Second life for cotton fibre/polymer composite materials

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Banknotes printed on composite sheet material from cotton fibres and poly(amide) manufactured by Landqart are incinerated at the end of their lifespan – releasing the contained CO2. Together with research partner EPFL, we intend to turn these valuable materials into useful composites by inoculating the shredded waste with fungal mycelium, harvesting the resulting mycelium/cellulose/polyamide composite and characterizing it in order to derive further use, for example as packaging, or insulation materials. AbstractSecurity documents such as banknotes and passports made from a highly durable composite material manufactured by Landqart (LQ), consisting of cotton-based paper and poly(amide) are, at the end of their lifespan, shredded and incinerated – releasing the CO2 contained in the materials. Within this call, we have, together with research partner EPFL (Prof. Tiffany Abitbol), identified an innovative approach to give these material mixtures a second life. The idea is to inoculate the shredded cotton/polyamide composite material with fungal mycelium, growing the mycelium, and harvesting the resulting mycelium/cellulose/polyamide composite by draining, drying and compacting. The resulting material will be characterized in order to derive further use, for example as packaging materials or materials for soundproofing or insulation.Thematic FocusThe thematic focus of this project proposal is the recycling of the sheet-like composite materials used in the printing of security documents such as banknotes. Processing waste from the manufacture of these cotton/poly(amide) composite sheets as well as the documents produced thereof are, at the end of their lifecycle, shredded and incinerated, releasing the CO2 contained therein. Together with EPFL, we intend to investigate end-of-life uses of such materials that do not release the CO2 but rather repurpose the materials. Our approach is to inoculate the shredded materials with fungal mycelium, growing the mycelium by digesting some of the cellulose contained in the cotton fibres, and in turn binding the shredded particles together to form a new, useful cotton/poly(amide)/mycelium (mostly chitin/chitosan) composite that can be used for packaging, soundproofing or insulation purposes. With this, instead of releasing the CO2 contained in the materials into the atmosphere by incineration, the materials receive a second life and can fulfil a useful function for many more years. Degree of InnovationComposite materials are inherently difficult to recycle. Separation of the components is virtually impossible. With the proposed approach, we intend not to separate the components of our composite sheet material (cotton fibres and poly(amide) core), but instead to use the composite flakes as they are and turn them into a new, useful composite structure by inoculating and growing fungal mycelium to bind the flakes together. The technique of forming so-called myco-composites has so far not been used for the repurposing of composite materials, but mostly for aggregating agricultural waste such as wood chips, corn husks and the like (see for example https://www.ecovative.com/). Also, the methodology we intend to employ is growing the mycelium in a liquid (or semi-solid) system instead of a humid, but solid system. This not only has the advantage of faster mycelium growth which is important for reasons of efficiency, but is also more in line with our industrial papermaking procedures. The group of Prof. Tiffany Abitbol at EPFL is the only research group within Switzerland specialized in mycelium composites (an impression of her work can be obtained from one of her presentations here: https://vimeo.com/559719727), but as she has only relocated to Switzerland in May, she could not participate in the co-creation workshop. To Landqart, the workshop was beneficial in that it made clear that the approach of turning the waste materials into myco-composite structures is truly unique and innovative and that a cooperation with Prof. Abitbol will be the right way forward to further investigate this disruptive approach of recycling composite materials. EffectSustainability is a topic of increasing importance in the banknote and security printing industry. Central banks are very aware of the importance and seek sustainable solutions. For example, the Swiss National Bank has recently published a life cycle assessment of their banknotes, to be found here: https://www.snb.ch/en/iabout/cash/cash_lifecycle/id/cash_lifecycle_ecoAs per this report, “the lifespan of ninth-series banknotes is longer because of their improved mechanical resilience” (p. 8), which is an effect of the composite structure. However, the report also states that “because of