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Feathers from waterfowl (c) Daunen- und Federnverbände Mainz
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05.03.2024

Adhesives: Feathers replace petroleum

Adhesives are almost always based on fossil raw materials such as petroleum. Researchers at Fraunhofer have recently developed a process that allows to utilize keratin for this purpose. This highly versatile protein compound can be found, for instance, in chicken feathers. Not only can it be used to manufacture a host of different adhesives for a variety of applications, but the processes and end products are also sustainable and follow the basic principles underlying a bioinspired circular economy. The project, developed together with Henkel AG & Co. KGaA, addresses a billion-dollar market.

Adhesives are almost always based on fossil raw materials such as petroleum. Researchers at Fraunhofer have recently developed a process that allows to utilize keratin for this purpose. This highly versatile protein compound can be found, for instance, in chicken feathers. Not only can it be used to manufacture a host of different adhesives for a variety of applications, but the processes and end products are also sustainable and follow the basic principles underlying a bioinspired circular economy. The project, developed together with Henkel AG & Co. KGaA, addresses a billion-dollar market.

Adhesives are found nearly everywhere: in sports shoes, smartphones, floor coverings, furniture, textiles or packaging. Even auto windshields are glued into place using adhesives. Experts recognize more than 1,000 different types of adhesives. These can bond almost every imaginable material to another. Adhesives weigh very little and so lend themselves to lightweight design. Surfaces bonded with adhesive do not warp because, unlike with screw fastenings, the load is distributed evenly. Adhesives do not rust, and seal out moisture. Surfaces bonded with adhesive are also less susceptible to vibration. Added to which, adhesives are inexpensive and relatively easy to work with.

Feathers from poultry meat production
Traditionally, adhesives have almost always been made from fossil raw materials such as petroleum. The Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB has recently adopted a different approach. Researchers there have been using feathers as a base material instead of petroleum. Feathers are a by-product of poultry meat production. They are destroyed or mixed into animal feed. But feathers are far too valuable to go to waste because they contain the structural protein keratin. This biopolymer is found in animals and makes up talons, claws, hooves or feathers. Its fibrous structure is extremely strong.

Why keratin is perfect for manufacturing adhesives
Keratin is a biodegradable and thus eco-friendly material whose structure has specific properties that make it particularly suitable for the manufacture of adhesives. Keratin's polymer structure, i.e., its very long-chain molecules, as well as its ability to undergo cross-linking reactions predestine it for the manufacture of various adhesives. “The properties required for adhesives are to some extent already inherent in the base material and only need to be unlocked, modified and activated,” explains project manager Dr. Michael Richter.

Platform chemical and specialty adhesives
Over the past three years, Fraunhofer IGB has been working with Henkel AG & Co. KGaA on the KERAbond project: “Specialty chemicals from customized functional keratin proteins” — Kera being short for keratin, combined with the English word bond. Henkel is a global market leader in the adhesives sector.

The partners in the project have recently developed and refined a new process. In the first stage, feathers received from the slaughterhouse are sterilized, washed and mechanically shredded. Next, an enzyme process splits the long-chain biopolymers or protein chains into short-chain polymers by means of hydrolysis.

The output product is a platform chemical that can serve as a base material for further development of specially formulated adhesives. “We use the process      and the platform chemical as a “toolbox” to integrate bio-enhanced properties into the end product,” says Richter. This means parameters can be specified for the target special adhesive such as curing time, elasticity, thermal properties or strength. Also, it’s not just adhesives that are easy to manufacture but also related substances such as hardeners, coatings or primers.

In the next stage, the Fraunhofer team set about converting the feathers on a large scale. Ramping up the process fell to the Fraunhofer Center for Chemical-Biotechnological Processes CBP in Leuna. The aim was to prove that the keratin-based platform chemicals can also be manufactured cost-efficiently on an industrial scale. This involved processing several kilograms of chicken feathers, with the material produced being used for promising initial material trials at Fraunhofer IGB and Henkel.

Foundations of a bioinspired economy
This bioinspired process is of particular significance for the Fraunhofer-Gesellschaft. Biotechnology is in fact one of the main fields of research for the Fraunhofer-Gesellschaft: “We draw our inspiration from functionality or properties that already exist in nature or in natural raw materials. And we attempt to translate these properties into products through innovative manufacturing methods. This generates a bioinspired cycle for valuable raw materials, Richter explains.

