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Chemist Unlocks Plastic Alternatives Using Proteins and Clothing Scraps Photo: Challa Kumar, professor emeritus of chemistry, in his lab. (Contributed photo)
21.12.2023

Chemist Unlocks Plastic Alternatives Using Proteins and Clothing Scraps

Challa Kumar has developed methods to create novel plastic-like materials using proteins and fabric.

Every year, 400 million tons of plastic waste are generated worldwide. Between 19 and 23 million tons of that plastic waste makes its way into aquatic ecosystems, and the remaining goes into the ground. An additional 92 million tons of cloth waste is generated annually.

Challa Kumar, professor emeritus of chemistry, “fed up” with the tremendous amount of toxic waste people continually pump into the environment, felt compelled to do something. As a chemist, doing something meant using his expertise to develop new, sustainable materials.

“Everyone should think about replacing fossil fuel-based materials with natural materials anywhere they can to help our civilization to survive,” Kumar says. “The house is on fire, we can’t wait. If the house is on fire and you start digging a well – that is not going to work. It’s time to start pouring water on the house.”

Challa Kumar has developed methods to create novel plastic-like materials using proteins and fabric.

Every year, 400 million tons of plastic waste are generated worldwide. Between 19 and 23 million tons of that plastic waste makes its way into aquatic ecosystems, and the remaining goes into the ground. An additional 92 million tons of cloth waste is generated annually.

Challa Kumar, professor emeritus of chemistry, “fed up” with the tremendous amount of toxic waste people continually pump into the environment, felt compelled to do something. As a chemist, doing something meant using his expertise to develop new, sustainable materials.

“Everyone should think about replacing fossil fuel-based materials with natural materials anywhere they can to help our civilization to survive,” Kumar says. “The house is on fire, we can’t wait. If the house is on fire and you start digging a well – that is not going to work. It’s time to start pouring water on the house.”

Kumar has developed two technologies that use proteins and cloth, respectively, to create new materials. UConn’s Technology Commercialization Services (TCS) has filed provisional patents for both technologies.

Inspired by nature’s ability to construct a diverse array of functional materials, Kumar and his team developed a method to produce continuously tunable non-toxic materials.

“Chemistry is the only thing standing in our way,” Kumar says. “If we understand protein chemistry, we can make protein materials as strong as a diamond or as soft as a feather.”

The first innovation is a process to transform naturally occurring proteins into plastic-like materials. Kumar’s student, Ankarao Kalluri ’23 Ph.D., worked on this project.

Proteins have “reactor groups” on their surfaces which can react with substances with which they come into contact. Using his knowledge of how these groups work, Kumar and his team used a chemical link to bind protein molecules together.

This process creates a dimer – a molecule composed to two proteins. From there, the dimer is joined with another dimer to create tetramer, and so on until it becomes a large 3D molecule. This 3D aspect of the technology is unique, since most synthetic polymers are linear chains.

This novel 3D structure allows the new polymer to behave like a plastic. Just like the proteins of which it is made, the material can stretch, change shape, and fold. Thus, the material can be tailored via chemistry for a variety of specific applications.

Unlike synthetic polymers, because Kumar’s material is made of proteins and a bio-linking chemical, it can biodegrade, just like plant and animal proteins do naturally.

“Nature degrades proteins by ripping apart the amide bonds that are in them,” Kumar says. “It has enzymes to handle that sort of chemistry. We have the same amide linkages in our materials. So, the same enzymes that work in biology should also work on this material and biodegrade it naturally.”

In the lab, the team found that the material degrades within a few days in acidic solution. Now, they are investigating what happens if they bury this material in the ground, which is the fate of many post-consumer plastics.

They have demonstrated that the protein-based material can form a variety of plastic-like products, including coffee cup lids and thin transparent films. It could also be used to make fire-resistant roof tiles, or higher-end materials like, car doors, rocket cone tips, or heart valves.

The next steps for this technology are to continue testing their mechanical properties, like strength or flexibility, as well as toxicity.

“I think we need to have social consciousness that we cannot put out materials into the environment that are toxic,” Kumar says. “We just cannot. We have to stop doing that. And we cannot use materials derived from fossil fuels either.”

