8 bio-based and sustainable material innovations from the Material Lab for the future of the sports industry

Algae are the fastest-growing organism on Earth and require neither fertilizers nor pesticides, not even land. A whole range of exhibitors presented products based on algae. These include, for example, the fiber Algaetex, which is part of the “Biotexfuture” research project by RWTH Aachen and Adidas. Using a prototype running shoe, the project demonstrated that thermoplastic biopolymers from algae are suitable for textile applications.

Bloom Sustainable Materials already works with over 100 well-known brand partners and offers algae-based plastics, e.g. for EVA midsoles and shoe soles. Beyond Surface Technology from Switzerland has developed the textile finish MiDori WA (With Algae) from microalgae oil, which wicks moisture away from the skin and accelerates evaporation. But dyes can also be extracted from algae, as can food supplements.

Hemp is considered a sustainable alternative to the traditional textile fiber cotton, because the plant requires little water and grows without the use of pesticides or chemical fertilizers. Compared to cotton, hemp consumes less land and resources and also grows very quickly in cooler climates, such as Germany. Felde Fibres is a German bast fiber manufacturer that has succeeded in producing a previously unrivaled fineness of hemp fibers. The fibers have a pleasant feel and are grown entirely in Germany, with traceability to the farms of origin guaranteed. In order not to compete with food production, the hemp is mainly grown as a second crop, providing farmers with an additional income.

In particular, plant-based waste materials such as walnut shells and olive stones have captured the imagination of material designers. The Swiss company Kuori has developed and patented novel bio-based, biodegradable and elastic plastics. The granules can be seamlessly integrated into existing production processes in various industries, such as fashion, outdoor equipment and tools. Overall, the material has a product carbon footprint (PCF) that is potentially 60 percent lower than that of conventional plastics.

St3ms from the USA also works with vegetable waste from food production, optimizing waste recycling. The banana plant is used as a raw material, and after harvesting, the residues are converted into high performance natural fibers. These fibers are naturally strong and light, antimicrobial and fire resistant, without the use of chemicals. They can be used for a variety of nonwoven and composite applications in various industries.

Research laboratories and start-ups are not the only ones working on the sustainable transformation of the sports and textile industry. Hyosung, a leading global fiber manufacturer, has developed a process for fermenting sugar from sugar cane with the company Geno, which is to be used to produce elastane. The new Regen™ BIO Elastane, which is to be produced in a newly built factory in Vietnam, is expected to reduce carbon emissions by up to 80 percent by 2026.

Sugarcup also uses sugarcane as a raw material to make foams that are used as foam cups in bras and swimwear, or as EVA foam for flip-flops and yoga mats. The patented Sugarcup™ foam technology contains up to 83 percent bio-based ingredients and reduces the carbon footprint by up to 71 percent. It also contains none of the harmful chemicals found in polyurethane foam and can be recycled - even with non-bio-based EVA foams.

Another heavyweight in the textile industry is working to transition the production of primarily petroleum-based fibers to bio-based materials. A collaboration between The Lycra Company and Qore®, maker of Qira®, is enabling the world's first commercial production of bio-based Lycra® fiber. About two years ago, the company developed a process to produce Lycra® fiber, which was previously made from petroleum, using renewable resources. The raw material used is called Qira® and is derived from industrial corn. Qira® can replace a major component of spandex and reduce the carbon footprint by up to 44 percent.

From forestry by-products to sustainable products: Swedish company Reselo has developed a novel, fossil-free and 100% bio-based elastomer made from forestry biomass, namely birch bark. Reselo Rubber's

patented technology can replace fossil-based rubber in a variety of applications, such as footwear and clothing, making the products renewable and reducing the carbon footprint by up to 90 percent.

US-based Rheom Materials produces innovative materials derived from bacterial fermentation, minerals and plant materials that seamlessly replace fossil-based plastics. Shorai™ is an eco-friendly vegetable leather made from natural materials such as fermentation products, biomass derivatives, minerals, clay and more. Benree™ is a 100% bio-based resin designed to replace petrochemical plastics and is suitable for a wide range of injection molding applications.

And what about the artificial turf? More and more sports fields are being equipped with artificial turf because it is much easier to maintain. However, artificial turf is usually filled with plastic granules, which can break off as microplastics and be carried into the environment by rain and wind. Due to this high environmental risk, the EU plans to ban the construction of artificial turf pitches with plastic infill throughout Europe in the next few years. The "Bioturf" artificial turf from the "Biotexfuture" research project at RWTH Aachen solves this problem and uses bio-polyethylene (PE) obtained from plant raw materials, mainly from agricultural waste (wood) or plants grown in Europe (rapeseed). This avoids competition with food production.