NON-WOVEN TEXTILE FROM UPCYCLED FRUIT AND VEGETABLE WASTE

Abstract

The present invention discloses a hydrophobic non-woven textile and the method of production thereof, the method for production comprising the steps of providing a fruit or vegetable pomace, comminuting the pomace, mixing the disrupted pomace with a density-modifying agent, dehydrating the disrupted pomace, distributing the water reduced pomace on a surface, drying the distributed water reduced pomace, and coating the non-woven textile with a hydrophobic polymer to provide the hydrophobic non-woven textile.

Claims

1. A method of producing a hydrophobic non-woven textile, the method comprising the steps of: providing a fruit or vegetable pomace, comprising water in the range of 60% to 95% (w/w) and a plant fibre; comminuting the pomace to provide a disrupted pomace comprising plant fibres of a fibre length below or equal to 2.0 mm; mixing the disrupted pomace with one or more density-modifying agents at an amount of density-modifying agent in the range of 10% (w/w) to 85% (w/w) of the weight of dry matter of the disrupted pomace; dehydrating the disrupted pomace by reducing the water content by 10% (w/w) to 30% (w/w) to provide a water reduced pomace; distributing the water reduced pomace on a surface and drying the distributed water reduced pomace at a drying temperature in the range of 20° C. to 150° C., for a drying duration to reduce the water content to 10% (w/w) to 30% (w/w) of the water reduced pomace, preferably to 20% (w/w) to 30% (w/w), to provide a non-woven textile; and coating the non-woven textile with a hydrophobic polymer to provide the hydrophobic non-woven textile.

2. The method of producing a hydrophobic non-woven textile according to claim 1, wherein the step of comminuting the pomace is preferably by milling or refining.

3. The method of producing a hydrophobic non-woven textile according to claim 1, wherein the step of dehydration preferably comprises one or more methods from the list consisting of heating, centrifugation, filtration and mechanical pressing.

4. The method of producing a hydrophobic non-woven textile according to claim 1, wherein the one or more density-modifying agents is selected from the list consisting of carbohydrates, plant fibres, proteins, polymer emulsions, gums, polyols, cationic polymers, siloxanes and fatty acids.

5. The method of producing a hydrophobic non-woven textile according to claim 1, wherein the coating comprises one or more of spray coating, wet spray coating, immersion dip coating, suspension plasma spraying, roller coating, direct coating, foamed foam coating, crushed foam coating, transfer coating, hotmelt extrusion coating, calendar coating, rotary screen coating, dry powder coating, curtain coating, slot-die coating, extrusion coating, mayer rod coating, kiss roll coating, gravure roll coating and reverse roll coating.

6. The method of producing a hydrophobic non-woven textile according to claim 5, wherein the coating step comprises applying one or more coating layers, wherein each coating layer comprises one or more of an amphiphilic polymer, a hydrophobic polymer and a conditioning agent.

7. A hydrophobic non-woven textile comprising a layer of a non-woven textile and a layer of hydrophobic coating, wherein: the non-woven textile comprises water at a content in the range of from 10% (w/w) to 30% (w/w) of the hydrophobic non-woven textile, a fruit or vegetable pomace comprising a plant fibre having a fibre length below or equal to 2.0 mm, and one or more density-modifying agents at a content in the range of 4% (w/w) to 70% (w/w) of the hydrophobic non-woven textile; and the hydrophobic coating comprises a hydrophobic polymer.

8. The hydrophobic non-woven textile according to claim 7, wherein the non-woven textile comprises two different density-modifying agents at a content in the ranges of 4% (w/w) to 40% (w/w) and of 10% (w/w) to 66% (w/w), respectively, of the hydrophobic non-woven textile.

9. The hydrophobic non-woven textile according to claim 7, wherein the hydrophobic non-woven textile has a tensile strength in the range of from 2 N per mm2 to 20 N per mm2.

10. The hydrophobic non-woven textile according to claim 7, wherein the one or more density-modifying agents is selected from the list consisting of carbohydrates, plant fibres, proteins, polymer emulsions, gums, polyols, cationic polymers, siloxanes and fatty acids.

