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Synthetic leather made from recyclable and bio-based PBS Photo: DITF
10.06.2024

Synthetic leather made from recyclable and bio-based PBS

A new type of pure synthetic leather meets the requirements of the European Ecodesign Regulation. Made from a bio-based plastic, it is biodegradable and meets the requirements for a closed recycling process.

A new type of pure synthetic leather meets the requirements of the European Ecodesign Regulation. Made from a bio-based plastic, it is biodegradable and meets the requirements for a closed recycling process.

Many synthetic leathers consist of a textile substrate to which a polymer layer is applied. The polymer layer usually consists of an adhesive layer and a top layer, which is usually embossed. The textile backing and the top coat are usually completely different materials. Woven, knitted, or nonwoven fabrics made of PET, PET/cotton, or polyamide are often used as textile substrates. PVC and various polyurethanes are commonly used for coatings. The use of these established composite materials does not meet today's sustainability criteria. Recycling them by type is very costly or even impossible. They are not biodegradable. The search for alternative materials for the production of artificial leather is therefore urgent. In 2022, the EU adopted the Sustainable Products Initiative (SPI) ("Green Deal"). It includes an eco-design regulation that considers a product's life cycle in the conservation of resources. For textile and product design, this means incorporating closing the loop or end-of-life into product development.

In an AiF project carried out in close cooperation between the DITF and the Freiberg Institute gGmbH (FILK), it has now been possible to develop a synthetic leather in which both the fiber material and the coating polymer are identical. The varietal purity is a prerequisite for an industrial recycling concept.

The aliphatic polyester polybutylene succinate (PBS) was recommended as the base material because of its properties. PBS can be produced from biogenic sources and is now available on the market in several grades and in large quantities. Its biodegradability has been demonstrated in tests. The material can be processed thermoplastically. This applies to both the fiber material and the coating. Subsequent product recycling is facilitated by the thermoplastic properties.

In order to realize a successful primary spinning process and to obtain PBS filaments with good textile mechanical properties, process adjustments had to be made in the cooling shaft at the DITF. In the end, it was possible to spin POY yarns at relatively high speeds of up to 3,000 m/min, which had a tenacity of just under 30 cN/tex when stretched. The yarns could be easily processed into pure PBS fabrics. These in turn were used at FILK as a textile base substrate for the subsequent extrusion coating, where PBS was also used as a thermoplastic.

With optimized production steps, PBS composite materials with the typical structure of artificial leather could be produced. Purity and biodegradability fulfill the requirements for a closed recycling process.

Source:

Deutsche Institute für Textil- und Faserforschung (DITF)

(c) Andritz
28.06.2021

ANDRITZ at ANEX/SINCE 2021

International technology Group ANDRITZ will be presenting its innovative nonwovens production and textile solutions at ANEX/SINCE 2021 in Shanghai, China, from July 22 to 24, 2021. The product portfolio covers state-of-the-art nonwovens and textile production technologies such as air-through bonding, needlepunch, spunlace, spunbond, wetlaid/Wetlace, converting, textile finishing, airlay, recycling, and bast fiber processing.

Among the largest end-use markets for nonwoven products are materials for durable uses. Interior linings for cars, materials for construction, geotextiles, synthetic leathers for clothing and furniture, carpeting, filtration and many other industries rely on the use of nonwovens produced using the needlepunch method.

International technology Group ANDRITZ will be presenting its innovative nonwovens production and textile solutions at ANEX/SINCE 2021 in Shanghai, China, from July 22 to 24, 2021. The product portfolio covers state-of-the-art nonwovens and textile production technologies such as air-through bonding, needlepunch, spunlace, spunbond, wetlaid/Wetlace, converting, textile finishing, airlay, recycling, and bast fiber processing.

Among the largest end-use markets for nonwoven products are materials for durable uses. Interior linings for cars, materials for construction, geotextiles, synthetic leathers for clothing and furniture, carpeting, filtration and many other industries rely on the use of nonwovens produced using the needlepunch method.

ANDRITZ Nonwoven’s processes play a pioneering role in the production of biodegradable materials. For many years, ANDRITZ has offered different processes, like spunlace, Wetlace and Wetlace CP, all with one goal in mind: Elimination of plastic components while maintaining the high quality of the desired product properties. Such processes achieve high performance entirely with plastic-free raw materials. The added benefit of using a blend of fibers, like wood pulp, short-cut cellulosic fibers, viscose, cotton, hemp, bamboo or linen, without chemical additives results in a 100% sustainable fabric, thus meeting customers’ needs exactly as well as supporting the strong tendency to move away from plastics and synthetics.

The latest development in this field is the ANDRITZ neXline wetlace CP line. This process combines the benefits of two forming technologies (inline drylaid and wetlaid web forming process) with bonding by hydroentanglement. Natural fibers, like pulp or viscose, can be processed smoothly and generate a high-performance and cost-efficient wipe that is fully biodegradable and plastic-free.

More information:
Andritz Andritz Nonwoven ANEX
Source:

Andritz