BB Engineering Advances Bio-Based Polyethylene Fibers in bioPEtex Project
In the German research project bioPEtex, BB Engineering (BBE) is collaborating with multiple partners to develop textile materials made from 100% bio-based polyethylene (PE). The project seeks to examine the use of this polymer in the chemical fibre sector, where it has previously had limited adoption. BBE is supporting the initiative with its technical expertise in spinning and texturizing and is working on scaling the texturing process to an industrial level. Initial results have already been reported.
For many years, the global chemical fibre market has largely been dominated by PET. The polymer is widely used for textile applications due to its technical maturity, versatility, and cost efficiency. However, PET has increasingly faced scrutiny because of its reliance on fossil raw materials, CO2 emissions along its value chain, and recycling challenges. These issues have led researchers and industry stakeholders to investigate alternative materials that combine economic viability with improved sustainability.
Biopolymers are frequently discussed as alternatives, yet PET cannot currently be produced on an industrial scale in a fully bio-based form. Other biopolymers that could theoretically enable 100% bio-based clothing remain largely confined to research studies due to high costs that limit their suitability for mass markets. Within this context, the bioPEtex project is examining polyethylene (PE), a polymer that has generally been considered unsuitable for chemical fibre production despite its potential advantages. Bio-based PE is comparatively inexpensive and environmentally favourable, but its application in textile production has not yet been fully developed.
BB Engineering is participating in the project alongside RWTH Aachen University. The initiative is funded by the German Federal Ministry of Research, Technology, and Space and aims to develop textiles made from 100% bio-based polyethylene that are both environmentally sustainable and economically viable. BBE, which supplies spinning, texturizing, recycling equipment, and extrusion and filtration technology globally, contributes its expertise in synthetic fibre production and recycling technologies to the project. The company provides technical consultation for the development of the spinning process and is responsible for the development of the texturizing stage, which significantly influences the functional and mechanical properties of the resulting textile fibres.
“With our participation in the bioPEtex project, we don’t just want to contribute to the development of sustainable solutions, we also want to focus on the economic benefits for our customers,” explains Dr. Klaus Schäfer, Managing Director of BBE. “Bio-PE textiles offer companies the opportunity to reduce their production costs while tapping into new market segments.”
Polyethylene is one of the most widely produced polymers globally. Known for its durability, hydrophobic nature, low weight, and chemical stability, it is primarily used in the packaging industry and in various other applications including construction materials and consumer goods. Despite its widespread production, PE has rarely been used for textile fibre manufacturing.
Technical processing challenges have limited its use in fibre production. PE crystallizes at relatively low temperatures, creating a narrow processing window for spinning and texturizing. In addition, its low polarity makes dyeing difficult. Currently, PE is mainly used as a functional component in composites, geosynthetics, or specialised high-performance fibres such as UHMWPE rather than in conventional clothing or home textile products.
Nevertheless, the polymer offers several characteristics that could be beneficial for specific textile applications. These include very low density, resulting in lightweight fibres; strong chemical resistance; high dimensional stability and abrasion resistance; potential recyclability due to its simple polymer structure; and water-repellent properties that enable quick drying and a cooling sensation. Dyeing challenges could potentially be addressed through spinning dyeing techniques.
Because of these characteristics, PE may become relevant for applications that require lightweight performance, hydrophobicity, durability, and recyclability. Potential uses include sports textiles, outdoor products, technical textiles, and hygienic disposable materials.
“This opens up completely new product architectures for our customers. A material such as PE, which has hardly been represented in the textile market to date, could – provided that processing is optimized – enable highly attractive applications in economic terms,” explains Dr. Klaus Schäfer.
Bio-based polyethylene differs from fossil-based PE primarily in the origin of its raw materials. Chemically, both materials are identical in structure and performance. Bio-based PE is typically produced using fermented sugar, such as sugar cane, or starch sources including corn. Compared with fossil-based PE, bio-based PE can offer a lower carbon footprint and provides the potential for a fully bio-based textile recycling cycle without quality loss.
The material’s relatively low melting temperature may reduce processing energy requirements, and the global availability of PE could contribute to lower material and energy costs. Existing raw material supply chains from the packaging and plastics industries may also support wider adoption in textiles. In addition, PE fibre development could enable manufacturers to create specialised product segments and differentiate through the use of alternative sustainable materials.
Within the bioPEtex consortium, BB Engineering is responsible for developing and adapting the texturizing processes required for PE fibre production. Texturizing plays a central role in determining fibre characteristics such as feel, functionality, and mechanical performance. The project aims to adapt processing conditions so that PE fibres can be integrated into established textile manufacturing systems.
“Our many years of experience in developing chemical fiber production plants and our in-depth understanding of process management enable us to develop innovative solutions that go far beyond the current state of the art,” says Ralf Morgenroth, Head of Engineering Texturizing at BBE.
The project includes several development stages. TECNARO is responsible for producing spin-able bio-PE compounds containing bio-based colour pigments. Process optimisation for melt spinning and false-twist texturing is being conducted at the Institute for Textile Technology at RWTH Aachen University and at BBE, with the goal of scaling the processes for industrial production. Textile partner FALKE is conducting knitting trials to evaluate the yarn, including demonstrator T-shirts.
Initial results indicate that the bio-PE yarns possess suitable mechanical characteristics and provide a cooling wearing effect, which may be beneficial for sportswear applications. The project also follows a design-for-recycling concept to support textile recycling at the end of the product life cycle. A key milestone achieved so far is the production of a first white t-shirt prototype, representing an initial step in assessing commercial viability. Further development and optimisation work is ongoing.
“We are very positive about the results so far. They show that PE has real potential in textile value creation and can offer significant economic and ecological advantages for the industry in specific applications. We are delighted to be involved in this pioneering project. It is our aim to provide our customers with sustainable and profitable innovations,” says Dr. Klaus Schäfer.