Algae Bio Textile

Abstract

Bio-textile material from filamentous algae. The invention provides a non-woven bio-textile composed of a single or multiple layers, including surface and structural layers, incorporating pre-treated algae, seaweed, natural fillers, and other additives wherein a specific weight ratio of algae and/or seaweed to natural fillers is maintained to achieve different level of thickness in the prepared bio-textile. The prepared bio-textile has good tensile and tearing strength in the range of 100-200 N/mm and 50-80 N/mm, respectively such that it can be used to produce different types of apparels. The process of preparation of the bio-textile using eco-friendly materials comprises the steps of harvesting, pre-treatment, slurry preparation, structural layer and double layer formation, drying and finishing steps.

Claims

1. A non-woven bio-textile comprising a single structural layer with a thickness of 0.5-5 mm or a plurality of layers including a surface layer and a structural layer with a thickness of 1-10 mm; characterized in that each layer further comprises pre-treated algae, natural fillers and other additives; or pre-treated algae, seaweed, natural fillers and other additives; wherein the weight ratio of pre-treated algae and natural fillers is between 3:7 and 7:3; and the weight ratio of pre-treated algae, seaweed and natural fillers is 5:2:3; wherein the other additives includes adhesives, binders, lacquers, softeners/plasticizers, preservatives and/or colouring agents; and the weight percentage of other additives is in the range of 0.5-10%.

2. The non-woven bio-textile fabric as claimed in claim 1, wherein the filamentous algae is selected from but not limited to different Classes including Chlorophyceae, Klebsormidiophyceae, Xanthophyceae, Bacillariophyceae (diatoms), Cyanophyceae, and the like; and the seaweed is selected from but not limited to different phylum including Rhodophyta, Cyanobacteria, Chlorophyta, Pheophyta and the like.

3. The non-woven bio-textile fabric as claimed in claim 1, wherein the fillers are selected from but not limited to rice husk, wheat straw, grass, cork powder, starches including tapioca, corn, potato, rice and the like; textile waste including include fabric scraps, leather buffing dust and the like; waxes including bees wax, paraffin wax, carnauba wax and the like; oil, polymer fillers and the like; the adhesives are selected from but not limited to heat-activated adhesives including gum/glue-based adhesives including guar gum, arabic gum, xanthan gum, jackfruit glue, arrow root glue, corn-starch glue and the like; chitosan-based adhesives, starch-based adhesives derived from plant sources including corn, wheat, or potatoes; rosin-based adhesives, natural rubber and polyurethane based adhesives; and the wax and oil as plasticiser or for waterproofing is selected from but not limited to carnauba wax, beeswax, vegetable or fruit oil and natural resin in the range of 3-5%, 2-4%, 1-2%, 1-3%, respectively and the colouring agents are selected from but not limited to natural dyes including onion skin, indigo leaves, beetroot, and charcoal powder used in the range of 2-3%, 1-2%, 0.5-1% and 1-2%, respectively.

4. The non-woven bio-textile fabric as claimed in claim 1, wherein the tensile strength of the single layered and double layered bio-textile is in the range of 100-200 N/mm and 150-200 N/mm, respectively; the tearing strength of the single layered and double layered bio-textile is in the range of 50-60 N and 70-80 N, respectively; and the GSM of the single layered and double layered bio-textile is in the range of 550-600 GSM and 1350-1450 GSM, respectively.

5. The non-woven bio-textile fabric as claimed in claim 1, wherein the distribution of weight % between the surface layer and the structural layer is in the ratio 3:7 and 7:3.