11. The hydrophobic non-woven textile according to claim 7, wherein the non-woven textile comprises at least 30% (w/w) of fruit or vegetable material.

12. The hydrophobic non-woven textile according to claim 7, wherein the layer of hydrophobic coating further comprises one or more of an amphiphilic polymer and a conditioning agent.

13. A hydrophobic non-woven textile according to claim 7 obtainable by the method of producing a hydrophobic non-woven textile according to any one of claims 1 to 6.

14. A composite material comprising the hydrophobic non-woven textile according to claim 7, an adhesive layer and a backing.

15. The composite material according to claim 14, wherein the adhesive layer is a glue selected from the list of dextrin, latex, modified latex, polyvinyl acetate, polyurethane, polyacrylic, polychloroprene, epoxy, cyanoacrylate, aliphatic resin, bone glue, hide glue and hotmelt including ethylene-vinyl acetate, polyolefins, polyamides and styrene block copolymers.

16. The composite material according to claim 14, wherein the backing is selected from list consisting of a textile backing, a glass fiber, a carbon fiber, a metal mesh and a latex sheeting.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0094] The above, as well as additional objects, features, and advantages of the present inventive concept will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present inventive concept, with reference to the appended drawings, wherein:

[0095] FIG. 1 is a flowchart for the production of the hydrophobic non-woven textile.

[0096] FIG. 2 discloses the effect of comminuting the apple pomace in relation to the fibre particle size in a sample of non-woven textile.

DETAILED DESCRIPTION OF THE INVENTION

[0097] The present invention in a first aspect relates to a method for producing a hydrophobic non-woven textile from fruit or vegetable pomace. In a second aspect the invention relates to a hydrophobic non-woven textile comprising a fruit or vegetable material, a density-modifying agent, and a layer of hydrophobic coating. In a third aspect, the invention relates to a composite material comprising a hydrophobic non-woven textile comprising a fruit or vegetable material, a density-modifying agent and a layer of hydrophobic coating, an adhesive layer and a backing.

[0098] FIG. 1 discloses the overall process of the disclosed method with the steps included in producing the hydrophobic non-woven textile. First, the fruit/vegetable pomace is supplied as by-product from industrial production (A), such as from juice and cider production. Next, the pomace is comminuted (B), which yields a disrupted pomace. Hereafter, the disrupted pomace is mixed with one or more density-modifying agent (C), following which the mixture is dehydrated (D) to obtain a water reduced pomace. In the two subsequent steps in the process, the water reduced pomace is formed (E) and dried (F) in suitable frames, depending on application, yielding a pomace-based non-woven textile. In the final step (G), the pomace-based non-woven textile is coated with one or more coating layers, of which at least one coating layer is a hydrophobic polymer to obtain the hydrophobic non-woven textile.

[0099] FIG. 2 discloses the effect of pomace comminuting on fibre size and tensile strength in the product. FIG. 2A discloses a sample which was obtained without milling and has a tensile strength of 6.8 N/mm.sup.2. FIG. 2 B discloses a sample which was obtained by milling performed in a toothed colloid mill and has a tensile strength of 9.33 N/mm.sup.2. The described milling reduced the average fibre width to <50 μm, and 70% of the fibres had a fibre length of 0.2-0.5 mm. The milling process significantly increased the tensile strength and influenced the texture of the textile. Surprisingly, the product obtained after milling has been found to be smooth, flexible, and strong.

EXAMPLES

[0100] The following examples relate to 2D hydrophobic non-woven textile compositions made from fruit or vegetable pomace in which apple pomace serves as a representative example. The examples are included solely to assist one of ordinary skill in obtaining a more complete understanding of the present invention. The examples are not intended in any way to otherwise limit the scope of the present invention.