the use of polymers and higher-quality cotton raw materials, the ninth banknote series has a significantly larger environmental footprint than the eighth”. If this environmental footprint could be reduced by recycling rather than incinerating the banknotes at their end of life, this would make a strong argument for the use of Landqart’s highly durable composite material in the international market.The potential to reduce CO2 emissions will be assessed during the project with the help of the recommended external experts. What can already be said is that a typical lot size for this product is in the range of 20-100 tons and that the manufacturing line has a yearly capacity of 2000-2500 tons, and that the composite product consists of roughly 75% cotton-based paper and 25% poly(amide). Methodological qualityThe funds are solely used to finance the work with research partner EPFL on this specific topic (see financial plan/budget below). Gender and diversityTiffany Abitbol is a female professor within the Institute of Materials at EPFL. Part of the work in this project will be carried out by one of her master students. Male and female students will be given equal opportunity to qualify for this project. The project is a cooperation between an industry partner in the (south-eastern) German speaking part of Switzerland together with a research institution in the (western) French speaking part of Switzerland. Scope and TasksThe scope of this project is to investigate to what extent shredded waste of the aforementioned cotton/polyamide composite can be turned into useful products by converting it into myco-composites. It is a feasibility study for which the implementation partner Landqart AG depends on the know-how and expertise of research partner EPFL. The project will be structured in the four work packages outlined below, each work package is a close cooperation between the two partners with one being the responsible partner in the lead of the respective work package. Work Package 1: Investigation of different fungal species. Responsible: EPFLInoculation of shredded banknote waste with different fungal species in a semi-liquid medium. Preferred species are Pleurotus ostreatus, the model system that preliminary work has been performed on; Schizophyllum commune, a species with promising preliminary results showing exceptionally fast growth, and Ganoderma lucidum, a species with high affinity to cellulosic substrates. Work Package 2: Pre- and Post-Processing. Responsible: LQPre-Processing: Different qualities of Banknote waste will be processed in different forms as input for WP1. These may include unprinted process waste from substrate production as well as shredded banknote waste from circulated banknotes (end-of-life), in different forms such as flakes, fine-cut strips, pellets.Post-Processing: The inoculated / mycelium infiltrated mixtures from WP1 will be drained of the water phase in Landqart’s paper making lab (on a lab-sheet former), dried in a drying oven and optionally compacted in a hot press. Work Package 3: Characterization. Responsible: LQThe different materials obtained from the different starting materials, fungal species, and post-processing routes will be characterized for their properties in Landqart’s QC and R&D labs and externally with a dedicated test laboratory. Work Package 4: Potential way forward. Responsible: EPFLBased on the results of the previous work packages, the most promising re-use paths for banknote waste will be proposed. Budget paid for by grant paid for by LQWork hours EPFL – Prof. Abitbol: 24 weeks / 5%, 50.4h @92_______4636Work hours EPFL – Master student: 24 weeks / 25%, 252h @48_____12096Work hours LQ – Project Manager: 24 weeks / 10%, 100.8 h @92_________________9273Work hours LQ – Lab Assistant: 24 weeks / 25%, 252h @48___________________12096Materials __________500 __________500Shipping cost __________500Travel ___________500External testing __________5000Miscellaneous __________1000_________1000Mandatory assessment of CO2 reduction w. experts____________100020% contribution to NTN IB @25kCHF _______________________5000 Total ________________25232_______ 27869 Based on the above budget, we are applying for 25kCHF of seed money by the NTN Innovation Booster. Co-FundingLandqart AG will act as implementation partner and pay the financial contribution of 20% of the seed money (10% to the NTN Innovation Booster and 10% into the project). Also, work hours and expense items by Landqart will be a contribution to the project and not be financed by the seed money from the NTN Innovation Booster. Lead OrganizationAs Prof. Tiffany Abitbol has only relocated to EPFL in May, only Landqart AG has qualified by submitting the project proposal and attending the co-creation workshop. Thus, Landqart will be the lead organization in this project.