6. A process of preparation of non-woven bio-textile fabric comprises the steps of: (a) harvesting, cleaning and optional detoxification of the biological source further including the steps of: (i) harvesting algae mats using either an automated netting system or a rotary drum collector and harvesting seaweed using hand harvesting technique; (ii) rinsing the harvested algae and seaweed with filtered water to remove sand, and debris either by hand washing or mechanical washers; (iii) detoxifying on detection of heavy metals and pollutants in the cleaned algae; (iv) soaking the seaweed in cold water for 12-24 hours to soften and desalinate it followed by sorting to remove non-target species, damaged seaweed, and plastic waste, and final rinsing; and (iv) drying each sources separately either by spreading on drying racks or using an oven at 40-50 C.; (b) pre-treatment of the source further including the steps of: (i) preparing two sets of enzymatic solution by mixing enzymes with water at 35-40 C. in a temperature controlled vat; wherein the first set of enzymes includes 1-2% cellulase, 1-2% pectinase and 0.5-1% hemicellulose, and the second set of enzymes includes 0.5-1% alginate lyase, 0.3-0.5% carragenase and 0.1-0.3% pectinase; (ii) immersing the cleaned/dried algae in the first set of enzyme solution followed by occasional paddling for even distribution and soaking for 3-4 h such that the selected enzymes softens and breaks down complex material and cell wall components in the algae; wherein the dried algae is rehydrated by soaking in warm water for 1-2 h before adding the enzyme solution; (iii) immersing the first treated algae and cleaned seaweed, separately in the second set of enzyme solution followed by occasional paddling for even distribution and soaking for 3-4 h such that the selected enzymes breaks down alginates, carrageenan and pectin; (iv) rinsing the treated algae and seaweed in clean water to remove excess enzymes and straining through a fine mesh to remove any remaining debris/impurities; and (v) soaking the enzyme treated algae and seaweed, separately with alkaline solution comprising sodium carbonate (5-7%) and calcium hydroxide (2-3%) that neutralizes pH, removes gels, further loosens and softens fiber; wherein the soaked seaweed in alkaline solution is boiled for 2-3 h at 90-100 C. and rinsing in cold water to remove excess gel; (c) preparation of pulp/slurry further including the steps of: (i) boiling the pre-treated algae from step (b) in a steam-heated vessel for 2-3 hours in the presence ultrasonic waves (20-40 kHz) to further soften and separate the fibers and enhancing pulp consistency; (ii) rinsing the boiled algae in clean water to remove excess gels and straining through a fine mesh to remove excess water; (iii) preparing algal slurry by transferring the boiled algae to a mechanical pulper or industrial blender, adding fillers and required amount of water to achieve a desired consistency; pulverizing the mixture for 30-60 minutes until the pulp reaches a smooth, homogenous consistency; applying ultrasonic processing (20-40 kHz) for 30-60 minutes at 80-90 C. to further refine the pulp and ensure uniform dispersion of algal fibers and fillers; pressing the algal pulp to achieve a slurry with workable consistency; and (iv) preparing algal-seaweed slurry by stripping the seaweed fibers either manually or by using a fiber extraction machine to separate the cellulose-rich parts; drying the fibers in drying racks drying oven at 40-50 C. until it is slightly damp but pliable; breaking down boiled algae from step (c (i)) into fine fibers using a blender or mechanical pulper; blending the fine fibers of algae and seaweed along with natural fillers evenly using a carding machine or hand carder; (v) optionally incubating the slurry in a eco-friendly bleaching agent overnight to achieve light-coloured bio-textile; (d) preparation of structural layer using wet felting or needle felting technique wherein (i) the wet felting technique further including the steps of layering algae-seaweed fiber mixture onto a felting mat or mesh screen and building up the layers to achieve desired thickness; preparing a soap solution comprising castile soap and hot water (60-70C) at 0.5% w/v and applying on the layered algae-seaweed fibers to moisten the fibers; rolling back and forth over the layered fibers by placing a bamboo mat or rolling pin or hydraulic rollers up to 30 minutes such that the friction causes the fibers to interlock and bond; wherein the pressure of hydraulic rollers is in the range of 200-300 psi; rinsing the felted sheet with cold water and repeating the rolling process multiple times to achieve desired density and strength; drying the felted sheets in air or using oven; and (ii) the needle felting technique further including the steps of layering algae-seaweed fiber mixture onto a felting mat or foam block; needle punching and poking the layered fibers using a felting needle tool such that the barbs on the needle catch the fibers and entangle them; building a layer on top of felted layer and repeating the needle punching and poking until it reaches desired thickness; heat setting the felted sheet using steam iron or heat press for increasing the durability; (e) preparation of double layered non-woven bio-textile/fabric using a vat-lifting technique or spray-gun technique; (f) pressing, drying, curing the bio-textile further including the steps of: (i) placing the air dried bio-textile sheet from step (e) on a pressing bed followed by placing a non-stick separator sheet to avoid sticking of fabric on the pressing plates; (ii) pressing for 2-5 min/sheet at a pressure range of 100-300 psi to remove excess water and improve fiber bonding; wherein the pressing is initiated at low pressure and is gradually increased to prevent uneven pressing and to produce a sheet of consistent thickness; (iii) removing the non-stick separator and applying a layer of adhesive on the surface of pressed sheets; (iv) transferring the adhesive treated sheets from the press to a drying equipment and drying the non-woven bio-textile fabric at 40-60 C. for a time period of 6-24 hours with a relative humidity maintained between 40-50%; wherein time of drying is selected based on the thickness of the bio-textile fabric; (v) the dried bio-textile sheets are pressed again for 2-5 min either in a hydraulic press or a heated press at a pressure range of 150-200 psi to improve bonding between fibers; (vi) cooling the sheets at room temperature for 12-24 h to allow the fibers to settle; and (g) finishing the bio-textile/fabric further including the steps of: (i) waterproofing by applying wax or natural oil using a spray gun or roller wherein the wax/oil is completely melted at 50-60 C.; (ii) curing the sheet at room temperature for 12-24 h that allows full absorption of the waterproofing layers; (iii) applying the natural dye solution using spray gun, brush or dip method and drying the sheets at 50-60 C. for 12-24 h; wherein the dye solution is prepared by boiling natural dye source including onion skin, indigo leaves, beetroot, and charcoal powder in water and straining the solution; (iv) placing the dried sheet on a pre-heated embossing plate and applying pressure with a hydraulic press for 30-60 s; (v) allowing the sheet to cool for 12 h to set the pattern and storing in a dry place until further usage.

