“Reducing textile footprint: biodegradable acoustic ceiling insulation innovation”
Abstract
Textile and Apparel are sun-riser industries in Bangladesh. It is also one of the oldest and largest
profits making industry. Textile contributes substantially to Bangladesh economy by exporting
goods to various countries in the globe. For the textile industry, it is time to take stock of the
situation and aim at vertical integration or tie up with downstream manufacturers to realize
greater benefits of value addition and face the future with greater confidence. As the
globalization of textile industry becomes a reality, we need to develop strategies for survival and
growth.
Today every country is trying to reuse their textile waste and trying to make different products
with them. Slowly the competition is increasing. So, we also need get in the competition. Now in
our country, 30-35 percent of the wastes are reused domestically to produce goods like baby
wear, pillow, car-seat coating, quilt, mattress and so. Local apparel and terry-towel exporters and
textile millers are, however, against exporting jhut while the exporters demand cash incentives to
earn more from exports. We need to make it all 100 percent reused to obtain sustainability.
In this paper, we have made an attempt to make waterproof celling using PLA resin and denim
fabric waste produced by the denim industries. PLA Resin takes annually renewable resources –
corn, cassava and other plants as raw material. After fermentation by microorganisms, lactic acid
will be extracted, and then PLA will be produced through a process of refining, dehydration
polymerization, high temperature pyrolysis and final polymerization. PLA resin has excellent
biodegradable property. After disposal, within one year, it can be degraded into carbon dioxide
and water by microorganisms in the soil, and do no harm to our environment.
Introduction
In the recent years denim industry is one of the most demanding RMG sectors. The textile
industry has been a significant contributor to global pollution and waste, with denim
manufacturing being one of the leading culprits in generating textile waste. Denim waste,
primarily consisting of discarded denim garments and off-cuts, poses a significant environmental
challenge. Given the effects of climate change and the progressive depletion of natural resources,
recycling waste products is becoming more and more commonly accepted. With 10% of all
carbon emissions generated globally, the textile sector is the second most polluting sector in the
world. A lot of textile materials ended up in landfills as a result of the fast fashion movement's
expansion. A research indicated that in 2030, an individual will produce about 17.5 kg of textile
waste annually, despite the fact that the amount generated is growing every day. The pre- and
post-consumer types of textile wastes are separated. Estimated pre-consumer waste. Waste
textiles are kept out of landfills by 75%. Postconsumer garbage is defined as any article of
apparel or home textile that is no longer usable to its original owner. According to a 2016
Greenpeace analysis, manufacturers use 11.4 G liters of water and nearly 1700 M kg of various
chemicals to produce 2 G pairs of jeans. According to a study by Jamy Retrace (2020), 2.3 G of
jeans will use around 11,000 liters of water, traverse 65,000 kilometers through the earth, and
have an important environmental impact at various times.
Denim Waste and its Environmental Impact: Denim, a popular fabric worldwide, is characterized
by its durability and versatility. However, the denim production process generates substantial
waste, including denim off-cuts, rejected garments, and scraps. Traditional disposal methods,
such as landfilling or incineration, contribute to environmental degradation, greenhouse gas
emissions, and resource depletion. Addressing the issue of denim waste has become a critical
aspect of sustainable textile practices.
A synthetic polymer with several uses in textiles, adhesives, and coatings is polyvinyl alcohol
(PVA). The utilization of PVA glue and epoxy resin as adhesives in this research project is a
deliberate choice driven by their unique properties and suitability for specific purposes within the
production of eco-friendly acoustic ceiling panels. PVA glue is valued for its strong adhesive
properties. It forms a durable bond between the denim fibers, ensuring the structural integrity of
the acoustic panels. This robust adhesion is essential to guarantee the panels' longevity and
performance. PVA glue is water-based and contains no volatile organic compounds. It aligns
with the project's sustainability goals by being non-toxic and environmentally friendly, reducing
potential harm to both human health and the ecosystem. Its ease of application contributes to the
efficiency of panel production. On the other hand, The PLA resin is renowned for its exceptional
durability and resistance to wear and tear. By applying PLA resin as a protective layer on the
surface of the panels, we enhance their longevity and ensure they can withstand the demands of
various environments. It helps to create a smooth, visually appealing surface finish. This not only
contributes to the panels' aesthetic appeal but also facilitates maintenance, as it can be easily
cleaned and maintained over time & it offers resistance to chemicals and moisture, making it a
suitable choice for applications where the panels may be exposed to varying environmental
conditions. The selection of PVA glue and epoxy resin as adhesives is a thoughtful decision
based on their adhesive strength, eco-friendliness, and ease of application, durability, and
aesthetic benefits. These adhesives not only serve the functional requirements of the acoustic
ceiling panels but also align with the broader objective of creating sustainable and
environmentally responsible construction materials. This project works aims to create ceiling
panels made from denim wastes which would be eco-friendly and bio-degradable and at the same
time it will be much cheaper than the PVC made ceiling panels. The creation of biodegradable
ceiling panels is a sustainable and environmentally friendly solution. It reduces textile waste in
landfills, conserves resources, reduces environmental impact, and promotes biodegradability.
Traditional construction materials require finite natural resources, making biodegradable panels a
sustainable alternative. They also have a lower carbon footprint, as they break down over time
and return to the environment. The project promotes a circular economy by repurposing waste
materials into valuable products, reducing the linear "take-make-dispose" approach.
Biodegradable ceiling panels align with the growing trend towards sustainable construction
practices, offering an eco-friendly alternative for architects, builders, and homeowners. They
raise environmental awareness by showcasing the benefits of biodegradable materials and help
builders and developers comply with evolving environmental standards. The project also
promotes a circular economy by repurposing waste materials into valuable products.
Literature Review:
In the past, many researches took place to put the denim waste to make different products. But it
is not the first time research on recycled material made insulation. But it is the first attempt to
make an acoustic ceiling out of the denim waste and PLA resin / PVA. So it can be
biodegradable material and do not do any harm to the environment.
Materials:
The Materials used in the research are:
1. Denim Waste
2. Hydraulic Press
3. PVA Glue
4. PLA Resin
5. Cutting Machine
6. Blending Machine
7. Resin Application tools
Methodology:
The methodology for this research involves collecting denim cutting waste from factories,
processing it into fiber form, and bonding the fibers using PVA glue through a hydraulic press.
Subsequently, a layer of PLA resin will be applied for durability. Specialized equipment such as
a hydraulic press, cutting and blending machinery, and resin application tools will be employed,
and a steady supply of denim waste will be ensured. Collaboration with experts in materials
engineering and adhesives may be sought, and safety measures will be strictly followed during
all phases of the project work. The project's success will be assessed based on sustainability,
acoustic performance, and biodegradability criteria, with any necessary adjustments made to
optimize the acoustic ceiling panel production process.