Project Idea Metadata

• Project Idea Name: Second life for cotton fibre/polymer composite materials
• Date: 3/31/2022 12:12:06 PM
• Administrators:

Project Idea Description

Abstract

Security documents such as banknotes and passports made from a highly durable composite material manufactured by Landqart (LQ), consisting of cotton-based paper and poly(amide) are, at the end of their lifespan, shredded and incinerated – releasing the CO₂ contained in the materials. Within this call, we have, together with research partner EPFL (Prof. Tiffany Abitbol), identified an innovative approach to give these material mixtures a second life. The idea is to inoculate the shredded cotton/polyamide composite material with fungal mycelium, growing the mycelium, and harvesting the resulting mycelium/cellulose/polyamide composite by draining, drying and compacting. The resulting material will be characterized in order to derive further use, for example as packaging materials or materials for soundproofing or insulation.

Thematic Focus

The thematic focus of this project proposal is the recycling of the sheet-like composite materials used in the printing of security documents such as banknotes. Processing waste from the manufacture of these cotton/poly(amide) composite sheets as well as the documents produced thereof are, at the end of their lifecycle, shredded and incinerated, releasing the CO₂ contained therein. Together with EPFL, we intend to investigate end-of-life uses of such materials that do not release the CO₂ but rather repurpose the materials. Our approach is to inoculate the shredded materials with fungal mycelium, growing the mycelium by digesting some of the cellulose contained in the cotton fibres, and in turn binding the shredded particles together to form a new, useful cotton/poly(amide)/mycelium (mostly chitin/chitosan) composite that can be used for packaging, soundproofing or insulation purposes. With this, instead of releasing the CO₂ contained in the materials into the atmosphere by incineration, the materials receive a second life and can fulfil a useful function for many more years.

Degree of Innovation

Composite materials are inherently difficult to recycle. Separation of the components is virtually impossible. With the proposed approach, we intend not to separate the components of our composite sheet material (cotton fibres and poly(amide) core), but instead to use the composite flakes as they are and turn them into a new, useful composite structure by inoculating and growing fungal mycelium to bind the flakes together. The technique of forming so-called myco-composites has so far not been used for the repurposing of composite materials, but mostly for aggregating agricultural waste such as wood chips, corn husks and the like (see for example https://www.ecovative.com/). Also, the methodology we intend to employ is growing the mycelium in a liquid (or semi-solid) system instead of a humid, but solid system. This not only has the advantage of faster mycelium growth which is important for reasons of efficiency, but is also more in line with our industrial papermaking procedures. The group of Prof. Tiffany Abitbol at EPFL is the only research group within Switzerland specialized in mycelium composites (an impression of her work can be obtained from one of her presentations here: https://vimeo.com/559719727), but as she has only relocated to Switzerland in May, she could not participate in the co-creation workshop. To Landqart, the workshop was beneficial in that it made clear that the approach of turning the waste materials into myco-composite structures is truly unique and innovative and that a cooperation with Prof. Abitbol will be the right way forward to further investigate this disruptive approach of recycling composite materials.

Effect

Sustainability is a topic of increasing importance in the banknote and security printing industry. Central banks are very aware of the importance and seek sustainable solutions. For example, the Swiss National Bank has recently published a life cycle assessment of their banknotes, to be found here: https://www.snb.ch/en/iabout/cash/cash_lifecycle/id/cash_lifecycle_eco

As per this report, “the lifespan of ninth-series banknotes is longer because of their improved mechanical resilience” (p. 8), which is an effect of the composite structure. However, the report also states that “because of the use of polymers and higher-quality cotton raw materials, the ninth banknote series has a significantly larger environmental footprint than the eighth”. If this environmental footprint could be reduced by recycling rather than incinerating the banknotes at their end of life, this would make a strong argument for the use of Landqart’s highly durable composite material in the international market.

The potential to reduce CO₂ emissions will be assessed during the project with the help of the recommended external experts. What can already be said is that a typical lot size for this product is in the range of 20-100 tons and that the manufacturing line has a yearly capacity of 2000-2500 tons, and that the composite product consists of roughly 75% cotton-based paper and 25% poly(amide).