7. The process of preparation of non-woven bio-textile fabric as claimed in claim 6, wherein the structural layer obtained after felting process is further pressed, dried and finished similar to that of step (f) and step (g) such that it acts as a single layered bio-textile fabric comprising algae and seaweed in the ratio 3:7.

8. The process of preparation of non-woven bio-textile fabric as claimed in claim 6, wherein the consistency of the slurry is dependent on the method of preparation of the structural layer or the non-woven bio-textile; wherein a thin slurry with a pulp content in the ranges between 5-8% is desirable for spray gun technique and a medium to thick slurry with a pulp content in the ranges between 8-15% is desirable for vat lifting and felting technique.

9. The process of preparation of non-woven bio-textile fabric as claimed in claim 6, wherein the adhesives is alternatively added before the pressing step (f) and the pressure in the press is gradually increased from 50 psi applied for 1-2 min up to 200 psi applied for 2-3 min to avoid seepage of adhesives.

10. The process of preparation of non-woven bio-textile fabric as claimed in claim 6, wherein the final composition of the single layered bio-textile includes 70-80% of algae/seaweed, 10-15% of natural fillers, 3-5% of softeners/plasticizers and 1-2% of colouring agent, and the double layered bio-textile includes 45-50% of algae, 20-25% of seaweed, 15-20% of natural fillers, 5-8% of softeners/plasticizers and 1-2% of colouring agent.

11. A non-woven bio-textile comprising a single structural layer or a plurality of layers, each layer comprising pre-treated seaweed, natural fillers, and other additives; wherein the weight ratio of pre-treated seaweed to natural fillers is between 3:7 and 7:3; and wherein the additives are selected from adhesives, binders, lacquers, softeners/plasticizers, preservatives, and/or colouring agents, present in an amount of 0.5-10% by weight.

12. A non-woven bio-textile comprising a single structural layer or a plurality of layers, each layer comprising pre-treated algae, natural fillers, and other additives; wherein the weight ratio of pre-treated algae to natural fillers is between 3:7 and 7:3; and wherein the additives are selected from adhesives, binders, lacquers, softeners/plasticizers, preservatives, and/or colouring agents, present in an amount of 0.5-10% by weight.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0020] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.

[0021] In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the invention. It is apparent, however, to one skilled in the art that the embodiments of the invention may be practiced without these specific details or with an equivalent arrangement. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the embodiments of the invention.

[0022] FIG. 1 illustrates a process of preparation of bio-textile as disclosed in one of the embodiments of the present invention.

DETAILED DESCRIPTION OF INVENTION

[0023] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and/or detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practised and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0024] Reference in this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase in an embodiment in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.

[0025] Moreover, although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present disclosure. Similarly, although many of the features of the present disclosure are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present disclosure is set forth without any loss of generality to, and without imposing limitations upon the present disclosure.

[0026] The term bio-textile or biofabric are interchangeably used in the Specification where all these terms have the same context and meaning as it describes the non-woven bio-textile fabric of the invention.

