WO2024042538A1 - Cuir végan à base de plante fabriqué à partir de déchets de culture de banane - Google Patents

Cuir végan à base de plante fabriqué à partir de déchets de culture de banane Download PDF

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Publication number
WO2024042538A1
WO2024042538A1 PCT/IN2023/050788 IN2023050788W WO2024042538A1 WO 2024042538 A1 WO2024042538 A1 WO 2024042538A1 IN 2023050788 W IN2023050788 W IN 2023050788W WO 2024042538 A1 WO2024042538 A1 WO 2024042538A1
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Prior art keywords
banana
leather
pulp
composition
banana pulp
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PCT/IN2023/050788
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English (en)
Inventor
Jinali MODY
Shshank SHRIVASTAVA
Sulata PAUL
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Mody Jinali
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Publication date
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Publication of WO2024042538A1 publication Critical patent/WO2024042538A1/fr

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/02—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with cellulose derivatives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L99/00—Compositions of natural macromolecular compounds or of derivatives thereof not provided for in groups C08L89/00 - C08L97/00
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0059—Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes
    • D—TEXTILES; PAPER
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    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0061—Organic fillers or organic fibrous fillers, e.g. ground leather waste, wood bark, cork powder, vegetable flour; Other organic compounding ingredients; Post-treatment with organic compounds
    • D—TEXTILES; PAPER
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
    • D06N3/0077—Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/042—Acrylic polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/10—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with styrene-butadiene copolymerisation products or other synthetic rubbers or elastomers except polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/121—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D06N3/142—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes mixture of polyurethanes with other resins in the same layer
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
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    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/04—Vegetal fibres
    • D06N2201/042—Cellulose fibres, e.g. cotton
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Definitions

  • the present invention relates to compositions for preparing vegan Leather and Vegan Leather prepared from such compositions.
  • This Food leather is a leather like material completely free of any animal product.
  • the invention relates to compositions for preparing vegan Leather wherein such compositions and vegan Leather are prepared from Banana crop waste including banana pseudostems. More particularly, compositions and Vegan Leather are prepared from processed Banana crop waste such as Banana pulp.
  • Compositions for preparing vegan Leather comprise of Banana pulp and at least one adhesive or binder. Further, the invention also relates to processes for preparing compositions and vegan leather from compositions containing Banana Pulp.
  • First object of the invention is to provide compositions to prepare Plant based vegan Leather wherein the compositions are completely free of animal product and thus avoids animal pollution of the leather industry.
  • Second object of the invention is to provide compositions to prepare Plant based vegan Leather wherein the compositions are employed in manufacturing vegan Leather by a tanning free process.
  • Third object of the present invention to provide a solution for leather manufacturing that causes minimal or zero pollution and majority of the material (>50%) is natural.
  • Fourth object of the present invention is to provide a solution for leather manufacturing that addresses the growing crop waste problem.
  • Fifth object of the invention is to use waste from the Banana crop after Harvest to prepare compositions which can be further employed in vegan Leather manufacturing. Therefore, the Vegan Leather is prepared from compositions which employ easily and abundantly available raw materials.
  • Sixth object of the invention is to provide a simple, economical and environment friendly process to prepare Plant based vegan Leather from compositions of the present invention containing processed waste from Banana crop.
  • Seventh object of the present invention is to provide a vegan leather material which looks, feels, and performs like leather.
  • Eighth object of the present invention is to develop sustainable and environmentally friendly alternatives which are significantly lower water intensive in comparison to animal leather manufacturing and lower carbon emissions
  • Ninth object of the present invention is to develop plant leather alternative with over 50% banana crop waste.
  • Present invention provides Plant based Vegan Leather completely free of any animal product.
  • the invention provides compositions to prepare Plant based vegan Leather wherein the compositions are completely free of animal product.
  • the said compositions incorporate plant based materials, particularly, plant based waste material which is otherwise discarded.
  • Using plant based materials for manufacturing compositions of the present invention completely eliminates use of animal skins or animal products in manufacturing of leather.
  • Tanning process used typically in manufacturing of leather employs harsh and toxic chemicals that are largely deposited untreated into wastewater responsible for polluting many water bodies.
  • Various types of Tanning processes typically involve use of basic chromium sulfate (BCS) and other toxic metals.
  • BCS basic chromium sulfate
  • Such use enhances Carcinogenic compounds in the wastewater like Cr(VI), Cadmium, Arsenic etc. which are known carcinogens.
  • chemicals like formaldehyde, lead, zinc, silicon are traced which are also hazardous. Therefore, stringent norms are applicable for estimating presence or formation of Cr (VI) in the final leather.
  • Manufacturing leather without requiring tanning step offers several ecological and environmental benefits such as reduction in water used, generation of toxic waste and significant reduction in carbon emissions.
  • the invention provides compositions to prepare Plant based vegan Leather wherein the compositions are employed in manufacturing vegan Leather by a tanning free process.
  • the present invention uses easily and abundantly available raw material to manufacture compositions which are further used to prepare Plant based vegan Leather.
