Periodic Reporting for period 2 - FibriTech (Technology for 3D fibrous eco materials)
Período documentado: 2023-09-01 hasta 2024-12-31
FibriTech is pioneering a new class of 3D fibrous materials designed to replace fossil-based materials in industrial applications. The project, lasting from September 2022 to December 2024, has successfully developed, tested, and demonstrated a sustainable, scalable process for manufacturing biodegradable fiber-based materials without chemical binders. This innovation directly addresses the growing demand for eco alternatives in agriculture, packaging, and industrial absorbents.
Through using natural cellulose and lignocellulose fibres, FibriTech has created materials with high mechanical strength, tailored porosity, and full biodegradability, making them ideal replacements for peat-based substrates, petroleum-based sorbents and polystyrene packaging fillers. Our binder-free process ensures a cleaner, more efficient production method than conventional bio-based materials requiring chemical modifications.
The project’s main objectives were:
• To develop and optimise an automated demo production line that manufactures customised fibre-based materials.
• To introduce and validate two key products in their respective markets:
o FibriAgri – A biodegradable, peat-free cultivation substrate for controlled-environment agriculture.
o FibriSorb – A high-performance oil and chemical sorbent that replaces mineral and petroleum-based absorbents.
• To demonstrate industrial scalability and market readiness through real-world validation with commercial partners.
• To establish regulatory and policy alignment with EU sustainability goals, supporting the transition to a circular economy.
Through using natural cellulose and lignocellulose fibres, FibriTech has created materials with high mechanical strength, tailored porosity, and full biodegradability, making them ideal replacements for peat-based substrates, petroleum-based sorbents and polystyrene packaging fillers. Our binder-free process ensures a cleaner, more efficient production method than conventional bio-based materials requiring chemical modifications.
The project’s main objectives were:
• To develop and optimise an automated demo production line that manufactures customised fibre-based materials.
• To introduce and validate two key products in their respective markets:
o FibriAgri – A biodegradable, peat-free cultivation substrate for controlled-environment agriculture.
o FibriSorb – A high-performance oil and chemical sorbent that replaces mineral and petroleum-based absorbents.
• To demonstrate industrial scalability and market readiness through real-world validation with commercial partners.
• To establish regulatory and policy alignment with EU sustainability goals, supporting the transition to a circular economy.
Our eco-fibrous biomaterials development efforts have centred on establishing a novel production process and validating core technologies. The project's key technical achievements include:
• Established a fully operational demo line enabling automated production of fibrous materials with controlled density ranging from 30 to 150 kg/m³.
• Developed a proprietary electromagnetic forming process combining different thermal techniques for optimal fibre bonding
• Achieved precise control over material porosity through advanced mould design and process parameters.
• Implemented real-time process monitoring and control systems for consistent quality.
• Optimized energy consumption through advanced drying techniques, reducing energy use by 50% compared to conventional methods.
• Demonstrated linear scalability with predictable throughput ratios up to 0.3 m³/hour per 100 kW installed power with a plan to increase further up to 0.5 m³/hour.
Material engineering
• Created hierarchical pore structures with controlled distribution across different scales of pore dimmensions.
• Achieved mechanical strength comparable to synthetic foams without using chemical binders.
• Developed methods for controlled hydrophobisation using bio-based additives.
• Established precise density gradients within single products through electromagnetic field manipulation.
• Validated biodegradability while maintaining wet and dry structural stability in use.
Process control and optimisation
• Developed master control system integrating multiple production modules.
• Created database structure for recipe management and process parameter optimisation.
• Established quality control protocols using non-destructive testing methods.
• Implemented automated data collection for continuous process improvement.
• Achieved reproducible production with less than 5% variation in key parameters.
• Established a fully operational demo line enabling automated production of fibrous materials with controlled density ranging from 30 to 150 kg/m³.
• Developed a proprietary electromagnetic forming process combining different thermal techniques for optimal fibre bonding
• Achieved precise control over material porosity through advanced mould design and process parameters.
• Implemented real-time process monitoring and control systems for consistent quality.
• Optimized energy consumption through advanced drying techniques, reducing energy use by 50% compared to conventional methods.
• Demonstrated linear scalability with predictable throughput ratios up to 0.3 m³/hour per 100 kW installed power with a plan to increase further up to 0.5 m³/hour.
Material engineering
• Created hierarchical pore structures with controlled distribution across different scales of pore dimmensions.
• Achieved mechanical strength comparable to synthetic foams without using chemical binders.
• Developed methods for controlled hydrophobisation using bio-based additives.
• Established precise density gradients within single products through electromagnetic field manipulation.
• Validated biodegradability while maintaining wet and dry structural stability in use.
Process control and optimisation
• Developed master control system integrating multiple production modules.
• Created database structure for recipe management and process parameter optimisation.
• Established quality control protocols using non-destructive testing methods.
• Implemented automated data collection for continuous process improvement.
• Achieved reproducible production with less than 5% variation in key parameters.
FibriTech has developed a scalable process for manufacturing structured fibre-based materials without synthetic binders. This approach provides biodegradable alternatives to peat, polystyrene, and petroleum-based absorbents with agriculture, industrial, and packaging applications.
Key results
• Advanced fiber structuring. The process allows for precise control over fibre orientation and porosity, optimising absorption, mechanical strength, and biodegradability for different applications.
• Energy-efficient drying. The use of electromagnetic technology improves drying efficiency, reducing energy consumption and production costs.
• Scalability. The automated demo production line confirms that the process can be adapted for larger-scale manufacturing while maintaining material performance.
• IPR. The project has secured one granted patent and two additional patent applications.
FibriTech’s innovations support EU sustainability objectives by providing renewable, biodegradable alternatives to fossil-based materials in industrial absorbents, horticulture, and packaging, reducing waste generation and CO2 emissions. The path forward requires further optimisation for industrial-scale production, the development of application-specific standards, and the establishment of appropriate certification frameworks. Through strategic partnerships and continued R&D, we aim to expand this platform technology into additional market segments, supporting the broader transition to sustainable materials across multiple industries such as automobile, construction, heavy-duty packaging, etc.
Key results
• Advanced fiber structuring. The process allows for precise control over fibre orientation and porosity, optimising absorption, mechanical strength, and biodegradability for different applications.
• Energy-efficient drying. The use of electromagnetic technology improves drying efficiency, reducing energy consumption and production costs.
• Scalability. The automated demo production line confirms that the process can be adapted for larger-scale manufacturing while maintaining material performance.
• IPR. The project has secured one granted patent and two additional patent applications.
FibriTech’s innovations support EU sustainability objectives by providing renewable, biodegradable alternatives to fossil-based materials in industrial absorbents, horticulture, and packaging, reducing waste generation and CO2 emissions. The path forward requires further optimisation for industrial-scale production, the development of application-specific standards, and the establishment of appropriate certification frameworks. Through strategic partnerships and continued R&D, we aim to expand this platform technology into additional market segments, supporting the broader transition to sustainable materials across multiple industries such as automobile, construction, heavy-duty packaging, etc.