[0027] The invention disclosed herein provides a non-woven bio-textile fabric comprising either a single structural layer or a plurality of layers including a surface layer and a structural layer. The surface layer and the structural layer further comprises either pre-treated algae and natural fillers or pre-treated algae, seaweed and natural fillers. The bio-textile fabric further comprises additives including adhesives, lacquers, binders, softeners/plasticizers, preservatives and/or colouring agents. The weight ratio of pre-treated algae and natural fillers in the fabric is between 0.01:10 and 10:0.01, specifically between 3:7 and 7:3. The weight ratio of pre-treated algae, seaweed and natural fillers in the fabric is 5:2:3. The weight percentage of additives in the fabric is in the range of 0.5-10%. The thickness of the single layered and multiple layered bio-textile fabric is in the range of 0.5-5 mm and 1-10 mm, respectively.

[0028] In an example embodiment, the filamentous algae is selected from but not limited to Classes Chlorophyceae, Klebsormidiophyceae, Xanthophyceae, Bacillariophyceae (diatoms), Cyanophyceae, and the like. Preferably, the algae are selected from different genera of the Class Chlorophyceae including Spirogyra, Zygnema, Mougeotia, and the like from the Order Zygnematales; Cladophora (especially Cladophora fracta) and the like from the Order Cladophorales, Ulothrix and the like from the Order Ulotrichales; Hydrodictyon and the like from the Order Chlorococcales; and Oedogonium and the like from the Order Oedogoniales. Preferably, the algae are selected from a genera of the Class Klebsormidiophyceae including Klebsormidium and the like. Preferably, the algae are selected from a genera of the Class Xanthophyceae including Vaucheria, Tribonematales, and the like. Preferably, the algae are selected from a genera of the Class Bacillariophyceae including Aulacoseira, Melosira, and the like. Preferably, the algae are selected from a genera of the Class Cyanophyceae including Oscillatoria, Nostocales, and the like.

[0029] In an example embodiment, the seaweed is selected from but not limited to different phylum including Rhodophyta, Cyanobacteria, Chlorophyta, Pheophyta and the like. Preferably, the seaweeds are selected from different genera of the Phylum Chlorophyta including Ulva and the like; Phylum Pheophyta including Sargassum, Durvillaea, Saccharina, and the like; Phylum Rhodophyta including Gracilaria, Gelidium, Rhodophyta and the like.

[0030] In some example embodiment, the fillers are selected from but not limited to rice husk, wheat straw, jute, grass, cork powder, starch, textile wastes, waxes, oil, polymer fillers and the like wherein starches include tapioca, corn, potato, rice and the like; waxes include bees wax, paraffin wax, carnauba wax and the like; and textile wastes include fabric scraps such as recycled fabrics, recycled fabric blends, leather buffing dust and the like.

[0031] In some example embodiment, the adhesive is selected from but not limited to heat-activated adhesives including gum/glue-based adhesives including guar gum, arabic gum, xanthan gum, jackfruit glue, arrow root glue, corn-starch glue and the like; chitosan-based adhesives, starch-based adhesives derived from plant sources including corn, wheat, or potatoes; rosin-based adhesives, natural rubber and polyurethane based adhesives.

[0032] In some example embodiment, the wax and oil as plasticiser or for waterproofing is selected from but not limited to carnauba wax, beeswax, vegetable or fruit oil and natural resin in the range of 3-5%, 2-4%, 1-2%, 1-3%, respectively. The colouring agents are selected from but not limited to natural dyes including onion skin, indigo leaves, beetroot, and charcoal powder used in the range of 2-3%, 1-2%, 0.5-1% and 1-2%, provides yellow/orange, red/pink, blue, and black colour, respectively.

[0033] In an exemplary embodiment, the tensile strength of the single layer and double layer is estimated using breaking force and elongation strip method as per ASTM D 5035:2011 standards wherein the size used for testing is 31. The tensile strength of the single layer and double layer bio-textile fabric is in the range of 100-200 N/mm and 150-200 N/mm, respectively. On comparison, the tensile strength of the bio-textile fabric is better than the conventional fabric including cotton, nylon, rayon, polyester and denim. This indicates that the single layered bio-textile is suitable for light wear applications and double layered fabric for heavy duty applications.

