I + D / Nanotecnología aplicada a materiales textiles. Desarrollo de fibras, hilatura y tejeduría.

Year: 2021

MOTIVATION

Industrial sectors such as textiles, packaging, automotive, construction and others, consume vast quantities of synthetic polymers, but current systems of production, distribution and use are almost completely linear, creating an unsustainable model of waste generation and accumulation (Figure 1). ^[1]Furthermore, the vast majority of synthetic polymers are designed for performance and durability, not for degradability and recyclability, which has led to a huge problem of waste accumulation in recent decades. At the end of 2018, of the 62 million tonnes produced in Europe, only 47% of post-consumer plastic waste was recovered, 43% was incinerated, 32% recycled and 25% deposited in landfills or in the environment. ^[2]

                                Figure 1: schematic representation of the conventional industrial textile system.

More specifically, the environmental impact of the textile industry has become one of today’s most worrying issues. In fact, in 2015, the global textile industry consumed approximately 79 billion m³ of water, generated 1.7 billion tonnes of CO₂ emissions (approximately 4.6% of total global carbon emissions), and was responsible for 92 million tonnes of waste. ^[3]

[1] Was Patwary, S. Consumer Clothing Behavior and Associated Environmental Impact. Preprints, 2019.

Without changes to the current industrial model, estimates indicate that these figures will increase by at least 50% by 2030. Therefore, in order to reduce the accumulation of textile waste and its environmental impact, the new European legislation (EU Directive 2018/851), included in the European Green Pact, proposes a transition from the conventional linear industrial model to a circular model, transforming waste into revalorised products at the end of its useful life.

[1] Ellen Macarthur Foundation

[2] Plastics Europe

[3] Was Patwary, S. Consumer Clothing Behavior and Associated Environmental Impact. Preprints, 2019.

OBJECTIVES

With the aim of promoting and facilitating industrial transition from the traditional linear model to the circular economy, the overall objective of the CHEMUP project is to spin yarns from:

• Biopolymers: PHB, PBS and PLA.
• Chemically recycled PET textile waste through a glycolysis process.

The expected result will be textile fibres for transformation into high value-added products at the end of their useful life.

EXPECTED RESULTS

Through CHEMUP, textile fibres will be created for transformation into high value-added products at the end of their useful life from:

• Biopolymers: textile fibres from blends of PHB, PBS and PLA will be produced by melt spinning processes to create easily compostable textiles which, at the end of their useful life, will serve as a source of nutrients for the crops used to grow new biopolymers.
• Chemically recycled PET: from PET waste, through a process of depolymerisation by glycolysis and subsequent polymerisation, the resulting virgin PET will be used in the manufacture of new meltspun textile fibres.

Therefore, based on the principles of the circular economy, the CHEMUP project will enable the production of new textile products, reducing the environmental impact of their production and disposal, and their carbon footprint.

This project is funded by the Conselleria d’Economia Sostenible, Sectors Productius, Comerç i Treball de la Generalitat Valenciana, through IVACE.

Additional Information

• Grant number: IMAMCI/2021/1

• More information: NON-ECONOMIC ACTIVITIES PLAN

• Year: 2021

• Status: In progress

• Entity: IVACE

Would you like more information about the project? Fill in the following form

I + D / Nanotecnología aplicada a materiales textiles. Desarrollo de fibras, hilatura y tejeduría.

Year: 2021

MOTIVATION

The huge leaps in the development of carbon fibre composites in recent years has made it necessary to introduce new manufacturing techniques that enable the reuse of these fibres after the end of their useful life.

Through the rGENERA project, AITEX aims to generate knowledge towards obtaining recycled carbon fibre thermoplastic composites with medium-high mechanical performance using staple fibre spinning technologies. The adaptation of these technologies will help the reindustrialisation of the staple fibre processing and spinning textile industry in the Valencian Community and in Spain, diversifying the traditional markets.

This is a broad area of research, with great potential for innovation that will contribute to implementing a new circular economy model in the composites industry, replacing the current unsustainable linear economy model and the problems of accumulation in landfills posed by this type of material.

In order to improve the processing of composite materials, rGENERA is committed to the combination of recycled carbon fibre with thermoplastic polymer fibres, which have shorter processing times and do not require controlled storage conditions. This will combine with the opportunity of dispensing with the different stages of curing and enable reprocessing, melt bonding and reuse, opening the door to new processing and production techniques not possible with the use of thermosetting resins.

OBJECTIVES

The main objective of rGENERA is the reuse of carbon fibres to create textile products which are subsequently destined for the manufacture of thermoplastic composites through carding, spinning and weaving.

In order to achieve the objective within the framework of rGENERA,, the following specific objectives are proposed:

• Optimisation of fibre opening and carding processes with recycled carbon fibre.
• Creating and optimising hybrid yarns of recycled carbon fibre and thermoplastic matrices from various staple fibre spinning processes.
• Creating and optimising recycled carbon fibre and thermoplastic matrix nonwovens using carding technology (Drylaid) and various consolidation techniques.
• Development and production of woven fabrics with different weaves from hybrid yarns of recycled carbon fibre and thermoplastic matrix.
• Development and characterisation of prototypes from thermoplastic composites based on recycled carbon fibre with the developed woven and non-woven textile structures.

