Single-Bath Enzymatic Conversion of Plant Biomass to Textile Fibers

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Solution Overview

Problem

The textile industry faces challenges in producing high-quality textile-grade fibers from plant-derived biomass without using excessive water and harsh chemicals, as conventional methods are water-intensive and environmentally harmful, and existing methods struggle to convert natural fibers like banana and jute into spinnable yarns for fine quality fabrics.

Innovation Solution

A single-bath enzymatic method for converting cellulosic biomass into high-quality textile-grade fibers, which involves sequential enzymatic treatments in a single water bath with pH adjustments, eliminating the need for intermittent draining and washing, and using enzymes with pectinolytic, cellulytic, and proteolytic activities, while potentially including bleaching and softening steps without chemical pre-treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional multi-bath processes are used to convert plant-derived biomass to textile-grade fibers, then fiber quality can be maintained, but water consumption increases significantly

Engineering Contradiction:

Improvewater consumptionVSAvoidfiber quality

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent combines multiple separate treatment steps (retting, scouring, bleaching, softening) that were traditionally performed in separate baths into a single integrated enzymatic treatment bath. This merging of processes eliminates the need for intermittent draining, refilling, and washing steps, reducing water consumption by 30-50% while maintaining fiber quality through sequential enzymatic actions on the same substrate in one continuous process.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If chemical retting and alkaline treatments are used to produce spinnable fibers from natural fibers, then fiber strength can be improved, but environmental harm increases due to harsh chemicals and water pollution

Engineering Contradiction:

Improvefiber strengthVSAvoidenvironmental pollution

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent replaces harsh chemical treatments (chemical retting, alkaline scouring, chlorine bleaching) with enzymatic treatments. Specific enzymes (cellulases, pectinases, hemicellulases for retting; lipases and proteases for scouring; peroxidases and laccases for bleaching; softening enzymes) are used to achieve the same functional outcomes - fiber separation, cleaning, whitening, and softening - without the environmental pollution and water contamination associated with conventional chemicals.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameter of the treatment medium from chemical-based (alkaline solutions, chlorine, acids) to enzyme-based (biocatalysts working at controlled pH and temperature). This parameter change enables the same transformation of raw natural fibers into spinnable textile-grade fibers while eliminating the harmful environmental effects of chemical discharge and reducing water pollution.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If multiple washing steps are performed after each treatment in the textile processing sequence, then fiber cleanliness can be maintained, but water usage increases substantially

Engineering Contradiction:

Improvewater usageVSAvoidfiber cleanliness

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent implements continuous enzymatic treatment in a single bath without intermittent draining and refilling. The enzymatic reactions proceed sequentially and continuously on the fiber substrate, with each enzyme group acting in sequence (retting enzymes, then scouring enzymes, then bleaching enzymes, then softening enzymes) to progressively transform the fiber while maintaining cleanliness through the cumulative action of all enzymatic steps in one continuous process.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method reduces water consumption by 30-50% compared to conventional multi-bath processes, produces fibers of the same quality as those from traditional methods, and allows for the production of spinnable yarns that can be woven into high-quality fabrics, addressing environmental concerns and water conservation needs.

Implementation Method 1

sequential enzymatic treatments in a single water bath with pH adjustments, eliminating the need for intermittent draining and washing

Methodology Applied

Scientific EffectEnzymatic hydrolysis: Hydrolysis

Implementation Method 2

using enzymes with pectinolytic, cellulytic, and proteolytic activities

Methodology Applied

Scientific EffectEnzyme: Enzyme

Implementation Method 3

sequential enzymatic treatments in a single water bath with pH adjustments

Methodology Applied

Scientific EffectpH adjustment:

Data Source

PatentUS20230295840A1Single bath conversion of plant derived biomass to textile grade fibers

Publication Date: 2023.09.21 GENCREST PTE LTD

AI summary

The current invention relates to methods and compositions for converting plant derived biomass to textile grade fibres by an enzymatic single bath method, which does not require draining, refilling or water washes after every treatment. The single bath conversion of raw natural fibres derived from plant based biomass to softer, finer textile grade fibres is an eco-friendly process which is efficient and conserves water. The textile grade fibres produced have same quality when compared to those derived from conventional multi bath process.