Bio-Based Synthetic Fibres

Bio-based synthetic fibres are man-made fibres produced from bio-derived monomers or polymers obtained from renewable biological feedstocks — sugarcane, corn starch, castor oil, wheat straw, algae — rather than petroleum, providing partial or complete fossil carbon replacement while retaining the processing advantages of synthetic polymer fibre production. The global bio-based fibre market was $4.2 billion (2022, Grand View Research) — dominated by polylactic acid (PLA, Ingeo by NatureWorks, USA, 180,000 tonnes/year capacity), bio-based PTT (Corterra/DuPont Sorona from corn-derived 1,3-PDO, 60,000 tonnes/year), bio-PA (Zytel RS, Rilsan PA11 from castor oil), and bio-PET (partially bio-based, 30% MEG from sugarcane ethanol — major brands target 100% bio-based PET). PLA properties: density 1.24 g/cm³, tenacity 2.0–3.5 cN/tex (staple) / 3.5–5.0 cN/tex (filament), moisture regain 0.4–0.6%, melting point 170–175°C (Tg 60°C), limiting oxygen index LOI 26% (FR properties advantage), biodegradable in industrial compost (58°C, 60% RH, 90 days → >90% mineralisation per EN 13432). Bio-based PTT (DuPont Sorona: 37% by weight from corn 1,3-PDO): properties superior to PET for carpet and stretch applications — Tg 45°C (lower than PET 80°C → better elastic recovery from stress, target for stretch applications), carpet crush recovery 40% better than PET BCF, dyeable at 100°C without carrier (versus 130°C for PET — significant energy saving in dyeing). Bio-PA11 (Rilsan, Arkema, from 11-aminoundecanoic acid derived from castor oil ricinoleic acid): density 1.04 g/cm³, tenacity 4.5–5.5 cN/tex, elongation 300–400%, Tm 185°C, chemical resistance excellent — high-performance technical fibre for oil & gas umbilicals, automotive fuel line, 100% bio-based.