The project carries some economic weight. According to Statista, around one million tons of adhesives were manufactured in Germany alone in 2019. Total value is around 1.87 billion euros.

A patent application has been filed for the new process and an article published in a scientific journal. Two PhD students who have conducted extensive research on the project at Henkel and Fraunhofer are expected to complete their theses in the first quarter of 2024. This new keratin-based technology will allow a host of platform chemicals to be produced in a sustainable, bioinspired way.

The KERAbond project has been funded and supported over the past three years by Fachagentur Nachwachsende Rohstoffe (FNR) in Gülzow on behalf of the Federal Ministry of Food and Agriculture (BMEL) under the Renewable Resources Funding funding program (grant number 22014218).

More information:
down and feathers Fraunhofer IGB adhesives Keratin biotechnology bionic
Source:

Fraunhofer IBG

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Bild: Christine Sponchia auf Pixabay
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05.05.2020

COVID-19: German Down and Feather Industry exemplary in Terms of Hygiene

  • Update on the economic situation of the industry
  • Supply availability secured for the next half-year
  • E-commerce wins in the crisis
  • Sector survey of the Association of the German Down and Feather Industry VDFI and Traumpass e.V. on the occasion of the Corona crisis

The corona pandemic not only poses great challenges for each and every one of us, but also for our businesses as an industry. The decisions of the Federal Government and the federal states to close down shops and restrict freedom of mobility have hit the predominantly medium-sized down and feather industry hard, not only on the sales side, but also through their trading partners. The declining demand was compounded by the industry's international dependencies within the supply chains, since the filling material, the covers and the packaging materials are largely imported.

  • Update on the economic situation of the industry
  • Supply availability secured for the next half-year
  • E-commerce wins in the crisis
  • Sector survey of the Association of the German Down and Feather Industry VDFI and Traumpass e.V. on the occasion of the Corona crisis

The corona pandemic not only poses great challenges for each and every one of us, but also for our businesses as an industry. The decisions of the Federal Government and the federal states to close down shops and restrict freedom of mobility have hit the predominantly medium-sized down and feather industry hard, not only on the sales side, but also through their trading partners. The declining demand was compounded by the industry's international dependencies within the supply chains, since the filling material, the covers and the packaging materials are largely imported. The closure of the borders within Europe and the overall tense global logistics situation contributed significantly to the worsening of the situation.
 
In the past few days, the federal and state governments have started cautious attempts to ease the contact bans and to revive the economy with a sense of proportion. The opening of shops and the continuation of business activities prompted the down and feather associations to question the status quo of the sector with an extensive survey.

Although the companies named significant losses in their turnover, they currently still got off relatively lightly compared with other sectors. Two thirds of the companies stated that they had suffered up to 25% sales losses due to the corona crisis. Approximately 17% reported a decline of up to 50%, the ones with same percentage were much harder hit with a decline of up to 75%.

On the occasion of Heimtextil in January 2020, the association's sector statement had described the position of the specialised trade as still stable from the bedding manufacturers' point of view: By expanding the range of services, such as cleaning down and feathers or refilling existing bedding, the local store was increasingly becoming a point of contact for consumers. Supporting the advisory competence and the deployment of sleep experts made an impact. This picture has changed significantly as a result of the contact ban:

The clear loser in terms of demand on the various sales channels, caused by the shop closures, was the traditional retail: 92% of the surveyed manufacturing companies registered declining demand for the retail trade, 90% for the furniture trade and 80% for the specialty stores. Even for the discounters, whose opening hours were not affected, 33% noted a drop in demand; 44% estimated the demand situation as unchanged. The winner in the crisis was the e-commerce, although perhaps to a lesser extent than expected: 45% of the German down and feather producers recorded an increase in demand, 36% estimated the level as unchanged.

In terms of supply capability, the industry in Germany considers itself as well positioned: Two thirds see no bottlenecks for the fulfilment of closed contracts within the next three months, and the majority also offers free capacities beyond that. And 55% guarantee this ability to deliver even for the next six months, including the satisfaction of additional requirements.