Example 1: Composition of Fruits

[0101] In some embodiments, apple pomace is used as the starting material for the non-woven textile. Apple pomace is obtained as a by-product of apple juice and/or cider production. 100% (w/w) of the apple pomace can be used for production of the non-woven textile of the present invention. However, besides apple pomace, also the pomace of other fruits or vegetables can be used as a starting material in the present invention. Tables 1-4 summarize the composition of regular biomass including apple pomace and banana peels. The percentages are given in % (w/w).

TABLE-US-00001 TABLE 1 Composition of gala apple pomace as representative example (wt %) (from Ma Y. et al, 2019, doi: 10.1007/ s13197-019-03877-5) Composition % (w/w) Cellulose 17.7 Hemicellulose 10.9 Pectin 19.6 Lignin 15.4 Ash 1.9

TABLE-US-00002 TABLE 2 Composition of gala apple pomace after de-pectinated as representative example (wt %) (from Ma Y. et al, 2019, doi: 10.1007/s13197-019-03877-5) Composition % (w/w) Cellulose 31.8 Hemicellulose 18.6 Pectin — Lignin 23.9 Ash 2.5

TABLE-US-00003 TABLE 3 Composition of William banana peel as representative example (wt %) (from Ragab M. et al., 2016, J. Agric. Res. Kafr E-Sheidk Univ. pp: 88-102, Vol. 42(4)) Composition % (w/w) Cellulose 14.62 Hemicellulose 13.06 Pectin 12.77 Lignin 8.69 Ash 13.84

TABLE-US-00004 TABLE 4 Composition of Maghrabi banana peel as representative example (wt %) (from Ragab M. et al., 2016, J. Agric. Res. Kafr E-Sheidk Univ. pp: 88-102, Vol. 42(4)) Composition % (w/w) Cellulose 12.58 Hemicellulose 11.08 Pectin 13.03 Lignin 7.74 Ash 12.44

Example 2: Oxidizing Agents for Odour and Colour Harmonization

[0102] This example describes an odour and colour harmonization step as a part of the manufacturing process. Herein, bleaching with oxidizing agents is described as a suitable method of odour and colour harmonization of the apple pomace. Bleaching with hydrogen peroxide (H.sub.2O.sub.2) is carried out in a closed tank with 0.01% (w/w) to 0.04% (w/w) of 31% 14202 at 80° C. and pH 10 for 1h with continuous stirring. The pH of the solution is preferably adjusted with a base, sodium hydroxide (NaOH) for example, to the desired pH. Representative findings related to these experiments are depicted in Table 5.

[0103] The assessments of degree of offensiveness in regard to colour and odour were carried out by a panel of organoleptically-trained experts. The degree of offensiveness of the odour and colour are given in values between 0 and 10, in which 0=no odour, and 10=extremely odorous. Table 5 shows that the concentration of H.sub.2O.sub.2 and the duration of bleaching affect the colour, odour, and tensile strength of the textile.

TABLE-US-00005 TABLE 5 Effect of odour and colour harmonization through hydrogen peroxide bleaching Concen- Time Tensile Degree Degree tration of Final strength of of of H.sub.2O.sub.2 bleach- pulp of offen- offen- Initial (volume ing density textile siveness siveness pH %) (min) (%) (N/mm.sup.2) of colour of odour 10 0.021 10 8 10.22 3 2 10 0.021 >60 8 7.12 1 3 12 0.017 40 8 8.96 6 5

Example 3: Solvents for Odour and Colour Harmonization

[0104] This example relates to the use of solvents for the odour and colour harmonization step during the manufacturing process of the non-woven textile. Ethanol, acetone and chlorine treatment, as non-limiting examples, were carried out with 300% (v/v) solvent in a closed vessel at 25° C. for 120h with continuous stirring. The pH of the solution is preferably adjusted to pH 3 with a weak organic acid, acetic acid for example. The assessments of degree of offensiveness in regard to colour and odour were carried out by a panel of organoleptically-trained experts. The degree of offensiveness of the odour and colour are given values between 0 and 10, in which 0=no odour and 10=extremely odorous. Table 6 shows that the pH of the solution affects both the product colour and the odour.

