Grantee Research Project Results

Final Report: Transforming Agricultural Waste into Bio-based, Nontoxic, and Biodegradable Fibers and Yarns

EPA Contract Number: 68HERC25C0018
Title: Transforming Agricultural Waste into Bio-based, Nontoxic, and Biodegradable Fibers and Yarns
Investigators: Saremi, Raha
Small Business: EcoaTEX, LLC.
EPA Contact: Richards, April
Phase: I
Project Period: December 16, 2024 through June 15, 2025
Project Amount: $100,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2025) RFA Text |  Recipients Lists
Research Category: Small Business Innovation Research (SBIR)

Description:

EcoaTEX is advancing the future of high-performance, sustainable materials by transforming agricultural byproducts into engineered biodegradable fibers. This project, funded through the EPA SBIR Phase I program, successfully demonstrated the technical feasibility of producing durable, nontoxic, and environmentally responsible alternatives to conventional synthetic and natural fibers. These next-generation materials are designed to support multiple industries, including textiles, hygiene, filtration, and medical applications through circular production and safe degradation at end-of-life. Background and Challenge: The textile and materials industry is under increasing pressure to move away from petroleum[1]based synthetics and chemically intensive natural fibers. Traditional fibers such as polyester shed microplastics and rely heavily on fossil fuels, while conventional cotton demands excessive water, pesticides, and land use. These environmental burdens are compounded by public health concerns related to toxic additives, persistent pollutants, and occupational exposure. To address these challenges, EcoaTEX developed a closed-loop, green chemistry-based process that valorizes underutilized biomass into advanced materials without compromising performance, safety, or scalability.

Summary/Accomplishments (Outputs/Outcomes):

EcoaTEX’s proprietary process converts agricultural byproducts into biodegradable fibers using a non-toxic, closed-loop system. In Phase I, the team successfully extracted and functionalized cellulose, integrated nanocellulose, and evaluated its potential for high-performance fiber production. Key achievements include:

• Successful extraction of cellulose pulp from multiple agricultural waste streams using NaOH/urea treatment, enabling flexibility for different fiber applications
• Reinforcement of cellulose matrix with nanocellulose, improving tensile strength and enabling antimicrobial functionality
• Wet-spinning of prototype fibers under mild conditions with tensile strength averaging 450 MPa, within the range of commercial textile-grade fibers
• Comprehensive characterization using FTIR, XRD, ¹³C CP/MAS NMR, TGA, SEM, and EDS to confirm structural integrity, crystallinity, and surface modification
• A preliminary life cycle analysis (LCA) indicates over 90% water reuse, approximately 80% solvent recovery, and significantly reduced carbon emissions and energy inputs compared to conventional rayon and cotton fiber production.

All Phase I work was completed in the United States, leveraging domestic agricultural waste and existing manufacturing infrastructure. These results validate the feasibility of producing safe, biodegradable fibers from local feedstocks and provide a strong foundation for pilot-scale manufacturing and further functionalization in Phase II.

Public Health and Environmental Impact:

EcoaTEX fibers are designed to avoid common toxicants and pollutants. No petroleum derivatives, formaldehyde, PFAS, or heavy metals are used in the process. The fibers degrade naturally without releasing harmful microplastics or leaching chemicals into soil and water systems. This makes them ideal for use in products with direct human contact, such as wound dressings, hygiene textiles, and everyday clothing, offering a safer and healthier alternative across consumer and industrial sectors.

Commercial Potential and Market Opportunity:

There is a growing global demand for safe and sustainable materials, with the sustainable fibers and technical textiles market projected to exceed 90 billion dollars by 2030. EcoaTEX’s materials can serve multiple high-impact industries, including:

• Textiles and apparel providing biodegradable, high-strength alternatives to polyester and cotton
• Medical and hygiene products offering breathable, skin-safe, and biodegradable solutions
• Filtration and nonwoven materials, supporting air and water filtration using bio-based performance fibers
• Composites and specialty materials enabling lightweight and circular fiber integration Early outreach has shown strong interest from textile manufacturers, consumer brands, and innovation partners seeking greener, U.S.-based sourcing options.

Next Steps and Vision for Phase II:

EcoaTEX is preparing for Phase II by scaling up its biodegradable fiber production process and tailoring material properties for a wide range of commercial uses, including apparel, hygiene, filtration, and sustainable packaging. A key focus will be the development of advanced functionalities for high-performance applications such as athletic wear, outdoor gear, and technical textiles that demand strength, durability, breathability, or thermoregulatory behavior. Planned efforts include pilot-scale production runs, in-depth performance testing with industry collaborators, and a comprehensive life cycle assessment to validate the environmental and economic benefits.

Conclusions:

EcoaTEX’s Phase I project represents a major step toward reshaping the materials economy through circular, health-conscious innovation. By leveraging agricultural waste, clean chemistry, and scalable manufacturing methods, EcoaTEX is developing a new class of fibers that addresses both environmental imperatives and performance demands. With a strong foundation established through EPA SBIR support, the company is well-positioned to advance its impact and commercialization goals in Phase II and beyond.