Kumar’s second technology uses a similar principle, but instead of just proteins, uses proteins reinforced with natural fibers, specifically cotton.

“We are creating a lot of textile waste each year due to the fast-changing fashion industry” Kumar says. “So why not use that waste to create useful materials – convert waste to wealth.”

Just like the plastic-like protein materials (called “Proteios,” derived from original Greek words), Kumar expects composite materials made from proteins and natural fibers will biodegrade without producing toxic waste.

In the lab, Kumar’s former student, doctoral candidate Adekeye Damilola, created many objects with protein-fabric composites, which include small shoes, desks, flowers, and chairs. This material contains textile fibers which serve as the linking agent with the proteins, rather than the cross-linking chemical Kumar uses for the protein-based plastics.

The crosslinking provides the novel material with the strength to withstand the weight that would be put on something like a chair or a table. The natural affinity between fibers and proteins is why it’s so hard to get food stains out of clothing. This same attraction makes strong protein-fabric materials.

While Kumar’s team has only worked with cotton so far, they expect other fiber materials, like hemp fibers or jute, would behave similarly due to their inherent but common chemical properties with cotton.

“The protein naturally adheres to the surface of the protein,” Kumar says. “We used that understanding to say ‘Hey, if it binds so tightly to cotton, why don’t we make a material out of it.’ And it works, it works amazingly.”

With the support of TCS, Professor Kumar is currently seeking industry partners to bring these technologies to market. For more information contact Michael Invernale at michael.invernale@uconn.edu.

Source:

Anna Zarra Aldrich '20 (CLAS), Office of the Vice President for Research

(c) PERFORMANCE DAYS
16.11.2021

PERFORMANCE DAYS 2021: Hybrid Event in December

From December 1 to 2, 2021, the industry will meet up again live at the trade fair center in Munich. Trade visitors, industry insiders and experts can look forward to inter-personal exchanges, intensive networking, exciting fabric innovations and various other program highlights. The fair will go ahead in strict compliance with the current official hygiene regulations and in close cooperation with the Messe München authorities. Planned as a hybrid event, PERFORMANCE DAYS offers the possibility to follow what is on offer digitally.

From December 1 to 2, 2021, the industry will meet up again live at the trade fair center in Munich. Trade visitors, industry insiders and experts can look forward to inter-personal exchanges, intensive networking, exciting fabric innovations and various other program highlights. The fair will go ahead in strict compliance with the current official hygiene regulations and in close cooperation with the Messe München authorities. Planned as a hybrid event, PERFORMANCE DAYS offers the possibility to follow what is on offer digitally.

Live in Munich: PERFORMANCE DAYS in Hall A6
In Hall A6 on the grounds of the New Trade Center in Munich, trade visitors can look forward to an extensive portfolio of exhibitors showcasing their latest functional textiles and fabric innovations for the upcoming winter season, winter 2023/24. Exhibitors who are unable to present their highlights on site can also be accessed via the PERFORMANCE DAYS LOOP digital platform throughout the course of the fair. As part of the newly developed “remote booths” concept, trade visitors will for the first time also find collections from exhibitors who cannot be in Munich in person for the trade show. Interactive exchanges via chat, call or video call is planned.

Two further PERFORMANCE DAYS fairs are planned as live events: The Functional Fabric Fair by PERFORMANCE DAYS in Portland, Oregon, USA on November 17-18, 2021 and Functional Textiles Shanghai by PERFORMANCE DAYS on December 6-7, 2021. Registration is open at www.functionalfabricfair.com/ and www.functionaltextilesshanghai.com/

PERFORMANCE FORUM together with USA Fair
As part of the PERFORMANCE FORUM, a select jury of experts assembles for two days prior to the fair to exchange views on the latest fabric innovations for the winter 23/24 season. In order to ensure a more global market overview, the PERFORMANCE FORUM will curate highlights for the first time in conjunction with the US fair in Portland. Consequently, the next fair in Munich will not only feature the latest products from exhibitors at the Munich fair, but also highlights from the fair in Portland. This year’s Focus Topic in cooperation with the Vaude Academy will engage with the topic “The Sustainable Future of Nylon” and a specific hand-chosen selection of fabric materials. Furthermore, as part of the winter fair, the “sustain & innovate” conference on sustainability, organized in close cooperation with SAZsport, will take an in-depth look at the topic comprising all its aspects along with speakers, webinars and discussion rounds. The program will be broadcast live from the fair and thus accessible for all who wish to follow it online in digital form.  