  • invention uses waste from the Banana crop after Harvest to prepare compositions which can be further employed in vegan Leather manufacturing. Therefore, the vegan Leather is prepared from compositions which employ easily and abundantly available raw material such as Banana crop waste.
  • Leather manufacturing is a complex process. It involves a series of processes to arrive at a leather having desirable characteristics. The processes involved are soaking, liming, deliming, bating, pickling, tanning, dyeing, and finishing, and the other machinery steps like splitting, sammying, staking, drumming etc. Each one of these processes is complicated and requires multiple steps with immense water and energy used.
  • Fourth object of the invention is to provide a simple, economical and environment friendly process to prepare i) Compositions of the present invention containing Banana pulp which is obtained by processed waste from Banana crop and ii) Plant based Vegan Leather from compositions of the present invention.
  • the process does not involve use of any toxic or hazardous chemical and the product produced is free of any such chemicals.
  • the leather industry is responsible for significant environmental damage and puts immense pressure on land, food, water resources and animal livestock too.
  • a typical cow leather bag requires 18,000 liters of water which is 25 years of drinking water for a single person and the carbon equivalent of charging 12,000 smartphones. This can also be looked at as the emissions from the manufacturing of 100K straws.
  • 14% w/w of all emissions globally are attributed to livestock rearing an industry that leather depends on. Additionally, 1 ton of raw material generates 20% w/w of finished leather and 60-80% w/w of solid and liquid waste that includes carcinogenic heavy metals, a by-product of the tanning processes. 90% w/w of leather processed is tanned using chromium and other toxic chemicals that are largely deposited untreated into wastewater responsible for polluting many water bodies.
  • the banana crop has more waste than most other crops as the plant only bears fruit once, after which the stem becomes redundant. 80% w/w of the plant by weight is wasted every harvest which amounts to about 120 ⁇ tones generated annually. And ⁇ 10% w/w of this cellulose and fibre rich waste is utilized despite its high value.
  • Indian Patent Application No. 202221054824 A provides a non-woven banana plant leather made of banana fiber, which is extracted from banana stem.
  • the extracted banana fibers are opened, carded, cross-lapped and needle punched to obtain banana fiber substrate which is a single layer non-woven substrate having density ranging from 1.5 to 2 g/mm3.
  • the banana fiber substrate is coated with adhesive coat to form composite with bio polyurethane in ratio of range of 3:0.1:1 to 5:0.1: 1 to give desired leather finish to the banana fiber substrate.
  • This prior art utilizes banana for preparing backing material wherein strength of Banana stem is not fully utilized.
  • Fig.l illustrates an exemplary flowchart that shows a plant-based method for manufacturing plant based vegan leather material, in accordance with an embodiment of the present invention.
  • Fig. 2 illustrates an exemplary view showing the plant-based panels of banana stem leather, in accordance of the present invention.
  • Fig.3 provides a process diagram depicting all steps in preparing plant based vegan leather of the present invention.
  • Fig. 4 provides different steps involved in the preparation for the plant based vegan leather starting from harvesting banana tree to finished product.
  • Fig. 5 and Fig.6 provides plant based vegan leather prepared as per the present invention.
  • Fig. 7A provides the composition containing banana pulp produced by processing banana crop waste and other additives which is used for preparing plant based vegan leather.
  • Fig. 7B provides the coating of composition of Fig. 7A by way of spraying, on the backing material to produce leather.
  • Fig. 7C provides the plant based vegan leather produced after coating of composition containing banana pulp produced by processing banana crop waste and other additives.
  • Fig. 8 provides the plant based vegan leather prepared as per the present invention.
  • Fig. 9 provides spraying of lacquering suspension.
  • Fig. 10 provides a wallet prepared as per the present invention.
  • Fig. 11A and Fig. 1 IB provides picture of bags prepared by using plant-based vegan leather prepared as per the present invention.
  • Fig. 12A and Fig. 12B provides a test reports of banana content (%) and other content (%) of the plant-based vegan leather prepared as per the present invention.
  • Fig. 13 A provides image of vegan Leather wherein of composition o having 60% Banana pulp + 30 % natural rubber + 10 % natural adhesive
  • Fig. 13 B provides image of vegan Leather wherein of composition q having 60% Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue
  • Fig. 14 A provides image of vegan Leather wherein of composition U having 55% Banana pulp + 26 % polyvinyl acetate + 14 % acrylic +5 % starch as filler.
  • Fig. 14 B provides image of vegan Leather wherein of composition q having 60% Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue.
  • Fig. 15A provides image of vegan Leather wherein of composition R having 55% Banana pulp + 25 % polyvinyl acetate + 20 % Magnopal IPF
  • Fig. 15B provides image of vegan Leather wherein of composition V having 60% Banana pulp + 30 % polyvinyl acetate + 10 % PEG.
  • the invention provides compositions to produce plant based vegan leather and Vegan leather produced from such compositions.
  • the invention provides compositions containing processed banana crop waste which are further used to produce vegan leather.
