Grantee Research Project Results
2016 Progress Report: Developing Sustainable Products Using Renewable Cellulose Fiber and Biopolymer Composites
EPA Grant Number: SU835733Title: Developing Sustainable Products Using Renewable Cellulose Fiber and Biopolymer Composites
Investigators: Lee, Young-A , Xiang, Chunhui , Wen, Zhiyou , Nam, Changhyun , Li, Rui
Current Investigators: Lee, Young-A , Xiang, Chunhui , Madbouly, Samy , Wen, Zhiyou , Farr, Cheryl , Nam, Changhyun , Li, Rui , Ramasubramanian, Gauri , Ghalachyan, Armine
Institution: Iowa State University
EPA Project Officer: Hahn, Intaek
Phase: II
Project Period: September 1, 2014 through August 31, 2016 (Extended to August 31, 2017)
Project Period Covered by this Report: September 1, 2015 through August 31,2016
Project Amount: $90,000
RFA: P3 Awards: A National Student Design Competition for Sustainability Focusing on People, Prosperity and the Planet - Phase 2 (2014) Recipients Lists
Research Category: P3 Challenge Area - Sustainable and Healthy Communities , P3 Challenge Area - Chemical Safety , Sustainable and Healthy Communities
Objective:
For the textiles and apparel industry, sustainability is a technical challenge on many different levels. First is the challenge of providing raw materials, fibers, as a sustainable process. The technical challenges can best be explained by the example of cotton. Consumers like the feel of cotton and other cellulosic fibers. Historically, cotton and other natural cellulosic (plant) fibers require cultivation processes that use petrochemical powered equipment, large quantities of water for irrigation, chemical fertilizers, pesticides and herbicides. Although organic production is increasing, challenges related to cellulosic fiber production remain an environmental challenge. Second is the challenge of sustainable process for the conversion of raw materials, fibers, into fabrics. Processing cellulosic fiber into fabrics is a high-energy consumption process because of the use of power equipment for spinning and weaving or knitting. Third is the challenge of design and production process that eliminate or minimize waste; and, at the same time, optimize the potential for textile product recycling. The environmental damage begins with design that does not plan for recycling. Fourth, there has been little exploration of alternative sources for fibers and fiber production. Fifth, the apparel industry has contributed to environmental damage through the disposal of post-production waste, the scraps remaining after the cut and sew operations.
One option to address these problems is to utilize a naturally occurring cellulosic fiber production method that grows cellulosic fibers in the form of a mat-like layer that can be utilized as a textile fabric as a leather-like non-woven. Thus, processing into yarns and forming fabric is not necessary. The Phase I project results proved us the concept that there is an optimal method to develop cellulose-based biocomposite materials, which have low moisture absorbent and good tensile strength.
Therefore, our objectives (scope of work) of Phase II project included to: 1) identify optimal solution by developing best conditioned cellulose-based biocomposites to have low moisture regains and good tensile strength, standardizing cellulose fiber mat growing process, and evaluating the materials to meet a commercial use; 2) design apparel or apparel-related products by linking with the Midwest-based apparel (or other product-related) company; and 3) evaluate the product made of the biocomposite materials and impact of the product on the promotion of sustainable apparel using a survey, focus group and wear test.
Progress Summary:
Measurable outcomes in this project include:
- Developing an optional method to produce sustainable composites
- Producing several prototypes made from the cellulose fiber mat composites;
- Conducting human wear testing of the prototype;
- Conducting focus group discussion;
- Conducting survey to explore consumer's perception toward the use of the composites in apparel design;
- Producing manuscripts and conference presentations that detail work completed for the study;
- Producing instructional materials with video tutorials for use in the classroom; and,
- Disseminating instructional materials on an educational public website.
During this project time period, we emphasized our work for the above (1), (2), (5), and (6).
Outcome 1: Optimization of Cellulose Fiber Mat Growing Process
- With the purpose of reducing bacteria cellulose (BC)'s moisture absorbency, we experimented a method of modifying BC by incorporating commercially available bio-based sustainable films during its growing process. Five film samples were placed on the surface of the tea medium prepared for BC growth that were left to grow for three weeks in a static condition. The experimental results showed that the selected films could not be incorporated with BC as they prevented adequate airflow and inhibited BC growth. Further experiments should be conducted using more porous and breathable films. Incorporating commercially available bio-based films could be one of efficient ways for enhancing BC to make it viable for apparel products.
Outcome 2: Consumer acceptance survey was completed.
- Online survey was conducted to explore consumers' perception and expectation toward the use of apparel products made of green tea-based renewable cellulose fiber mats. This was for evaluating the results and success of the biocomposite materials developed and the use of these on product development, and the implementation of the mass production-based design.
- 166 individuals participated in the survey. A total of 132 valid responses were used for the data analysis. The participants had a positive perception and attitude of the cellulose material and thought it was unique and interesting. However, participants expressed concerns about the color and the texture of the material. They thought there should be more color variations and that the hard and stiff texture might cause discomfort for the wearers. The study results indicate that bacteria cellulose (BC) material has the potential to gain consumers in the future. Although participants did not perceive BC material as good as other currently available sustainable materials, they presented great interest in this material, providing ideas for its potential use like shoes, hats, accessories, packaging materials, or home furnishings (e.g., curtains). Further study should be done for further exploring the potential of BC material for a variety of products beyond apparel. Further consumer testing is also recommended involving study participant's physical inspections of BC material by conducting sensory evaluation (e.g., tactile, odor) and wear testing of apparel products made of this material.
Outcome 3: The survey participants suggested using the BC material for apparel-related products such as shoes and bags beyond apparel (vest). Sustainable shoes prototypes for men and women were developed for further testing.
Outcome 4: One of internally known footwear companies approached our research team to do collaborative work for the use of this material to an actual commercial product development, particularly shoes. Currently discussion for a mutual partnership.
Future Activities:
Continued Process & Product Optimization
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- Standardize scale-up production
- Improve material to be competitive with comparable products on the market
User Satisfaction and Product Performance Evaluation:
One doctoral student is working his dissertations on this topic.
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- Evaluate utility and performance of cellulose-based apparel and (or) its related products by conducting human wear-testing and user survey (e.g., men's shoes). It is anticipated to complete data collection no later than May 2017.
Build Industry Partnerships
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- Develop novel apparel or apparel-related products from the biocomposite material, and maximize cost effective scale-up for commercial use
- Potential industry partnerships have been identified. Series of discussions including each site visit will be occurred to identify both parties' needs and maximize the outcome of this partnership.
- Continuously explore other innovative utilities of biocomposite materials beyond apparel
Knowledge Dissemination to Public and Professionals
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- Conference presentations, journal publications, public outreach
Journal Articles:
No journal articles submitted with this report: View all 9 publications for this projectSupplemental Keywords:
science, technology, innovation, teaching resource, consumerProgress and Final Reports:
Original AbstractP3 Phase I:
Developing Sustainable Products Using Renewable Cellulose Fiber and Biopolymer Composites | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.