ADVERTISEMENT FEATURE A new approach to nonwovens
Unipetrol RPA has been working to develop renewable formulations for single-use nonwovens that offer compostability without performance or processing compromises
Nonwoven fabrics have revolutionised the production and performance of hygiene products such as diapers but it is becoming ever clearer that benefits in service bring challenges at end of life. Hygiene products are almost always disposable single-use products and diapers, for example, lead to significant waste volumes that cannot be upcycled. Much ends in landfill, where it may cause environmental problems for the future. The European Union is bringing in new legislation aimed at restricting single-use plastics and this is likely to become a worldwide trend. Daipers and other nonwoven hygiene products may not be within the scope of these regulations but, as the materials cannot be re-used or re-processed into another product, new approaches are needed to develop better end-of-life solutions while maintaining performance. Typical nonwovens and fabrics are
made from non-renewable petrochemical resources such as polypropylene or polypropylene/polyethylene blends. This is not a “green” solution — each child will use at least five single-use diapers a day creating thousands of tonnes of non- recyclable and non-degradable plastic waste every year. Czech petrochemical and refinery
producer Unipetrol RPA cooperated with the Polymer Institute Brno to develop a
Nonwoven fibres produced with the new compostable bio-based polyester formulations
Processing of virgin bio- polyester by fibre spinning
new approach to plastic nonwovens. The main criteria were to ensure easy processing, to maintain end-product properties, comply with relevant legislation on human safety and body contact, and to ultimately reduce environmental impact at end of life. A key focus was to use renewable plant-based bioplastics that biodegrade under industrial composting conditions. Meeting all the required criteria, and
particularly the performance, was accepted as a challenge but a slight deterioration in final product properties was considered acceptable if compensated for by the added benefits that could come from the switch to a
compostable polymer. A compromise was to be found between material processing, product service life and subsequent waste management. The goal was to enhance biopolymer
processing using fibre spinning technology to obtain nonwovens with properties and behaviour comparable to typical polypropylene fibres but with the additional benefit of industrial compostability. Laboratory scale tests have shown good results for blends based on bio-polyesters in combination with anti-hydrolysis, melt-thickening and surface modification additives. These ensure high melt strength and eliminate fibre failure during processing. The new fibre formulations show
performance comparable to polypropylene fibres in terms of soft-touch and strength while maintaining suitable elongation. The polyester-based formulations can also meet UV stability requirements without the need for additional additives. All of the components are non-toxic and meet FDA and pharmacopoeia restrictions. Tests show the nonwoven formulations can be used in the same applications as standard polypropylene nonwovens. They will now be pilot tested at production scale in cooperation with a major Czech nonwovens producer and compostability behaviour will be evaluated.
www.unipetrol.cz/en
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