[0034] In other exemplary embodiment, the tearing strength of the single layer (31) and double layer (31) is estimated using IS 6489 (Part 1): 2011 R2021 standards and is in the range of 50-60 N and 70-80 N, respectively. On comparison, this is better than rayon, silk, chiffon and linen fabric. This indicates that both the single layered and double layered bio-textile is resistant to tearing and is suitable durable applications such as workwear, industrial use, and outdoor fabrics.

[0035] In yet other exemplary embodiment, the pH of both single and double layered bio-textile is in the range of 6-7. The GSM of the single layer (31) and double layer (31) bio-textile fabric with cotton scraps as fillers is estimated using IS 19864:2001 method A standard and is found to be in the range of 550-600 GSM and 1350-1450 GSM. Fabrics with a high GSM tend to provide better thermal insulation due to their thickness. This makes them suitable for winter clothing (like heavy jackets or coats), blankets, or heavy-duty outdoor gear. The distribution of weight between the surface layer and the structural layer is in the ratio 3:7 and 7:3 based on the weight of algae and algae/seaweed.

[0036] Thus, the physical properties of the bio-textile fabric is based on the number of layers and the amount of algae or algae/seaweed that is packed within each layers. On changing the weight of material added, the fabric can be changed for manufacturing different apparels.

[0037] In another embodiment, a process of preparation of bio-textile as shown in FIG. 1 comprises the steps of (a) harvesting, cleaning and optional detoxification of the biological source; (b) pre-treatment of the source; (c) preparation of pulp/slurry; (d) preparation of structural layer using algae and seaweed mixture; (e) preparation of double layered non-woven bio-textile/fabric; and (f) drying, curing and finishing the bio-textile/fabric.

[0038] In an exemplary embodiment, the first step of harvesting, cleaning and and optional detoxification of the biological source including algae and seaweed in the preparation of bio-textile further comprises the steps of: [0039] (i) harvesting algae mats using either an automated netting system or a rotary drum collector; and harvesting seaweed using hand harvesting technique with tools like scissors, knives, pruning shears, rakes or hooks; [0040] wherein the floating automated rake or net system equipped with sensors to detect algae density and ensure optimal harvesting time collects algae mats from the water surface and the rotary drum collector skims algae by rotating the drum and lifting the algae onto a conveyor belt; [0041] (ii) rinsing the harvested algae and seaweed with filtered water to remove sand, debris, and impurities either by hand washing or mechanical washers; [0042] (iii) detoxifying on detection of heavy metals and pollutants in the cleaned algae either by a biological method using microbes or by a chemical method using chelating agent to bind and remove metals from algae; and [0043] (iv) soaking the seaweed in cold water for 12-24 hours to soften and desalinate it followed by sorting to remove non-target species, damaged seaweed, and plastic waste, and final rinsing; [0044] (iv) drying either by spreading the algae on drying racks or using an oven at 40-50 C.

[0045] In an exemplary embodiment, the second step in the preparation of bio-textile further comprises the steps of: [0046] (i) preparing two sets of enzymatic solution by mixing the enzymes with water in a temperature controlled vat that is maintained between 35-40 C. for optimal enzyme activity; [0047] wherein the first set of enzymes includes 0.5-2% cellulase, 1-2% pectinase and 0.5-1% hemicellulose, and the second set of enzymes includes 0.5-1% alginate lyase, 0.3-0.5% carragenase and 0.1-0.3% pectinase; [0048] (ii) immersing the cleaned/dried algae in the first set of enzyme solution followed by occasional paddling for even distribution and soaking for 3-4 h such that the selected enzymes softens and breaks down complex material and cell wall components in the algae; [0049] wherein the dried algae is rehydrated by soaking in warm water for 1-2 h before adding the enzyme solution; [0050] (iii) immersing the first treated algae and cleaned seaweed, separately in the second set of enzyme solution followed by occasional paddling for even distribution and soaking for 3-4 h and 2-3 h, respectively such that the selected enzymes breaks down alginates, carrageenan and pectin; [0051] (iv) rinsing the treated algae and seaweed in clean water to remove excess enzymes and straining through a fine mesh to remove any remaining debris/impurities; [0052] (v) soaking the enzyme treated algae and seaweed, separately with alkaline solution comprising sodium carbonate (5-7%) and calcium hydroxide (2-3%) that neutralizes pH, removes gels, further loosens and softens fiber; [0053] wherein the soaked seaweed in alkaline solution is boiled for 2-3 h at 90-100 C. and rinsed in cold water to remove excess gel.

