Production and Optimization of ALT TEX's PLA Based Biodegradable Textile

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With the fashion industry projected to account for a quarter of the world's greenhouse gas emissions by 2050, the sustainable fashion sector has witnessed over 450% growth since 2016. With limited sustainable material solutions, the current widely adopted solution, recycled polyester, is facing "greenwashing" backlash due to its lack of recyclability and contribution to microplastic pollution. Furthermore, one company, NatureWorks, has attempted to create a more sustainable alternative using PLA. By adjusting the ratio of lactide isomers within the polymerization process (D vs L-Lactide), the PLA is created with variable molecular weights and crystallinity. While this improves PLA's heat processability, industry adoption has been poor as this process alone does not significantly improve the durability and mechanical properties required for apparel lifecycle. Toronto-based ALT TEX Inc. is a business-to-business biomaterials company, creating sustainable fabric solutions for eco-conscious fashion retailers. The company operates through a closed-loop model, sourcing organic and recyclable feedstock for conversion into synthetic and natural apparel filaments and fibres. These filaments are subsequently manufactured into high-quality apparel-grade fabrics that are biodegradable and carbon neutral, to remedy the substantial ecological footprint of the fashion industry. Through the addition of a novel combination of bio-additives and nanocomposites, this project aims to optimize PLA for apparel manufacturing by improving its resistance to thermal and physical degradation - properties that have thus far rendered the polymer unsuitable for textile applications. Through the collaboration between Lambton College's Manufacturing Innovation Centre and ALT TEX, this project aims to test various ratios of the proposed additives to optimize and produce apparel-grade PLA pellets (modified from pre-purchased PLA) which can be subsequently manufactured into fabric. The research is expected to support product development for ALT TEX's $7 billion sustainable synthetic fabric line, expected to launch with the next 2 years, while growing Canada's sustainable chemistry portfolio.