Bioplastics are revolutionising the textile sector, offering sustainable alternatives to conventional plastics. These innovative materials, especially in non-woven textiles, are reducing the industry's environmental impact and transforming applications such as sportswear, face masks and single-use textiles

The textile sector is constantly evolving, looking for sustainable alternatives to reduce its environmental impact. Bioplastics have emerged as a promising solution, especially in the field of non-woven textiles. The textile industry is one of the world’s largest consumers of resources and generators of waste. According to a report by Circle Economy and the H&M Foundation, the global textile industry consumes 3.25 billion tonnes of resources annually to produce items, of which only 0.3% comes from recycled sources, mainly plastic bottles.

In addition, the production of clothing, footwear and home textiles generates major environmental impacts, including water pollution, greenhouse gas emissions and waste. These data underline the importance of implementing more sustainable practices in the textile sector to mitigate its ecological footprint.

This article explores the current prospects for bioplastics in the textile sector, with a focus on nonwoven materials, and highlights some of the most successful applications in the market.

Bioplastics in the Textile Sector

Every year, more than one million tonnes of fabric is produced in Europe for the manufacture of clothing, using spinning techniques that combine natural fibres, such as cotton or wool, with synthetic fibres, such as polyester.

These blends of natural and synthetic fibres aim to improve the comfort and durability of garments. However, recycling these fabrics at the end of their useful life presents significant challenges, as the combination of both types of fibres makes them difficult to separate and process.

Bioplastics are polymers derived from renewable sources that can be biodegradable or non-biodegradable. In the textile sector, these materials offer an environmentally friendly alternative to conventional plastics, reducing dependence on fossil resources and reducing the carbon footprint of companies. Biomaterials that have the ability to biodegrade provide a clear end-of-life advantage, helping to reduce the environmental problem of plastic waste accumulation.

Considering that there are many types of textile products, it is worth noting that one of the most attractive sectors for biomaterials, especially compostable materials, are textiles that are single-use or have a short life span. In this section of textile products, one of the main processes is the extrusion of non-woven fabrics.

During these processes of creating fabrics from bioplastic materials, structures are manufactured by joining fibres together using mechanical, thermal or chemical methods, without the need for hand weaving. These materials are widely used in both disposable and durable applications due to their versatility and production efficiency.

There are several methods of manufacturing biodegradable fabrics in the textile industry, the first two being the most widely used in the nonwovens industry:

• Spunbond: Produced by extrusion of continuous fibres, which are then thermally bonded.
• Meltblown: Manufactured through the extrusion and dispersion of molten fibres, which solidify during a cooling process.
• Spunlace: Formed by bonding fibres together using high-pressure water jets.
• Airlaid: Obtained by dispersing fibres in an air stream, followed by bonding.
• Needlepunch: Created by interlacing fibres using needles.
• Others: Include methods such as heat bonding and chemical adhesion, among others.

Current Prospects for Bioplastics in Textiles

The bioplastics market is experiencing significant growth. The global production capacity of bioplastics is expected to reach approximately 7.59 million tonnes by 2026. This growth is driven by the increasing demand for sustainable solutions in various industries, including the textile sector.

Research and development in the field of bioplastics has led to the creation of materials with improved properties such as increased strength, flexibility, toughness and biodegradability. A prominent example is polyhydroxybutyrate (PHB), a biopolymer that has proven to be a viable alternative for the production of nonwoven textiles. Another competitive material for this industry is bio-based and compostable polylactic acid (PLA), which, when additivated, can significantly improve its properties and processability to achieve improved final characteristics that can compete strongly with fossil-based plastics.

An example of advanced development of improved PLA material is ADBioplastics’ PLA-Premium, which has been successfully adapted, with its Newex grades, to the manufacture of sustainable nonwoven fabrics through nonwoven extrusion technology (mainly spunbond), improving aspects such as flexibility, tenacity or torsional strength according to the specific needs of the textile industry customer.

Advantages of bioplastic non-woven fabric

Bioplastic nonwoven fabric offers multiple technical advantages that make it ideal for a variety of applications:

Production efficiency

This type of fabric significantly reduces the consumption of energy, water and chemicals during its manufacture. In addition, its ability to be produced in large continuous rolls improves productivity and facilitates its integration into automated production lines, optimising industrial processes.

Versatility

Nonwovens can be made from a wide range of fibres, either natural or blended. This versatility allows them to be endowed with diverse properties, such as high mechanical strength, liquid absorption, efficient filtration, thermal insulation, UV resistance, water repellency, and even flame retardant characteristics, thus adapting to different technical needs.

Specific properties

These fabrics can be designed to meet particular technical requirements, making them highly customisable. In addition, they can be treated with additives or chemical coatings to enhance or add specific properties, such as increased moisture resistance or antimicrobial characteristics.

Strength and durability

Thanks to their cohesive structure and fibre bonding, nonwovens are often extremely strong and durable. They offer remarkable tear and abrasion resistance, making them a reliable choice for applications requiring robust materials.

Recyclability and sustainability

Many nonwovens are recyclable, biodegradable or compostable, contributing to sustainability and promoting the circular economy. Their manufacture generates a lower environmental impact and encourages the reuse of resources, aligning with the more responsible and environmentally friendly industrial production practices sought in Europe by 2030.

Successful market applications

Bioplastics have found successful applications in the textile sector, especially in non-woven products:

Nappies

Disposable nappies are one of the most common applications of nonwoven textiles. Bioplastics, such as PLA (polylactic acid) and PHA (polyhydroxyalkanoates), are used to manufacture the absorbent layers and outer covers of nappies. These materials are not only biodegradable, but also offer absorbency and strength properties comparable to conventional plastics. These materials provide a soft and comfortable texture for baby’s skin, reducing the risk of irritation.

Face Masks

The COVID-19 pandemic increased the demand for disposable facemasks. Bioplastics have proven to be a sustainable alternative for the production of non-woven face masks. Materials such as PLA are used to manufacture the filtering layers and outer covers of face masks, providing a biodegradable and effective solution for the medical industry. The breathability and light weight of these materials make the masks more comfortable to wear for extended periods.

Wet Wipes

Wet wipes are another disposable product that benefits from bioplastics. Nonwoven textiles made from bioplastics, such as PLA and PHA, are used to produce biodegradable wet wipes. These wipes offer the same functionality as conventional wipes with optimal strength and durability, but with less environmental impact.

Sportswear

Bioplastics are also being used in the production of technical sportswear. Materials such as PLA and PHA are used to make breathable and durable fabrics suitable for sportswear. These materials are not only sustainable, but also offer performance properties comparable to conventional plastics.

Non-woven bags

Non-woven bags made from bioplastics are a sustainable alternative to conventional plastic bags. These materials are biodegradable and compostable, which significantly reduces their environmental impact. Nonwoven bags made from bioplastics are used in a variety of applications, from shopping bags to industrial packaging. These bags decompose naturally, reducing their environmental impact.

Bioplastics continue to emerge as a promising solution for the textile sector, especially in the field of nonwoven textiles. With improved properties thanks to the impetus of research and reduced environmental impact, these materials offer a sustainable alternative to conventional plastics. As technology advances and the demand for sustainable solutions increases, bioplastics are expected to play an increasingly important role in the textile industry.