Sugar-Based Biopolymers and their application in textiles

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This project aims to evaluate if melt spinning of fibres on Sugar-Based Biopolymers and their application in textiles will be possible and which modification of the polymer would be necessary to find a entry into textile applications. Thematic focusMost of the plastic products in our daily life are made out of fossil resources. This causes harm to the natural environment as plastic production emits a lot of greenhouse gases, and a high volume of the plastic waste is encountered in nature or found in the oceans. Bioplastics are promising materials to reduce the environmental impact of plastic products as they encompass both bio-based and biodegradable materials. This confers them the advantage of avoiding CO2 emissions and being less polluting. Bloom has prepared new polymers which are part of a new family of bioplastics, called poly(alkylxylose), and made from non-edible lignocellulosic sugar. This family of biopolymers has several advantages: i) they are 100% bio-based and thus only contain biogenic carbon, ii) their barrier properties are comparable to commercial polymers, iii) it is fully chemically and mechanically recyclable, and iv) its biodegradability in water makes it the first kind of polyester which does not lead to a build-up of micro- or nano-plastics as it degrades within months. Especially the latter sets this polymer apart from currently available solutions and makes it an ideal candidate for the textile industry which needs to innovate on the end-of-life of synthetic garments. ON AG is one of the most innovative textile companies in the world with a focus on sustainability and circularity. The main goals of ON’s sustainability strategy is reducing the use of fossil resources by implementing recycled and recyclable materials in products. Further to reduce our CO2 footprint. ON AG has joined the “Science Based Targets” initiative which commits to reducing the CO2 emissions to a level that will support the limiting of average global temperature rising to 1.5°C (34.7°F) above pre-industrial levels. A study conducted by the McKinsey Center for Business and Environment has shown that a more circular economy has the potential to reduce carbon emissions in Europe, India and China by 22 - 44% by 2050. Therefore, our project not only reduces waste, it also responds to the wider challenges our planet faces like biodiversity loss, pollution and CO2 reduction. The objective is to engineer a textile based on natural resources (sugar residues) a tuneable end-of-life. This project aims to evaluate if melt spinning of fibres will be possible and which modification of a specific polymer from the PAX family, namely poly(butylene xylosediglyoxylate) (PBX), would be necessary to find an entry into textile applications. Degree of innovationThe novelty of the approach is that the polymer to be used to make textiles is completely new and has multiple advantages compared to existing materials (as mentioned above). The creation of a fibre which is chemically recyclable and biodegradable in marine environments would constitue a first of a kind for the textile industry. In addition, this project covers all aspects of the product development: end user knowhow / demand, processing and polymer formulation. Up to know no knowledge, publication exists about spinning of PBX fibers and their performance and this project evaluates the feasibility and creation of a prototype for further interactions between the partners. The idea was initiated by Bloom Biorenewables and ON. The team was extended by the FHNW and was further refined during the Co-creation workshop. EffectThe industry is responsible for making the production as efficient as possible by using the most efficient techniques (BAT) and making use of best available technologies. The origin of the raw materials is traditionally divided as: natural (cotton, wool, flax, silk, hemp etc), synthetic (polyester, polyamide, polypropylene, acrylics etc) or man-made bio-based (cellulosic fibres). In the textile sector, different types of raw materials have their own environmental and social impacts. For circularity, durable fibres are needed to achieve recyclability, however mechanical and chemical recycling technologies provide for different approaches and solutions.As mentioned above, ON has set its targets extremely high in terms of sustainability and circularity of their products and are at the forefront of innovative design, materials, and manufacturing. Bloom’s biopolymer can provide a competitive advantage to ON and thus allow for economic growth from a renewable and sustainable material. For Bloom, the ability to create a prototype with an innovative and large player in the textile industry would allow to gather necessary market traction for the closure of its Series A financing round planned for 2025. In addition, should this feasibility study lead to a positive outcome, further agreements between ON and Bloom will be discussed for follow up development studies and concrete off-take agreements. Preliminary estimates have shown that the production of the PAX-family monomer, called dimethyl glyoxylate xylose (DMGX), has a reduced global warming potential compared to the synthesis of fossil fuel based terephthalic acid (L. Manker et al, 2021, ChemRxiv). Further refinements of this model are being performed by Bloom, but the preliminary data already clearly shows the advantages of this monomer compared to currently established commodity monomers. Methodological qualityThe funds will be used by FHNW to enable melt spinning of selected PBX polymers. The PBX polymers will be synthesised and provided by Bloom according to the specifications and experience by ON and FHNW. First spinning trials will be performed, initial fibres will be processed, characterised, and compared to the requirements of ON. Through continuous discussions, further refinements of the polymer formulation or properties will be performed by Bloom. The ability to draw fibres with suitable characteristics for the textile industry will be the basis for further developments and further innovation projects or joint developments including all partners. Gender and DiversityBoth ON and Bloom Biorenewables are driving towards a sustainable material future, to which a sustainable and diverse team structure is key. Bloom, for example, has a balanced male-female employee ratio within its global structure. It just so happens, that in this project the contact points for each partner are male: · Jean-Philippe Romain, On· Philip Scholten, Bloom· Prof. Dr. Christian Brauner Further people involved in the project:- Bloom: Chloé Wegman, Monique Figueirêdo- FHNW : Delal Arslan Scope and TasksThe scope of the project is very product and market-need focussed as it aims to demonstrate the feasibility of melt spinning PBX into fibres suitable for the project partner ON active in the textile market. The whole supply chain and knowledge necessary for the success of this project is covered by the partners in this consortium. In accordance iwht the expertise of each partner, the work packages are split as follows: WP1: Definition of fibre requirements and specification for textile market (ON)WP2: Selection of polymer formulation, initial characterisation, improvement of formulation according to results from WP3 (BLOOM, FHNW)WP3: Initial melt spinning of fibers, characterisation of these fibers (FHNW)WP4: Discussion of results, drafting of further steps along the supply chains (ON) and for polymer development (BLOOM) In order to reach the goals of this project, WP2 and WP3 need to be completed. These two will allow to evaluate the feasibility of making fibres from this Budget and Co-FundingNo, not needed as a life cycle assessment has already been performed for the monomer synthesis. We would ask for 25000CHF funding which will be used by FHNW (WP 2,3). 20% of the third-party contribution will be paid by ON.