TABLE-US-00006 TABLE 6 Effect of odour and colour harmonization through different solvent treatment Type of Duration of Lethal dose Degree of Degree of solvent for treatment (LD.sub.50)- offensiveness offensiveness odour (hours) mg/kg.bw (rat) of colour of odour Chlorine 120  850 (inhaled) 3 4 Acetone 120 5800 (oral) 4 6 Ethanol 120 7600 (oral) 6 3

Example 4: Density-Modifying Agents

[0105] Density-modifying agents are added in the manufacturing process of the non-woven textile. As an example, at least one complex non-water-soluble carbohydrate or lignocellulosic fibre is added as density-modifying agent to the pomace. As seen in Table 7, the type of lignocellulosic fibre chosen can affect the tensile strength of the non-woven textile. The type of lignocellulosic fibre is also evaluated based on its adhesion potential with apple pomace. The adhesion potential is important for the mixing during the manufacturing of the non-woven textile. The assessments are carried out by a panel of organoleptically trained experts. The degree of adhesion is given values from 0 to 10 (0=no adhesion; 10=extreme adhesion).

TABLE-US-00007 TABLE 7 Influence of lignocellulosic fibres on product strength (bleached apple pomace using hydrogen peroxide as representative example) Tensile strength of textile Adhesion to Lignocellulosic fibre (N/mm.sup.2) textile — 2.75 —  4% soft wood fibres 5.3 9 10% hemp fibres 3.5 4 cotton (1 sheet) 7.1 5 cotton (2 sheet) 6 5

[0106] In addition to lignocellulosic fibres, the textile may contain other insoluble carbohydrates, water-soluble carbohydrates, and proteins. The soluble carbohydrate can constitute up to 20% (w/w) of the final composition of the textile. The protein can constitute up to 30% (w/w) of the final composition of the textile. Table 8 summarizes the influence of addition of different carbohydrates and proteins on tensile strength of the apple non-woven textile. To further increase the strength of the textile, enzymatic cross-linking reaction can be performed. In one embodiment, the enzyme transglutaminase was used to crosslink soy protein. The transglutaminase and soy protein were added to the sample containing apple pomace, 3% soft wood fibres and 3% sucrose at 35° C. The sample then was mixed and dried at 35° C. for 6 h.

TABLE-US-00008 TABLE 8 Influence of carbohydrates and proteins on product strength (bleached apple pomace using hydrogen peroxide as representative example) Mixtures of different density-modifying agents added to Tensile strength the dry matter of the milled apple pomace (N/mm.sup.2) 41% soft wood fibres + 23% sucrose 3.5 10% soft wood fibres + 23% sucrose + 10% gum Arabic 5.6 10% soft wood fibres + 23% sucrose + 50% gum Arabic 6.5 10% soft wood fibres + 14% soy protein 4.9 10% soft wood fibres + 23% sucrose + 52% glutinous 5.6 rice starch + 7.7% glycerin 10% soft wood fibres + 23% sucrose + 10% gum 4.3 Arabic + 7.7% glycerine + 52% glutinous rice flour 10% soft wood fibres + 23% sucrose + 40% soy 4.15 protein + 4% transglutaminase

[0107] In another embodiment natural latex milk is used as density-modifying agent. The use of natural latex milk as density-modifying agent affects the tensile strength of the product as depicted in Table 9. The addition of 9.6% and 19% natural latex milk in combination with 10% soft wood fibres and 23% sucrose to the dry matter of the milled apple pomace has been found to provide a high tensile strength between 8.95 to 9.90 N/mm.sup.2.

