Cost-competitive cellulose-based leather alternative produced from organic waste using novel production process accelerating green transformation of fashion industry

The consortium aims to develop a unique leather-like material based on nanocellulose, ModernTex, with minimal environmental impact. The patented manufacturing method enables the production of a composite material consisting of a biobased textile scaffold encapsulated in a bacterial cellulose matrix. This composite material structure provides unparalleled opportunities for design and performance customization as well as optimized production efficiency that far exceeds the current biobased leather alternatives.

The project will develop a fast, end-to-end continuous process to produce a 100% circular and recyclable material. Key results include a scalable prototype for fast production of ModernTex, a first-of-its-kind 100% recyclable leather alternative composed of a nanocellulose matrix reinforced with a yarn scaffold, and an efficient recycling process that converts ModernTex back into feedstocks for future nanocellulose production.

The implementation involves the production of a natural yarn scaffold encapsulated in a cellulose matrix using a non-GMO strain of Komagataeibacter rhaeticus bacteria to produce bacterial cellulose fibers with high strength and stiffness. The yarn mesh is coated with a biobased polymer mixture, where the challenge is to achieve high adhesion between the yarn scaffold and the casted thin film of BC polymer mixture to create a composite material of interwoven bacterial cellulose fibers and yarn mesh.