Grantee Research Project Results
2015 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 , Madbouly, Samy , Wen, Zhiyou , Ghalachyan, Armine , Li, Rui , Nam, Changyun
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, 2014 through August 31,2015
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 by linking with the Midwest-based apparel (or other product) 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 included and will include:
(1) Developing an optional method to produce sustainable composites
(2) Producing several prototypes made from the cellulose fiber mat composites;
(3) Conducting human wear testing of the prototype;
(4) Conducting focus group discussion;
(5) Conducting survey to explore consumer's perception toward the use of the composites in apparel design;
(6) Producing manuscripts and conference presentations that detail work completed for the study;
(7) Producing instructional materials with video tutorials for use in the classroom; and,
(8) Disseminating instructional materials on an educational public website.
Outcome 1: Optimization of Cellulose Fiber Mat Growing Process
- Experiment to identify optimal temperature for cellulose fiber mat growth
− Tested 35o, 30o, 25o, 20o C conditions: 25-30oC produced the best cellulose, considering cellulose uniformity, appearance, thickness and weight.
- Experiment to identify optimal combination of ingredients for cellulose growth using central composite design
− Based on preliminary results, increasing tea and vinegar amounts resulted in better growth. Also, sugar amount might be reduced.
− Sugar concentration analysis: Exploring the influence of sugar concentration on cellulose fiber mat growing process
- Experiment to use leftover sweetened iced tea from the campus dining facilities, which minimize the use of consumable ingredients. The results revealed that iced tea could be used for growing cellulose; however, more experiments are necessary to confirm the finding.
Outcome 2: Improving Material Properties and Material Testing
- Experiment with cellulose microcrystals for improving mechanical properties
- Reducing the level of water absorbency
− Material samples were treated with commercially available waterproofing products and tested for water absorbency (AATCC 79-2007 method) and water repellency (spray test method, AATCC 22-2005)
− Air permeability was measured according to ASTM D737-04 test method for untreated/control cellulose mats and treated cellulose mats (coated with Clear Coat as this was found to offer effective water repellency). Treated mats had higher air permeability. While the average permeability for untreated cellulose mat was approximately 0.3cm3/cm2/S, the average of treated mat was approximately 9.9 cm3/cm2/s. However there was a lot of variance between the samples tested (individual sample results: 14.4, 22.8, 1.78, 0.47cm3/cm2/s). This could be because of the uneven surface of the material.
- Material dyeing using natural waste sources
− Yellow and red onion peels as well as leftover coffee grounds were used for dying
− Mordant use results in more vibrant color
Outcome 3: Consumer Survey
− 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, in the 2-year Phase II project.
− 86 individuals participated in the survey had a positive perception of the cellulose material and thought it was unique and interesting. Most 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 results indicated a need for further study where participants will have the opportunity to physically inspect the material.
Outcome 4: Apparel Development (men's sleeveless jacket) using zero waste approach
Outcome 5: Initiated industry partnerships with Iowa-based Kombucha health drink company
Future Activities:
Conclusions:
Continued Process & Product Optimization
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- Standardize scale-up production
- Improve material to be competitive with comparable products on the market
Consumer Satisfaction and Product Performance Evaluation:
Two doctoral students are working their dissertations on this topic.
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- Evaluate user/consumer satisfaction and acceptance of microbial cellulose-based products using sensory test (e.g., tactile, odor, visual)
- Evaluate utility and performance of cellulose-based apparel and its related products (wear-testing) (e.g., men's shoes)
Build Industry Partnerships
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- Develop novel apparel products from the biocomposite material, and maximize cost effective scale-up for commercial use
- Continuously build industry partnerships with local and global Midwest industries
- 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, website
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.