TABLE-US-00009 TABLE 9 Influence of natural latex milk on product strength Tensile Mixtures of different density-modifying agents added to the dry strength matter of the milled apple pomace (N/mm.sup.2) 10% soft wood fibres + 23% sucrose + 9.6% natural latex milk 9.90 10% soft wood fibres + 23% sucrose + 19% natural latex milk 8.95 10% soft wood fibres + 29% natural latex milk 9.70 10% soft wood fibres + 23% sucrose + 29% natural latex milk 7.34 10% soft wood fibres + 23% sucrose + 48% natural latex milk 5.07 10% soft wood fibres + 23% sucrose + 76.8% natural latex milk 4.45

[0108] In another embodiment chemical cross-linking agents are added as density-modifying agents. Cross-linking agents have been found to alter the product strength. Exemplary, a mixture of citric acid and TiO.sub.2 was added to apple pomace together with 9% soft wood fibres and 23% sucrose, and thereafter heated at 80° C. for 1 h. The sample then was dried at 70° C. for 5 hours with or without curing at 165° C. for 5 minutes. This treatment resulted in a tensile strength of 7.82 N/mm.sup.2 for the final product. In another example, polyamidoamine epichlorohydrin (PAE) was added as cross-linking agent. For cross-linking PAE, the apple pomace was preferably bleached. The sample was dried at 40° C. for 6 h. As seen in Table 10, the addition of 8% soft wood fibres, 3% sucrose and 2% PAE (percentage of PAE based on the weight of the soft wood fibres) to the dry matter of milled apple pomace results in a product with tensile strength of 10.28 N/mm.sup.2.

TABLE-US-00010 TABLE 10 Influence of carbohydrates and proteins on product strength with cross-linking agents Tensile Mixtures of different density-modifying agents added strength to the dry matter of milled apple pomace (N/mm.sup.2) 9% soft wood fibres + 23% sucrose + 0.6% citric 7.82 acid + 0.2% TiO.sub.2 9% soft wood fibres + 23% sucrose + 3% citric 6.62 acid + 0.2% TiO.sub.2 9% soft wood fibres + 23% sucrose + 0.6% citric 5.89 acid + 0.8% TiO.sub.2 (cured) 9% soft wood fibres + 23% sucrose + 3% citric 4.85 acid + 0.8% TiO.sub.2 (cured) 9% soft wood fibres + 23% sucrose + (1% PAE*) 8.76 8% soft wood fibres + 23% sucrose + (2% PAE*) 10.28 8% soft wood fibres + 23% sucrose + (5% PAE*) 7.96 *The percentage of PAE is based on the weight of soft wood fibres added.

Example 5: Use of Humectants

[0109] The hydrophobic non-woven textile may additionally or alternatively include a humectant as a density-modifying ingredient. The humectant can constitute between 0.1% (w/w) to 2% (w/w) of the final composition of the textile and helps to preserve moisture content of the textile. The use of glycerol as a humectant was tested. Glycerol at concentrations 0% (w/w), 0.75% (w/w) or 1.5% (w/w) was added to the mixture containing milled apple pomace, 9% soft wood fibres, and 23%, 17.25% or 11.5% sucrose. The mixtures were heated at 70° C. for 2h and dried at 70° C. for 5h. As seen in Table 11, the treatment of the present embodiment adversely affected the tensile strength of the textile, however, improved the moisture retention in the apple pomace-based non-woven textile.

TABLE-US-00011 TABLE 11 Influence of glycerol humectant on product flexibility Mixtures of density-modifying Tensile Water content agents added to the dry matter of Humectant strength reduction after milled apple pomace (wt %) (N/mm.sup.2) 10 days (%) 9% soft wood fibres + 23% sucrose 0 5.3 30-35 9% soft wood fibres + 17.25% 0.75 4.4 18-25 sucrose 9% soft wood fibres + 11.5% 1.5 4.2 10-13 sucrose

Example 6: Forming and Drying

[0110] The process disclosed in the present invention includes forming and drying as parts of manufacturing the non-woven pomace-based textile. In one embodiment, biodegradable cellulose acetate frames are used for forming the textile. Therein, the sample is dried at 30° C. under a free flow of air until the moisture content in the non-woven textile is reduced to 20%. The temperature setting for drying different samples can differ for each sample composition. Examples of drying temperature settings with regards to product composition are given in Table 12.