[0054] In an exemplary embodiment, the third step in the preparation of bio-textile further comprises the steps of: [0055] (i) boiling pre-treated algae in a steam-heated vessel for 2-3 hours in the presence ultrasonic waves to further soften and separate the fibers and enhancing pulp consistency; [0056] (ii) rinsing the boiled algae in clean water to remove excess gels and straining through a fine mesh to remove excess water; [0057] (iii) preparing algal slurry by [0058] transferring the boiled algae to a mechanical pulper or industrial blender, adding filler material and required amount of water to achieve a desired consistency; [0059] pulverizing the mixture for 30-60 minutes until the pulp reaches a smooth, homogenous consistency; [0060] applying ultrasonic processing (20-40 kHz) for 30-60 minutes at 80-90 C. to further refine the pulp and ensure uniform dispersion of algal fibers and fillers; [0061] pressing the algal pulp to achieve a workable consistency; and [0062] (vi) preparing algal-seaweed slurry by [0063] stripping the seaweed fibers either manually or by using a fiber extraction machine to separate the cellulose-rich parts; [0064] drying the fibers in drying racks drying oven at 40-50 C. until it is slightly damp but pliable; [0065] breaking down boiled algae into fine fibers using a blender or mechanical pulper; [0066] blending the fine fibers of algae and seaweed along with natural fillers evenly using a carding machine or hand carder; [0067] wherein natural binders are added optionally along with little water to activate binders; wherein the preferable weight ratio between algae and seaweed is 3:7 and the preferable weight ratio of algae+seaweed and filler is 7:3.

[0068] In some example embodiment, the consistency of the slurry is dependent on the method of preparation of the structural layer or the non-woven bio-textile including spray gun, felting or vat lifting technique. For spray gun technique, a thin slurry is desirable wherein the pulp content ranges between 5-8%. For vat lifting and felting technique, a medium and thick slurry is required, respectively wherein the pulp content ranges between 8-12% and 12-15%, respectively. The slurry can also be stored in an air tight container up to 2 days at room temperature and has to be remixed before using for the next step.

[0069] In an exemplary embodiment, the optional fourth step in the preparation of bio-textile includes incubating the pulp/slurry in an eco-friendly bleaching agent overnight. This step is performed only when light-coloured bio-textile is required. The eco-friendly bleaching agents include hydrogen peroxide, ozone, sodium percarbonate, citric acid, lemon juice, sodium bicarbonate, peracetic acid and enzyme-based bleaches. In a specific embodiment, hydrogen peroxide is used.

[0070] In an exemplary embodiment, the fifth step in the preparation of bio-textile including preparation of structural layer by felting technique further comprises the steps of: [0071] (i) wet felting method including [0072] layering algae-seaweed fiber mixture onto a felting mat or mesh screen and building up the layers to achieve desired thickness; [0073] preparing a soap solution comprising castile soap and hot water (60-70C) at 0.5% w/v and applying on the layered algae-seaweed fibers to moisten the fibers; [0074] rolling back and forth over the layered fibers by placing a bamboo mat or rolling pin or hydraulic rollers up to 30 minutes such that the friction causes the fibers to interlock and bond; [0075] wherein the pressure of hydraulic rollers is in the range of 200-300 psi; [0076] rinsing the felted sheet with cold water and repeating the rolling process multiple times to achieve desired density and strength; [0077] drying the felted sheets in air or using oven. [0078] (ii) needle felting method including [0079] layering algae-seaweed fiber mixture onto a felting mat or foam block; [0080] needle punching and poking the layered fibers using a felting needle tool such that the barbs on the needle catch the fibers and entangle them; [0081] building a layer on top of felted layer and repeating the needle punching and poking until it reaches desired thickness; [0082] heat setting the felted sheet using steam iron or heat press for increasing the durability.

[0083] In an exemplary embodiment, the sixth step in the preparation of bio-textile including preparation of non-woven double layered bio-textile is performed either using a vat-lifting technique or spray-gun technique.

