Revolutionary Bioprocess Reduces Chemical Use and Energy Consumption, Paving the Way for Greener Textile Manufacturing
By Marina Guillén Montalbán
The OXIPRO project has developed an innovative biocatalytic process that enhances the sustainability of cotton bleaching, a critical step in textile manufacturing. This breakthrough biobleaching process utilizes carbohydrate-rich wastewaters generated during cotton processing to produce hydrogen peroxide (H₂O₂) using a carbohydrate oxidase. The hydrogen peroxide-rich wastewater is then employed for bleaching cotton, significantly improving the efficiency and environmental footprint of the process.
The OXIPRO project’s novel approach not only reduces the need for synthetic bleaching agents but also optimizes process conditions, reducing the required temperature from 102ºC to 90ºC and lowering the pH from 12 to a neutral 7. These advancements contribute to a more eco-friendly and energy-efficient textile production chain, marking a significant step forward in the industry’s transition toward sustainability.
A Game-Changer in Textile Processing
Traditional cotton bleaching relies heavily on chemical-intensive processes that consume large amounts of water, energy, and harsh chemicals, including sodium hydroxide and high-concentration hydrogen peroxide. These conventional methods generate considerable chemical waste, impacting both the environment and human health.
OXIPRO partners RUG, UAB, ZORLU, and VTT have addressed these challenges by leveraging a cutting-edge biocatalytic process that repurposes carbohydrate-rich wastewaters—a by-product of cotton processing—into a sustainable bleaching agent. By employing a carbohydrate oxidase, the process efficiently converts carbohydrates in the wastewater into hydrogen peroxide. This biological approach reduces the need for external hydrogen peroxide production, reducing the dependency on chemical suppliers and minimizing the environmental impact of traditional bleaching methods.
Moreover, the carbohydrate oxidase required for this process has been successfully produced at a scale of up to 50L. In addition, the enzyme has been immobilized and purified in just one step using cellulose as a matrix, a more environmentally friendly alternative compared to other materials typically used for enzyme immobilization. This advancement further enhances the sustainability of the biobleaching process by reducing waste and reliance on synthetic immobilization supports.
Sustainability at the Core
One of the most compelling aspects of the OXIPRO biobleaching process is its sustainability. By repurposing wastewater, the method effectively promotes circularity in textile production, turning waste into a valuable resource. The integration of biocatalysis not only reduces chemical load but also ensures a significant reduction in water pollution, as it avoids the introduction of harmful chemicals into wastewater streams.
Furthermore, the process operates under milder conditions compared to traditional methods. The ability to bleach cotton at a lower temperature (90ºC instead of 102ºC) translates into substantial energy savings, reducing greenhouse gas emissions associated with high-temperature processing. Additionally, the required bleaching pH from is shifted to 7, the process becomes much safer for workers, reducing chemical handling risks and lowering the need for pH increase before wastewater disposal.
Industry Implications and Market Potential
The textile industry is under growing pressure to adopt more sustainable practices as consumers, regulators, and environmental groups demand greener alternatives. The OXIPRO biobleaching technology presents a scalable solution for textile manufacturers aiming to reduce their environmental footprint without compromising fabric quality.
A Step Toward Climate-Positive Textile Manufacturing
The textile industry is one of the largest contributors to global pollution, with traditional bleaching processes playing a significant role in water contamination and excessive energy use. OXIPRO’s innovative approach aligns with the industry’s need to decarbonize operations and adopt cleaner, more sustainable practices.
By implementing this biobleaching technology on a larger scale, textile manufacturers can significantly reduce their carbon footprint and contribute to a more sustainable supply chain. The process’s compatibility with existing production facilities makes it an attractive solution for companies looking to transition toward greener operations without requiring extensive infrastructure overhauls.
Watch our video to see the process!