings suggest there is sufficient support for a neoprene recycling facility, the team will develop an investment pack to share with funders to help build it.

Future Fibres Network Plus – which aims to bring environmental science into the heart of the UK fashion, clothing and textile sectors – is a network led by the University of Exeter, collaborating with the universities of Leeds, Huddersfield and Plymouth, University of the Arts London, and the UK Fashion and Textile Association (UKFT).

Through its flexible fund, Future Fibres Network Plus is investing a total of £1 million in the eight projects.

Those projects include another initiative being led by the University, in partnership with Plan B Recycling Technologies Ltd, centred around the fibre-to-fibre recycling potential of polyester.
Recycled polyester pellets are often of low quality due to contamination by other materials, and the new project will develop a pre-recycling treatment process to improve recycled polyester quality.
It will address barriers to fibre recycling, examine the levels of microfibre release during laundry, and create a knowledge repository to optimise recycling processes.

Future Fibres Network Plus sits within the Network Plus in Circular Fashion and Textiles, a collaboration of three sub-networks that seeks to understand and drive the fashion and textile industry towards sustainable and responsible practices. The Network Plus is part of the UKRI £15million Circular Fashion and Textile Programme.

Source:

University of Plymouth

The DITF light lab. (c) DITF
20.01.2025

Textile daylight management when the winter sun is at an angle

When the sun is currently shining, shading textiles face particular challenges. On the one hand, they should allow as much daylight as possible into the rooms during the dark season. On the other hand, the angle of incidence of the sun's rays is so low that the light is particularly dazzling - much more so than in summer. The German Institutes of Textile and Fiber Research (DITF) are using special light measurement techniques to research suitable shading textiles.

Daylight enhances well-being and has many advantages over artificial lighting. Sensible daylight management can therefore increase the ability to perform and concentrate. As less artificial light is required and solar gains and losses are used for room air conditioning, daylight management also saves energy.

When the sun is currently shining, shading textiles face particular challenges. On the one hand, they should allow as much daylight as possible into the rooms during the dark season. On the other hand, the angle of incidence of the sun's rays is so low that the light is particularly dazzling - much more so than in summer. The German Institutes of Textile and Fiber Research (DITF) are using special light measurement techniques to research suitable shading textiles.

Daylight enhances well-being and has many advantages over artificial lighting. Sensible daylight management can therefore increase the ability to perform and concentrate. As less artificial light is required and solar gains and losses are used for room air conditioning, daylight management also saves energy.

Textile daylight systems influence the incidence of light and are mainly designed to be movable. Internal systems include, for example, roller blinds, folding blinds and curtains. External systems are external venetian blinds, awnings and screens that are guided in front of the façade. The DITF can precisely measure daylight behavior in its light and dark laboratories - even beyond existing standardized test methods. A test method developed in Denkendorf allows the glare control of solar protection devices to be re-evaluated and has been included in the standard to determine the cut-off angle. This cut-off angle describes the extent to which a solar protection device can block the transmission of direct light from a certain angle of incidence. In the currently valid standard, glare control is quantified using the two characteristics of normal and diffuse light transmittance. For solar protection devices with an openness coefficient of 1-3 %, a higher glare control class can be achieved. This applies to cut-off angles of 65° or less. The cut-off angle is determined by an angle-dependent measurement of the direct light transmittance. During the test, the solar protection textile is rotated in a modified test sample holder from the zero point until the direct light transmittance falls below a defined threshold value. This process is repeated after a gradual azimuthal rotation of the test sample, in other words a rotation of the textile in the test sample holder. Depending on the symmetry properties of the sample, up to 29 individual measurements may be required to determine the cut-off angle.

At the DITF, testing and development facilities for other photometric requirements such as incident light, self-luminous textiles and light-conducting textiles are available for industrial product developments.

Source:

Deutsche Institute für Textil- und Faserforschung Denkendorf

Silk Yarn Photo: LoggaWiggler from Pixabay
14.01.2025

Discarded silk yarn can clean up polluted waterways

Cornell researchers have developed an elegant and sustainable way to clean up waterways: reusing one waste product to remove another.

Cornell researchers have developed an elegant and sustainable way to clean up waterways: reusing one waste product to remove another.

Led by Larissa Shepherd, Ph.D., assistant professor in the Department of Human Centered Design, in the College of Human Ecology, the team has proposed using discarded silk yarn for the removal of dye and oil from water. Studies on several different forms of silk: fabrics, yarns, and fibers revealed that yarn unraveled from silk fabric, soaked up methylene blue (MB), a common textile dye, from water at a substantially higher rate than other forms of silk they tested.
 
What’s more, the silk yarn can be cleaned and reused. Shepherd’s group found that the textile can withstand at least 10 cycles, with minimal loss of functionality.
 
Shepherd is the corresponding author of “Waste Bombyx Mori Silk Textiles as Efficient and Reuseable Bio-Adsorbents for Methylene Blue Dye Removal and Oil-Water Separation,” published in November 2024 in the journal Fibers. Co-authors are Hansadi Jayamaha, doctoral candidate in the field of fiber science, and Isabel Schorn ’26, a fiber science undergraduate.

Jayamaha found that 12 milligrams of silk filament yarn have 90% MB dye removal efficiency within 10 minutes of exposure, for concentrations up to 100 parts per million, substantially greater than the efficiency of other forms – even electrospun fiber mats or fabrics treated with the hollow silk microparticle spheres, which was a surprise, the researchers said.

“By creating the spheres,” Jayamaha said, “we were creating a more hydrophilic surface compared to the silk fabric, which is more hydrophobic. But by disassembling the fabric to the yarn stage, we are creating higher surface area, and that improves the adsorption.”

The group also tested silk textile adsorption capacity with oil, and found that Noil fabric (a textile that contains silk yarns composed of short fibers, rather than filament) displays oil adsorption capacities three times the initial weight of the fabric for corn oil, and close to twice the weight for gasoline.

Tests on both materials showed that, following a diminishment of function after the first cleaning-reuse cycle, the material maintained its functionality for the subsequent nine cycles.
This intrinsic property of silk as a dye adsorbent, the group found, can be achieved without chemical or other alteration of the material – just deconstructing the textile product.
     
“When you regenerate silk, you have to use very harsh chemicals,” Shepherd said. “In our case, we’re just using the fabrics themselves. Yes, we may have to unravel them to get the benefit, but that’s much better than putting these harsh chemicals out into the environment.”

Shepherd envisions “pillows” containing the silk yarn unraveled from discarded textiles and remnants from the cut and sew operations of the textiles industry as being an effective means of cleaning up spills and waste materials, including MB dye, which is detrimental to agricultural land and waterways when it is accidentally released from textile plants.

“We realized that we can kill two birds with one stone: We can get rid of waste textiles, which is a big issue in the textile industry in general,” Shepherd said. “And then we found that it’s actually really good at adsorbing, just because of its natural, structural properties.”

This work made use of the Cornell Center for Materials Research Shared Facilities, as well as the Cornell NanoScale Science and Technology Facility, a member of the National Nanotechnology Coordinated Infrastructure, which is supported by the National Science Foundation. This work was partially funded by an American Association of Textiles Chemists and Colorists graduate research grant.

Source:

Tom Fleischman, Cornell Chronicle