Methodological quality

The funds are solely used to finance the work with research partner EPFL on this specific topic (see financial plan/budget below).

Gender and diversity

Tiffany Abitbol is a female professor within the Institute of Materials at EPFL. Part of the work in this project will be carried out by one of her master students. Male and female students will be given equal opportunity to qualify for this project. The project is a cooperation between an industry partner in the (south-eastern) German speaking part of Switzerland together with a research institution in the (western) French speaking part of Switzerland.

Scope and Tasks

The scope of this project is to investigate to what extent shredded waste of the aforementioned cotton/polyamide composite can be turned into useful products by converting it into myco-composites. It is a feasibility study for which the implementation partner Landqart AG depends on the know-how and expertise of research partner EPFL. The project will be structured in the four work packages outlined below, each work package is a close cooperation between the two partners with one being the responsible partner in the lead of the respective work package.

Work Package 1: Investigation of different fungal species. Responsible: EPFL

Inoculation of shredded banknote waste with different fungal species in a semi-liquid medium. Preferred species are Pleurotus ostreatus, the model system that preliminary work has been performed on; Schizophyllum commune, a species with promising preliminary results showing exceptionally fast growth, and Ganoderma lucidum, a species with high affinity to cellulosic substrates.

Work Package 2: Pre- and Post-Processing. Responsible: LQ

Pre-Processing: Different qualities of Banknote waste will be processed in different forms as input for WP1. These may include unprinted process waste from substrate production as well as shredded banknote waste from circulated banknotes (end-of-life), in different forms such as flakes, fine-cut strips, pellets.

Post-Processing: The inoculated / mycelium infiltrated mixtures from WP1 will be drained of the water phase in Landqart’s paper making lab (on a lab-sheet former), dried in a drying oven and optionally compacted in a hot press.

Work Package 3: Characterization. Responsible: LQ

The different materials obtained from the different starting materials, fungal species, and post-processing routes will be characterized for their properties in Landqart’s QC and R&D labs and externally with a dedicated test laboratory.

Work Package 4: Potential way forward. Responsible: EPFL

Based on the results of the previous work packages, the most promising re-use paths for banknote waste will be proposed.

Budget

paid for by grant paid for by LQ

Work hours EPFL – Prof. Abitbol: 24 weeks / 5%, 50.4h @92_______4636

Work hours EPFL – Master student: 24 weeks / 25%, 252h @48_____12096

Work hours LQ – Project Manager: 24 weeks / 10%, 100.8 h @92_________________9273

Work hours LQ – Lab Assistant: 24 weeks / 25%, 252h @48___________________12096

Materials __________500 __________500

Shipping cost __________500

Travel ___________500

External testing __________5000

Miscellaneous __________1000_________1000

Mandatory assessment of CO₂ reduction w. experts____________1000

20% contribution to NTN IB @25kCHF _______________________5000

Total ________________25232_______ 27869

Based on the above budget, we are applying for 25kCHF of seed money by the NTN Innovation Booster.

Co-Funding

Landqart AG will act as implementation partner and pay the financial contribution of 20% of the seed money (10% to the NTN Innovation Booster and 10% into the project). Also, work hours and expense items by Landqart will be a contribution to the project and not be financed by the seed money from the NTN Innovation Booster.

Lead Organization

As Prof. Tiffany Abitbol has only relocated to EPFL in May, only Landqart AG has qualified by submitting the project proposal and attending the co-creation workshop. Thus, Landqart will be the lead organization in this project.

Banknotes printed on composite sheet material from cotton fibres and poly(amide) manufactured by Landqart are incinerated at the end of their lifespan – releasing the contained CO2. Together with research partner EPFL, we intend to turn these valuable materials into useful composites by inoculating the shredded waste with fungal mycelium, harvesting the resulting mycelium/cellulose/polyamide composite and characterizing it in order to derive further use, for example as packaging, or insulation materials.