Eco Award and Performance Award for Innovative Winter Fabrics 23/24
This year, in addition to a PERFORMANCE AWARD, the jury also presented an ECO PERFORMANCE AWARD. An integral part of the winter edition of PERFORMANCE DAYS is the presentation of the fabric highlights and accessory trends in the respective categories for the Winter Season 2023/24 at the PERFORMANCE FORUM. The well-known segments will be joined for the first time this winter by the Shoes & Bags category, while the renowned Lifestyle Category will be continued under its new title, “Function Meets Fashion”. The high level of innovation and quality of many of the fabrics submitted this year are particularly striking.

“The fusion of the two PERFORMANCE FORUMs of our fairs in Munich and Portland has lead to a significant increase in quality and innovation. Thanks to the new partnership, not only were we able to get new, exciting manufacturers on board, but there was also a significant increase in participation in general“, says Marco Weichert, CEO of PERFORMANCE DAYS.

Natural fabrics such as organic cotton, wool or canvas remain in demand. These are joined by significantly more plant fibers such as hemp, coconut shell, bamboo or fibers derived from pineapple or banana leaves. The additional use of castor oil, zinc or ginger supports the antibacterial effect, ensures enhanced breathability, optimum temperature management and makes the fabric soft, light and kind to the skin. The topic of recycling presents itself in various new facets and features exciting trends. The portfolio ranges from the recycling of marine waste, such as old buoys, plastic waste or fishing nets, to the recycling of waste from the automotive and computer industries, such as old car tires or computer chips. Natural dyeing methods are also gaining increasing importance, as is the recycling of materials into the textile loop.

In the Marketplace, visitors have the opportunity to view over 13,000+ products from exhibitors, including the fabric highlights of the individual categories at the PERFORMANCE FORUM. In order to be able to present the fabrics to the digital visitors as realistically as possible in terms of feel, design and structure, the PERFORMANCE FORUM has been equipped with groundbreaking 3D technology, including innovative tools such as 3D images, video animations and U3M files for download.

In addition to the PERFORMANCE AWARD WINNER, which goes to drielease/Optimer, there is also an ECO PERFORMANCE AWARD WINNER, awarded to Long Advance.

Completely new look: With the innovative Dricomfort Geo, drirelease turns to a blend of 6 % Lycra, 44 % polyester and 50 % recycled polyester. The processing of the various fibers in the knitting process, in combination with the Dricomfort GEO finishing, makes the reversible interlock fabric unique.

Unique, new pattern and knit designs are possible thanks to a special jacquard knitting process used to process the recycled polyester yarn. The material impresses with its lightness and versatility. The GEO technology also ensures optimal body temperature management. The adaptable technology provides excellent thermal regulation features through efficient heat management and enhanced moisture transport to optimize comfort and performance. Moreover, GEO boasts UV protection up to 50+.

New recycling variant: Long Advance presents LNT-21191-Z4C, a post consumer nylon that opens up a new world to recycling. The fabric, which consists of 7 % elastane and 93% recycled polyamide via Mass Balance, introduces new facets to the topic of recycling. BASF is using tire waste from now on and processes them into a new fiber. fiber. Due to the recycling, the need for synthetic fabrics are reduced to replace petroleum-based plastics with plastics made from renewable raw materials.

08.12.2020

Fraunhofer FEP: Boosting Innovations for COVID-19 Diagnostic, Prevention and Surveillance

The recently launched 6.1 million Euro project INNO4COV-19, funded by the European Commission (grant agreement no. 101016203), will support the marketing of new products to combat COVID-19 over the next two years, throughout Europe. The Fraunhofer Institute for Organic Electronics, Electron Beam and Plasma Technology FEP is contributing its know-how in sterilization using accelerated electrons and on near-to-eye visualization.