Project Idea Metadata

• Project Idea Name: Sugar-Based Biopolymers and their application in textiles
• Date: 3/18/2022 8:29:01 AM
• Administrators:
  • Christian Brauner

Project Idea Description

Thematic focus

Most of the plastic products in our daily life are made out of fossil resources. This causes harm to the natural environment as plastic production emits a lot of greenhouse gases, and a high volume of the plastic waste is encountered in nature or found in the oceans. Bioplastics are promising materials to reduce the environmental impact of plastic products as they encompass both bio-based and biodegradable materials. This confers them the advantage of avoiding CO2 emissions and being less polluting. Bloom has prepared new polymers which are part of a new family of bioplastics, called poly(alkylxylose), and made from non-edible lignocellulosic sugar. This family of biopolymers has several advantages: i) they are 100% bio-based and thus only contain biogenic carbon, ii) their barrier properties are comparable to commercial polymers, iii) it is fully chemically and mechanically recyclable, and iv) its biodegradability in water makes it the first kind of polyester which does not lead to a build-up of micro- or nano-plastics as it degrades within months. Especially the latter sets this polymer apart from currently available solutions and makes it an ideal candidate for the textile industry which needs to innovate on the end-of-life of synthetic garments.

ON AG is one of the most innovative textile companies in the world with a focus on sustainability and circularity. The main goals of ON’s sustainability strategy is reducing the use of fossil resources by implementing recycled and recyclable materials in products. Further to reduce our CO2 footprint. ON AG has joined the “Science Based Targets” initiative which commits to reducing the CO2 emissions to a level that will support the limiting of average global temperature rising to 1.5°C (34.7°F) above pre-industrial levels. A study conducted by the McKinsey Center for Business and Environment has shown that a more circular economy has the potential to reduce carbon emissions in Europe, India and China by 22 - 44% by 2050.

Therefore, our project not only reduces waste, it also responds to the wider challenges our planet faces like biodiversity loss, pollution and CO2 reduction. The objective is to engineer a textile based on natural resources (sugar residues) a tuneable end-of-life.

This project aims to evaluate if melt spinning of fibres will be possible and which modification of a specific polymer from the PAX family, namely poly(butylene xylosediglyoxylate) (PBX), would be necessary to find an entry into textile applications.