TABLE-US-00012 TABLE 12 Examples of drying temperature settings with regards to product composition Range of drying Sample composition temperature (° C.) apple pomace + soluble carbohydrates + 40-45 lignocellulosic fibre apple pomace + soluble carbohydrates + 30-35 lignocellulosic fibre + protein apple pomace + soluble carbohydrates + 50-70 lignocellulosic fibre + natural latex milk

Example 7: Hydrophobic Coatings

[0111] The non-woven pomace-based textile achieved by the process disclosed in the present inventive concept is coated with a hydrophobic polymer to increase water resistance and to control moisture transport. One embodiment exemplifies the use of the polymer-based coatings polyvinyl butyrate (PVB) and a polymer emulsion in the presence and absence of corona treatment to improve coating adhesiveness. As seen in Table 13, a coating of the polymer emulsion followed by a layer of PVB, with (PVB corona) or without corona treatment (PVB), showed appreciable water resistance of the textile, resulted in a matte finish of the textile, and in good adhesiveness to the non-woven textile.

TABLE-US-00013 TABLE 13 Properties of polymer-based coatings (apple textile as representative example) Coating Aqueous liquid Coating layer #1 Coating layer #2 layer #3 repellency PVB — — 8 polymer emulsion — — 2 polymer emulsion PVB + plasticizer — 8 polymer emulsion PVB corona PVB 8 natural latex milk — — 6

[0112] The aqueous liquid repellency test is carried out according to DS/ISO 23232:2009. The degree of aqueous liquid repellency is given values from 0 to 8 (0=not aqueous liquid repellent; 8=a surface tension of <24.0 dyne/cm, which is seen as highly aqueous liquid repellent).

Example 8: Composite Material

[0113] The non-woven pomace-based textile achieved by the process disclosed in the present inventive concept may be used to form a composite material by attaching a textile backing to the finished non-woven textile using a certain adhesive solution. As an example, at least one layer of textile is attached as a backing. As seen in Table 14, the types of woven textile backing can affect the tensile strength of the non-woven textile. The type of textile backing is also evaluated based on the tear strength, measured in newtons (N) of the composite non-woven textile. The tear strength is important for the durability of the final composite material. The tear strength assessments are carried out and evaluated according to the standard ISO 3377-1-2016. The adhesion used for the embodiments listed in Table 14-16 is ester acrylic copolymer. As seen in Tables 14 and 15, the tear strength varies according to the types of backing textile used, e.g. when using linen plain woven textile the composite material has a high tear strength of 30.85 N (Table 14), whereas e.g. the use of cotton wrap knitted textile as backing for the composite non-woven textile results in a tear strength of 7.52 N (Table 15).

TABLE-US-00014 TABLE 14 Influence of woven textile backing on tensile and tear strength of the composite material Tensile Tear strength Strength Type of Textile backing (N/mm.sup.2) (N) Cotton plain woven textile (0.2 mm) 8.38 10.25 Linen plain woven textile 9.38 30.85 Pima Cotton satin woven textile 10.55 21.49 Cotton twill woven textile 12.90 23.41 Polyester plain woven textile (chiffon) 9.10 24.04 Tencel twill woven textile 6.22 18.73 (regenerated cellulose)

TABLE-US-00015 TABLE 15 Influence of knitted textile backing on tear strength Type of Textile backing Tear Strength (N) Cotton knitted textile 10.7 Cotton wrap knitted textile 7.52 Cotton/Polyester.sup.I wrap knitted textile 5.84 Polyester knitted textile 15.80 Polyester wrap knitted textile 24.50 Polypropene (PP) wrap knitted textile 14.25 .sup.IThe textile is composed of a mixture of 54% cotton and 46% polyester.

[0114] Alternative textiles to the woven and knitted textiles listed in Tables 14 and 15, respectively, were also tested. The tear strengths of polyester tulle textile and natural fiber non-woven textile is shown in Table 16. For this experiment, the natural fiber was composed of 50% cotton and 50% soy.

TABLE-US-00016 TABLE 16 Influence of other types of textile backing on tear strength Type of Textile backing Tear Strength (N) Polyester tulle textile 2.49 Natural fiber non-woven textile 5.84