The €6.1 million project INNO4COV-19 is committed to supporting the commercialization of new products across Europe for combatting COVID-19 over the next two years. Looking for the fast development of products – from medical technologies to surveillance solutions - the project will boost innovation to tackle the new coronavirus, reinforcing Europe's technological leadership, and invigorating an industrial sector capable of protecting citizens' safety and well-being.

The recently launched 6.1 million Euro project INNO4COV-19, funded by the European Commission (grant agreement no. 101016203), will support the marketing of new products to combat COVID-19 over the next two years, throughout Europe. The Fraunhofer Institute for Organic Electronics, Electron Beam and Plasma Technology FEP is contributing its know-how in sterilization using accelerated electrons and on near-to-eye visualization.

The €6.1 million project INNO4COV-19 is committed to supporting the commercialization of new products across Europe for combatting COVID-19 over the next two years. Looking for the fast development of products – from medical technologies to surveillance solutions - the project will boost innovation to tackle the new coronavirus, reinforcing Europe's technological leadership, and invigorating an industrial sector capable of protecting citizens' safety and well-being.

Officially starting on October 1, the virtual kick-off took place on October 6 – 7, counting with the support of two European Commission officers.

The 11-partner consortium led by INL – International Iberian Nanotechnology Laboratory, is looking for efficient and fast solutions that can help in the fight against COVID-19 jointly with the other actively involved industrial and RTO partners.

The mission of INNO4COV-19 is to create a “lab-to-fab” platform and a collaboration resource where companies and reference laboratories will find the tools for developing and implementing innovative technologies – from idea assessment to market exploitation. This work will be carried out as part the European Union Coronavirus initiative and in strong collaboration with all the funded projects where to accelerate the time to market for any promising product.

INNO4COV-19 is set to assist up to 30 test cases and applications from several areas spanning from Medical technologies, Environmental Surveillance systems, Sensors, Protection of Healthcare workers and Artificial Intelligence and Data mining. To achieve this, INNO4COV-19 is awarding half of the budget to support 30 enterprises selected through a set number of open calls during the first year of the project.

The first call will be launched in November 2020 across several platforms. Awardees will receive up to €100,000 each and benefit from the INNO4COV-19 consortium's technical, regulatory, and business expertise.

Roll-to-Roll Equipment and Electron Beam Technology for Large Area Sterilization of textile materials
During pandemic events like COVID-19, MERS, SARS or Ebola a substantial shortage of sterile materials for medical uses was observed due to peak demands. Fraunhofer FEP will contribute their roll-to-roll equipment and electron beam technology for the purpose of large area sterilization of textile materials to the INNO4COV-19 project.

Usually the textile material is produced in non-sterile conditions and therefore must be sterilized before being delivered to the consumers (e. g. hospitals); Sterilization at product level (sterilizing the final manufactured masks) is limited in throughput, due to a high number of individual small pieces, that must be sterilized.

Project manager Dr. Steffen Günther of Fraunhofer FEP explains the role and aims of the institute in more detail: “INNO4COV-19 will establish and verify a process chain for high throughput (4500 m²/h) electron beam sterilization of fabric material in roll-form in a single TRL 7 pilot machine to allow efficient manufacturing of sterile face masks and other fabric based sterile products without the need to sterilize the final product.”

OLED Microdisplays for Detecting Infected People
Another topic of Fraunhofer FEP within INNO4COV-19 deals with the earliest possible detection of infected people. A widely used strategy to early identify individuals with disease symptoms is body temperature screening using thermal cameras.

One possibility to allow continuous body temperature monitoring, is the integration of a thermal camera into a smart wearable device. Therefore, Fraunhofer FEP is using their OLED microdisplay technology. This allows small (< 3 × 2 cm²), ultrathin (< 5 mm including control circuitry) and ultra-low power (< 5 mW) devices to show visual information. In combination with an infrared sensor a thermal imager will be realized to both measure body temperature and directly displays the result via near-to-eye visualization. The system can be embedded within smart glasses, hats, caps or personal face shields.

About INNO4COV-19 project:
Website: www.inno4cov19.eu
Please contact: info@inno4cov19.eu

 

Source:

Fraunhofer Institute for Organic Electronics, Electron Beam and Plasma Technology FEP