Degree of innovation

The novelty of the approach is that the polymer to be used to make textiles is completely new and has multiple advantages compared to existing materials (as mentioned above). The creation of a fibre which is chemically recyclable and biodegradable in marine environments would constitue a first of a kind for the textile industry. In addition, this project covers all aspects of the product development: end user knowhow / demand, processing and polymer formulation. Up to know no knowledge, publication exists about spinning of PBX fibers and their performance and this project evaluates the feasibility and creation of a prototype for further interactions between the partners.

The idea was initiated by Bloom Biorenewables and ON. The team was extended by the FHNW and was further refined during the Co-creation workshop.

Effect

The industry is responsible for making the production as efficient as possible by using the most efficient techniques (BAT) and making use of best available technologies. The origin of the raw materials is traditionally divided as: natural (cotton, wool, flax, silk, hemp etc), synthetic (polyester, polyamide, polypropylene, acrylics etc) or man-made bio-based (cellulosic fibres). In the textile sector, different types of raw materials have their own environmental and social impacts. For circularity, durable fibres are needed to achieve recyclability, however mechanical and chemical recycling technologies provide for different approaches and solutions.

As mentioned above, ON has set its targets extremely high in terms of sustainability and circularity of their products and are at the forefront of innovative design, materials, and manufacturing. Bloom’s biopolymer can provide a competitive advantage to ON and thus allow for economic growth from a renewable and sustainable material. For Bloom, the ability to create a prototype with an innovative and large player in the textile industry would allow to gather necessary market traction for the closure of its Series A financing round planned for 2025. In addition, should this feasibility study lead to a positive outcome, further agreements between ON and Bloom will be discussed for follow up development studies and concrete off-take agreements.

Preliminary estimates have shown that the production of the PAX-family monomer, called dimethyl glyoxylate xylose (DMGX), has a reduced global warming potential compared to the synthesis of fossil fuel based terephthalic acid (L. Manker et al, 2021, ChemRxiv). Further refinements of this model are being performed by Bloom, but the preliminary data already clearly shows the advantages of this monomer compared to currently established commodity monomers.

Methodological quality

The funds will be used by FHNW to enable melt spinning of selected PBX polymers. The PBX polymers will be synthesised and provided by Bloom according to the specifications and experience by ON and FHNW. First spinning trials will be performed, initial fibres will be processed, characterised, and compared to the requirements of ON. Through continuous discussions, further refinements of the polymer formulation or properties will be performed by Bloom. The ability to draw fibres with suitable characteristics for the textile industry will be the basis for further developments and further innovation projects or joint developments including all partners.

Gender and Diversity

Both ON and Bloom Biorenewables are driving towards a sustainable material future, to which a sustainable and diverse team structure is key. Bloom, for example, has a balanced male-female employee ratio within its global structure. It just so happens, that in this project the contact points for each partner are male:

· Jean-Philippe Romain, On

· Philip Scholten, Bloom

· Prof. Dr. Christian Brauner

Further people involved in the project:

- Bloom: Chloé Wegman, Monique Figueirêdo

- FHNW : Delal Arslan

Scope and Tasks

The scope of the project is very product and market-need focussed as it aims to demonstrate the feasibility of melt spinning PBX into fibres suitable for the project partner ON active in the textile market. The whole supply chain and knowledge necessary for the success of this project is covered by the partners in this consortium. In accordance iwht the expertise of each partner, the work packages are split as follows:

WP1: Definition of fibre requirements and specification for textile market (ON)

WP2: Selection of polymer formulation, initial characterisation, improvement of formulation according to results from WP3 (BLOOM, FHNW)

WP3: Initial melt spinning of fibers, characterisation of these fibers (FHNW)

WP4: Discussion of results, drafting of further steps along the supply chains (ON) and for polymer development (BLOOM)

In order to reach the goals of this project, WP2 and WP3 need to be completed. These two will allow to evaluate the feasibility of making fibres from this

Budget and Co-Funding

No, not needed as a life cycle assessment has already been performed for the monomer synthesis.

We would ask for 25000CHF funding which will be used by FHNW (WP 2,3). 20% of the third-party contribution will be paid by ON.

This project aims to evaluate if melt spinning of fibres on Sugar-Based Biopolymers and their application in textiles will be possible and which modification of the polymer would be necessary to find a entry into textile applications.