German researchers aim to develop 100% bio-based polyethylene

In Germany, as part of an innovation space for bio-based textile research (Biotexfuture) funded by the Federal Ministry of Research, Technology and Space (BMFTR), numerous new, ongoing pioneering projects are being presented. Biotexfuture is led by adidas AG and RWTH Aachen University. These include projects on many aspects of the bioeconomy.

The ongoing bioPEtex project, funded by the BMFTR, aims to develop 100% bio-based polyethylene (BioPE) from bio-based raw materials and establish it on the clothing market. BioPE is an environmentally friendly plastic made from fermented starches or sugar and offers a sustainable alternative to PET. By using spun-dyed BioPE, energy and water consumption can be cut by 50% and CO2 emissions reduced by 60%.

The first results of the project show progress in the processing of BioPE in spun-dyed yarns suitable for textile applications. Process development with the dyed BioPE compounds is currently underway. The resulting partially oriented yarns (POY) have suitable properties for subsequent false wire texturing. Production speeds for melt spinning are currently in the industrial range (2,500 m/min). Tensile strengths of approx. 20 cN/tex have been achieved to date and the target values derived from PET-POY have therefore already been met. False wire texturing in the laboratory (ITA) and on a semi-industrial scale (BB Engineering GmbH, Remscheid) has also been successful. The mechanical yarn characteristics of the textured yarns (Draw-Textured Yarn, DTY) are thus improved and the yarn volume and heat retention capacity are increased.

Initial knitting tests with the laboratory DTY were successfully carried out at the industrial partner FALKE KGaA, Schmallenberg, and confirm a cooling feeling when touching the textile, due to the use of biofibers. Further yarns are being developed so that, as a next step, a T-shirt for sports applications can be produced from semi-industrial yarns and validated as a demonstrator. The bio-based elastic finish is also currently being developed.