While 2019 was a year of consolidation for the German down and feather sector and, after difficult months with sharply increased raw material prices, a calming down on a high level prevailed, good results from the previous year were maintained and, in some cases, even increased, the assessment for 2020 is much more pessimistic.

As far as the price situation for the coming autumn/winter season is concerned, member companies were correspondingly cautious in their forecasts.    
The unresolved and in some cases very fragile situation in the supplier countries currently not allows to make reliable statements. At the earliest in late summer, a well-founded opinion can be obtained. Especially since 45% of the companies expect to be confronted with requests for price reductions.
 
The down and feather industry is a professional when it comes to hygiene. The highest purity requirements are placed on down and feathers: Before being used as filling material, they must be cleaned by thorough water washing and dried at a temperature of at least 100°C, usually higher. This ensures that bedding meets the hygiene requirements of European Standard EN 12935 with reliably killing bacteria, viruses and other germs. In addition to the applicable standards, the companies have taken additional precautions to protect employees, trade partners and consumers.

In addition to the intensive workplace and hand disinfection, which all manufacturers have increased, the companies focused particularly on the equalization of the workforce. 73% designed home office workplaces for employees outside production, 45% introduced strict shift separation, two thirds shifted working hours and changed the use of common rooms in order to have as few employees as possible in the company at the same time and thus minimized the risk of infection. At the same time, many companies started the production of mouth and nose masks and made their sewing facilities available for this purpose. A list of the manufacturing companies is available from the Association of the German Down and Feather Industry VDFI e.V.

With the start of the lockdown, the German government had announced extensive financial aid, which focused on bridging payments for small businesses, granting loans, short-time work and tax deferrals. Improvements had to be made for small and medium-sized enterprises. In the recent weeks, the sector has not primarily addressed the question for bridging loans nor reducing the interest burden; emergency aid in the form of financial injections and non-repayable grants was also of interest only to one third. The majority of the association members concentrated on measures to secure liquidity (45%), tax deferrals and the suspension of advance payments of VAT (73%) as well as the changeover to short-time work (73%) and the accelerated processing and granting of short-time work compensation (45%). Also, two thirds requested binding statements on the easing of the contact ban and on the economic upturn.

An update on the industry survey is planned for late summer 2020.

More information:
down and feathers Verband der Deutschen Daunen- und Federnindustrie
Source:

VDFI e.V. / Traumpass e.V.

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DOWNPASS e.V.’s FIRST TRADE FAIR IN CHINA Traumpass e.V.
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20.03.2018

DOWNPASS e.V.’s FIRST TRADE FAIR IN CHINA

  • The association's zero tolerance standard was presented at Intertextile Shanghai Home Textiles between 14 and 16 March
  • The association enjoyed a successful appearance together with three certification bodies from Germany, Japan and the US/China
  • Chinese manufacturers showed great interest in the unique combination of animal welfare and quality control

‘We met many committed companies – primarily from China – that showed great interest in traceability and the ethically sound sourcing of feathers and down. The potential that Downpass offers as a traceability standard together with continuous quality control was clearly recognised and won companies over not only for export-oriented purposes, but also for the domestic Chinese market’, explained Dr Juliane Hedderich, who was responsible for the trade fair appearance as managing director of Downpass e.V.

  • The association's zero tolerance standard was presented at Intertextile Shanghai Home Textiles between 14 and 16 March
  • The association enjoyed a successful appearance together with three certification bodies from Germany, Japan and the US/China
  • Chinese manufacturers showed great interest in the unique combination of animal welfare and quality control

‘We met many committed companies – primarily from China – that showed great interest in traceability and the ethically sound sourcing of feathers and down. The potential that Downpass offers as a traceability standard together with continuous quality control was clearly recognised and won companies over not only for export-oriented purposes, but also for the domestic Chinese market’, explained Dr Juliane Hedderich, who was responsible for the trade fair appearance as managing director of Downpass e.V.
‘The follow-up after the trade fair will be crucial to translate Chinese companies’ interest into actual memberships.’

The association's representatives and rotating teams from the certification bodies Wessling, QTEC and IDFL advised visitors at a large stand in the foyer of hall 4.2 (HOME) with a deliberately puristic design. These independent testing institutes and auditing organisations are companies’ direct contacts for audits and product monitoring. As is common for trade fairs, the largest crowds were seen on the afternoon of the first and second day of the event.