[0084] The vat lifting technique further comprises the steps of: [0085] (i) filling a large vat with clean water such that it fully submerge a lifting frame; [0086] (ii) adding the algal pulp to the vat followed by stirring for even distribution of the algal fibers; [0087] (iii) attaching a structural layer from previous step over a mesh covered frame and submerging the frame completely into the vat using a lever system; [0088] (iv) moving the frame side to side such that the pulp gets evenly settled on the structural; [0089] (v) lifting the frame vertically out of the vat such that excess water is drained off through the mesh in the frame; [0090] (vi) air drying the layer partially for 1-2 h and repeating the lifting process to form multiple layers; [0091] wherein each layer is partially dried before next lifting cycle to ensure proper adhesion between each layers; [0092] (vii) transferring the final bio-textile sheet into a pile of sheets for post-processing.

[0093] In a specific embodiment, the number of layers are decided based on the thickness of the bio-textile. For medium thickness bio-textile, 3-4 layers are required whereas for thick bio-textile, 5-6 layers are required.

[0094] The spray gun technique further comprises the steps of: [0095] (i) dispersing the slurry in water to achieve desired consistency and mixing in a blender or mixer for uniform dispersion; [0096] (ii) filtering the slurry through a fine mesh of about 100 to 200 microns to remove any large particles and avoid clogging the spray gun; [0097] (iii) transferring the slurry into a spray gun reservoir and adjusting the pressure in spray gun; [0098] (iv) selecting a suitable nozzle size and fixing the distance between the spray gun and the mesh covered frame; [0099] wherein the frame is attached with a structural layer before spraying in case of double layer; [0100] (v) spraying a thin and even coat of the slurry on the structural layers attached over a mesh covered frame and air dying for 1-2 h; [0101] (vi) repeating the spraying cycle until the desired thickness is reached and ensuring that each layer is air dried before spraying the next layer; [0102] wherein the preferable number of spray layers is in the range of 2 to 4 depending on the thickness of the produced bio-textile; [0103] (vii) transferring the final air dried bio-textile sheet into a pile of sheets for post-processing.

[0104] In a preferable embodiment, the slurry consistency loaded in the gun reservoir is in the range of 5-15% that is selected based on the required thickness of the bio textile wherein a slurry of 5%, 10% and 15% indicates 5 kg, 10 kg, and 15 kg of pulp dispersed in 95 L, 90 L and 85 L of water, respectively. Also, a slurry of low, medium, and high consistency is suitable to produce thin/flexible sheets, medium-thickness sheets and thick/durable sheets, respectively. The table given below indicates the relationship between various parameters that is required to be followed for a specific thickness of the bio-textile.

TABLE-US-00001 TABLE 1 Relationship between sheet thickness and other parameters in the process Pulp Spray Thickness Sheet Type Consistency Pressure (after drying) Thin Sheets 5-8% 20-30 psi 0.5-1 mm Medium Sheets 8-12% 30-40 psi 1-2 mm Thick Sheets 12-15% 40-60 psi 2-4 mm

[0105] In an exemplary embodiment, the seventh step in the preparation of bio-textile including pressing, drying and curing of single layered and double layered bio-textile further comprises the steps of: [0106] (i) placing the air dried bio-textile fabric on a pressing bed followed by placing a non-stick separator sheet to avoid sticking of fabric on the pressing plates; [0107] (ii) pressing for 2-5 min/sheet at a pressure range of 100-300 psi to remove excess water and improve fiber bonding; [0108] wherein the pressing is initiated at low pressure and is gradually increased to prevent uneven pressing and to produce a sheet of consistent thickness; [0109] (iii) removing the non-stick separator and applying a layer of adhesive on the surface of pressed sheets; [0110] wherein the adhesives is selected from but not limited to heat-activated adhesives that is activated only during the curing procedure; [0111] wherein the addition of adhesives after pressing step avoids seepage of adhesives from the bio-textile; [0112] (iv) transferring the adhesive treated sheets from the press to a drying equipment and drying the non-woven bio-textile fabric at 40-60 C. for a time period of 6-24 hours with a relative humidity maintained between 40-50%; [0113] wherein time of drying is selected based on the thickness of the bio-textile fabric; [0114] (v) the dried bio-textile sheets are pressed again for 2-5 min either in a hydraulic press or a heated press at a pressure range of 150-200 psi to improve bonding between fibers; [0115] (vi) cooling the sheets at room temperature for 12-24 h to allow the fibers to settle.

[0116] In a preferable embodiment, the pressing equipment includes but not limited to hydraulic press, roller press, vacuum press, and hand press that is ideal for small scale, large scale, achieving even thickness, and artisanal production, respectively. While using a heated press, the temperature is maintained between 40-60 C. to fasten the drying process during pressing. In an example embodiment, non-stick separators used between sheets are selected from but not limited to silicone-coated paper, Teflon sheets, parchment papers, polypropylene fabric wherein except parchment paper other separators are reusable that are used for multiple cycles.