EXPECTED RESULTS

The rGENERA project will produce textile structures based on recycled carbon fibres and thermoplastic fibres, which can subsequently be used to manufacture thermoplastic composites with medium-high mechanical performance.

The core of the project is the carding process by means of which the following types of textile structures can be obtained from thermoplastic fibres and recycled carbon fibres:

• Tapes and hanks for use in the development of hybrid yarns from staple fibre spinning techniques. These yarns will be woven on looms into different structures and weaves to maximise their mechanical properties.
• The production of non-woven veils, which by means of various consolidation techniques will enable the production of non-woven fabrics based on recycled carbon fibre.

The different woven and non-woven textile structures obtained will then be employed to create prototypes using thermoforming techniques, to characterise the mechanical properties of the composites obtained based on recycled carbon fibre and a thermoplastic matrix.

This project is funded by the Conselleria d’Economia Sostenible, Sectors Productius, Comerç i Treball de la Generalitat Valenciana, through IVACE.

Additional Information

• Grant number: IMAMCI/2021/1

• More information: NON-ECONOMIC ACTIVITIES PLAN

• Year: 2021

• Status: In progress

• Entity: IVACE

Would you like more information about the project? Fill in the following form

I + D / Nanotecnología aplicada a materiales textiles. Desarrollo de fibras, hilatura y tejeduría.

Year: 2021

MOTIVATION

The use of bio-based polymers is growing in many industrial sectors and the increasing demand is forcing these materials to match the performance of the most commonly used thermoplastic polymers. Their versatility makes biopolymers a marvellous alternative for introduction into current thermoplastic manufacturing processes and, over time, as a replacement for conventional polymers obtained from non-renewable resources. This will lead to a reduction in the environmental footprint of the plastics industry.

The introduction of biomaterials in manufacturing processes on an industrial scale entails having to adapt their structure to the demands and requirements of companies, additivating the structure of biopolymers is necessary to provide improved properties that guarantee their performance in the manufacture of polymeric components. Manufacturing processes such as 3D printing and industrial sectors such as textiles, where the use of biopolymers is widespread, provide information on the characteristics of the materials. Other processes such as injection moulding, where the use of biopolymers is beginning to increase, can benefit from the incorporation of these materials to manufacture high performance components with an added-value factor.

The replacement of current polymers by thermoplastics obtained from renewable resources and their rapid introduction into industry is key in the fight against climate change. The widespread use of plastics and their huge impact on the environment requires immediate action, which is why the use of biomaterials is of great importance to begin a much needed change for the planet and for people.

OBJECTIVES

The main objective of PLABITEX is to develop new biomaterials with improved properties through the incorporation of additives or other polymers, to introduce this type of material into industry.

The project has several lines of research, both of which focus on the use of PLA (Polylactic Acid) as a thermoplastic matrix.

Firstly, new materials will be developed from the additivation of PLA with various powder additives derived from metal oxides and natural antioxidants, as well as other biopolymers. These additives promise to enhance both the thermal and mechanical properties of PLA, giving it improved characteristics that will enable it to compete with other polymers obtained from non-renewable sources, which are currently much more widely used. Specifically, the PLABITEX project will focus developments on the introduction of these biomaterials in 3D printing and thermoplastic injection processes, with the aim of producing functional components on an industrial scale.

The use of PLA and its introduction to the textile industry will require the Institute to develop bicomponent multifilaments of the CORE/SHETH type by combining various grades of PLA. These multifilaments are used in textile fiber texturing and shed weaving processes, as well as in dyeing processes.

Within the framework of the project and according to the current needs of the industry, we can identify the following specific objectives:

• Functionalising biopolymers using particles and other biopolymers.
• Improving thermal and mechanical properties by functionalisation with metal oxides.
• Increasing the resistance of biopolymers to environmental conditions by using antioxidant additives of natural origin.
• Manufacturing test pieces and prototypes using thermoplastic manufacturing processes, such as 3D printing and injection moulding.
• Introducing biopolymers to industry by improving their characteristics.
• Using biomaterials in textile manufacturing processes in the manufacture of textile structures.

EXPECTED RESULTS

Biomaterials with improved properties are expected to be obtained from the additivation of PLA, increasing its deformation capacity and resistance to both mechanical stress and UV radiation exposure.

Furthermore, the aim is to be able to introduce these improved biopolymers in industrial manufacturing processes, specifically in the injection of thermoplastic components and for prototyping methods such as 3D printing.

Finally, it is aimed to introduce the PLA fabrics developed in the manufacture of openwork fabrics for their subsequent introduction in dyeing processes.

This project is funded by the Conselleria d’Economia Sostenible, Sectors Productius, Comerç i Treball de la Generalitat Valenciana, through IVACE.

Additional Information

• Grant number: IMAMCI/2021/1

• More information: NON-ECONOMIC ACTIVITIES PLAN

• Year: 2021

• Status: In progress

• Entity: IVACE

Would you like more information about the project? Fill in the following form