The markets are increasingly demanding materials that guarantee trading partners and therefore consumers the greatest possible security when it comes to ethics and sustainability, alongside high product quality. Products certified by independent testing institutes gain in importance and set sales standards.

Ms Anna Elisa Wessling, legal representative of the subsidiary Wessling Consulting (Shanghai) Ltd. and representative of the German Wessling Group at the trade fair, was happy to engage with customers directly, explaining, ‘our presence as a consulting, analysis and testing company at Intertextile Home gave us the opportunity to talk to visitors and thus allowed us to increase transparency on the Chinese market such that retailers and consumers are suitably informed of the highest requirements of product quality and of the origin of bedding filled with feathers and down.’
As a German family company, the Wessling Group has stood for continuous improvement in the quality and security of products and processes for 35 years and is set to move into new, larger premises for its subsidiary in Shanghai in the near future so that it can fulfil the increasing number of testing requests in Asia with a larger team.
‘We expect constant growth in our analysis and consulting segment feathers and down, especially as our international customers see Downpass as a clear advantage for customer acquisition domestically and abroad. As an independent testing institute, we play a substantial role in underpinning trust in the Downpass brand’, highlighted Ms Weßling.

The Japanese institution QTEC also confirmed Downpass’ high level of visitor interest and, like its colleagues, stressed the importance of an institute’s independence. The managing director of Shanghai QTEC Testing Laboratory, Hiroyuki Nakamoto, who successfully presented the company’s three Chinese sites – including Shanghai and Wuxi – at the home textiles trade fair, explained, ‘our knowledge of the Japanese market, together with our testing expertise, make us a top contact for manufacturers of bedding and clothing products filled with feathers and down to ensure the supply chain is ethically sound.’ The institute expects a steady rise in the number of testing requests for Downpass, especially at Chinese sites.

A large, bilingual English-Chinese sales team from IDFL China, based in Hangzhou was available at the trade fair in Shanghai to answer all questions relating to audits and testing procedures with its varied specialist expertise. Together with its cooperation partner, the Chinese national down and feather laboratory CIQ Xiaoshan, IDFL has capacities for a broad range of different tests and audits.
IDFL’s Global Audit Manager Bryan Mortensen highlighted that Downpass had become a standard and therefore a seal that is recognised worldwide and in China in particular. The joint appearance with other certification bodies provided the opportunity to answer the questions of Chinese companies along the supply chain, from wholesalers to clothing and home textile brands and trading partners.
‘We are seeing strong demand for the current version of the standard, Downpass 2017, and its seal. IDFL carried out numerous audits across the globe in 2017 and we receive new requests every day. Overall we anticipate a successful future for Downpass in the down and feather industry’, explained Mortensen. IDFL – which will celebrate 40 years in the industry in 2018 – has been carrying out audits in the field of down and feathers for more than 10 years and is currently undergoing certification in accordance with ISO/EN 17065 and 19011.

In their first summary of the event, the extended Downpass trade fair team took stock of a successful trade fair premiere. ‘We aim to promote the sustainable use of natural resources across the globe and to increase transparency in the supply chain’, explained Dr Juliane Hedderich. ‘Animal welfare and guaranteed product quality are our hallmarks. We did a great job in Shanghai of jointly informing others about these and finding new collaborators.’

 

About the zero tolerance standard DOWNPASS 2017
Products filled with feathers and down that are certified in accordance with Downpass 2017 exclude products sourced from live plucking and production based on force feeding. The animals’ rearing is monitored and monitoring may be extended to the parent animal farms.
To this end, farms, commodities traders and producers are subject to audits and monitoring.
Pre-made products are bought by mystery shoppers at the point of sale and subsequently undergo quality control in independent testing laboratories.
As of January 2018, 503 million animals had been audited in accordance with DOWNPASS 2017.
Labelled products are available in North America, Europe and Asia.

DOWNPASS e.V.’s FIRST TRADE FAIR IN CHINA Traumpass e.V. DOWNPASS e.V.’s FIRST TRADE FAIR IN CHINA Traumpass e.V. DOWNPASS e.V.’s FIRST TRADE FAIR IN CHINA Traumpass e.V.
More information:
Downpass Animal welfare zero tolerance standard down and feathers
Source:

Traumpass e.V.

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