[0117] In another embodiment, the adhesive is also be added before pressing process. In such cases, the pressure in the press is gradually increased from 50 psi applied for 1-2 min up to 200 psi applied for 2-3 min such that it avoids seepage of adhesives.

[0118] In a preferable embodiment, the heat-activated adhesive is selected from but not limited to gum/glue-based adhesives, chitosan-based adhesives, starch-based adhesives, rosin-based adhesives, natural rubber and polyurethane based adhesives. The gum-based adhesives are activated at relatively low temperatures, around 50 C. to 80 C. whereas the chitosan-based, rosin-based and starch-based adhesives are usually activated from 60 C. to 120 C. PU-based adhesives that are activated in the temperature range of 100-180 C. are chosen when high flexibility, durability and water resistance are desired.

[0119] In a preferable embodiment, the drying equipment includes air drying racks, infrared dryers, conveyor dryers, or hot air oven that is selected based on level of drying required and scale of production. In an example embodiment, air drying racks, infrared dryers, or conveyor dryers are used for artisanal, medium and large scale production whereas hot air oven is used for precise drying options. While using air drying racks, it is essential to manually flip the sheets every 4-6 h to ensure even drying whereas in other dryers it is essential to monitor the moisture content of the sheets periodically till it reaches 10-15%. The drying timeline for thin, medium and thick sheets are 6-8 h, 12-16 h, and 18-24 h, respectively. In case of infra-red dryers the recommended temperature is set in the range of 45-55 C. whereas for other dryers it is 40-60 C.

[0120] In an exemplary embodiment, the seventh step in the preparation of bio-textile including finishing/conditioning further comprises the steps of: [0121] (i) waterproofing by applying wax or natural oil using a spray gun or roller wherein the wax/oil is completely melted at 50-60 C.; [0122] (ii) curing the sheet at room temperature for 12-24 h that allows full absorption of the waterproofing layers; [0123] (iii) applying the natural dye solution using spray gun, brush or dip method and drying the sheets at 50-60 C. for 12-24 h; [0124] wherein the dye solution is prepared by boiling natural dye source including onion skin, indigo leaves, beetroot, and charcoal powder in water and straining the solution; [0125] (iv) placing the dried sheet on a pre-heated embossing plate and applying pressure with a hydraulic press for 30-60 s; [0126] (v) allowing the sheet to cool for 12 h to set the pattern and storing in a dry place until further usage. [0127] that improves water resistance, flexibility, adhesion and durability;

[0128] In another embodiment, the natural dye solution is added in multiple stages based on the requirement of colour design outcome of the fabric including at the slurry preparation step, at the spraying step or in both slurry preparation and spraying steps.

[0129] In a preferable embodiment, the embossing is selected based on the type of pattern and each embossing type has a specific range of pressure. The different types of embossing pattern with its purpose and recommended pressure are listed in the table 2 below:

TABLE-US-00002 TABLE 2 Preferable types of embossing pattern used for finishing process Embossing Recommended Pattern Purpose Pressure NDM Embossing Natural leather-like grain 200-300 psi Croco Embossing Crocodile skin texture 250-300 psi Geometric Patterns Modern design aesthetics 150-250 psi

[0130] In an example embodiment, the surface treatment of the prepared bio-textile fabric also includes lacquering, milling and the like.

[0131] In a preferable embodiment, the final composition of the single layered biotextile includes 70-80% of algae/seaweed, 10-15% of natural fillers, 3-5% of softeners/plasticizers and 1-2% of colouring agent and that of the double layered biotextile includes 45-50% of algae, 20-25% of seaweed, 15-20% of natural fillers, 5-8% of softeners/plasticizers and 1-2% of colouring agent.

[0132] Thus, the bio-textile fabric disclosed herein is completely made from biological sources and materials that includes algae, seaweed, natural fillers, natural plasticizer and natural colouring agent thereby completely reducing or avoiding the use of chemical substances. This effective uses of waste resources creates a sustainable recycling system and/or circular economy that lowers the amount of waste disposal and reduces pollution. The biological nature of this bio-textile makes it biodegradable and compostable with a lower carbon footprint.

[0133] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.