  • the invention covers compositions containing i) Banana pulp produced by processing banana crop waste and ii) other additives. More particularly, the invention covers compositions containing i) Banana pulp and ii) at least one adhesive / binder and optionally other additives selected from fillers, softeners / plasticizers, preservatives etc. . .
  • compositions are coated on the backing material to produce leather.
  • compositions of the present invention are also referred as “coating compositions”.
  • These compositions are also referred as leather mixtures.
  • the invention further provides leather produced by depositing / spraying / applying coating compositions / leather mixtures of the present invention on backing material.
  • the leather produced is further subjected through various processes to enhance adhesion between backing material and coated composition and to enhance look of a leather. These processes include plating, colour spraying, embossing and lacquering and drying in between these steps whenever required.
  • the plant-based vegan leather material looks, feels and performs like leather.
  • the vegan leather and compositions from which it is prepared do not contain any animal product.
  • the processes to prepare compositions and Vegan Leather are tanning free processes.
  • the compositions and vegan Leather are prepared from raw materials which are easily and abundantly available and processes are simple, economical and environment friendly.
  • compositions that meld around 40 - 70 % w/w of banana pulp, from 5 - 50 % w/w of adhesive and / or binder and optionally other additives into a cohesive and versatile mixture.
  • the amalgamation of these components is a strategic endeavour aimed at crafting compositions with distinctive properties.
  • the abundant presence of banana pulp, constituting almost half of the mixture serves as a foundational element. Its natural binding attributes, coupled with inherent biodegradability, offer a sustainable adhesive quality.
  • compositions to produce vegan Leather are made from processed Banana crop waste.
  • Banana crop generates significant waste than most other crops as the plant only bears fruit once, post which the stem becomes redundant and needs to be cut and discarded.
  • Banana crop generates significant waste than most other crops as the plant only bears fruit once, post which the stem becomes redundant and needs to be cut and discarded.
  • 80% w/w of the plant by weight is wasted every harvest which amounts to about over 120 million metric ⁇ tones are generated annually globally.
  • India which produces 25% w/w of the world's bananas, the waste generated is 30 million metric tons.
  • ⁇ 10% w/w of this cellulose and fibre rich waste is utilized despite its high value.
  • the present invention utilizes abundantly and easily available raw materials which are usually discarded as waste.
  • compositions of the present invention include processed Banana crop waste.
  • Banana crops can be processed in a number of ways. In a preferred way, Banana crop waste is processed to obtain Banana pulp.
  • compositions of the present invention for preparing vegan leather comprise of Banana pulp.
  • compositions for preparing vegan leather comprise of Banana pulp and at least one adhesive or binder. More particularly, compositions contain Banana pulp, one or more adhesives or binders and other additive such as a filler, softener / plasticizer, preservatives etc.
  • the Healthy leather prepared in accordance with the present invention comprises a backing material coated with a composition containing Banana pulp and other additives.
  • vegan leather prepared in accordance with the present invention comprises Banana pulp and adhesives and / or binders, fillers, softeners. plasticizers, colours / pigments, preservatives, lacquers, chemicals to prevent colour leakage ⁇ water repellents.
  • Backing material comprises up to 20 % w/w of the final leather, preferably up to 10 % w/w of final leather, and most preferably up to 5 % w/w of the final leather.
  • compositions of the present invention are coated on the backing material, they are also referred to as coating compositions and coated backing material is called panels.
  • Coating compositions comprise at least 85 % w/w, preferably at least 90 % w/w, more preferably at least 95 % w/w of the produced leather. Coating compositions are also called leather mixtures.
  • leather After coating of backing material with compositions of the present invention and plating which is done to enhance adhesion between backing material and coated compositions, leather is subjected to several finishing processes. Finishing of leather includes a series of steps to give buyers variety in the colours, embossing, shiny or matt finishes etc. and include top coating, surface treatment and adding chemicals to stop colour leakage and water proofing etc.
  • Upper coating contains colours / pigments, binders, preservatives, lacquers, chemicals to prevent colour leakage and water repellents together up to 5 % w/w, preferably, from 0.5 - 5 % w/w of final finished leather produced.
  • the vegan leather prepared in accordance with the present invention comprises from 1 - 15 % w/w of backing material, colours / pigments, binders, lacquers, chemicals to prevent colour leakage and water repellents and 85 - 99 % w/w of coating composition containing Banana pulp and at least one adhesive / binder and optionally one or more of other additives such as fillers and softeners / plasticizers. Additionally, from 0.001 to 0.1 % w/w of preservatives are present when required.
  • compositions to prepare vegan leather include at least one adhesive / binder and optionally other additives such as fillers, softeners / plasticizers, preservatives, colours etc.
  • Filler provides structure and fullness to the leather.
  • Starch is a preferred filler.
  • Preferably starch is added in liquid form prepared as provided below.
  • Starch from Tapioca, corn, potato and rice etc. can be used.
  • Other fillers include polymer filler, waxes such as bees wax, paraffin wax, carnauba wax, cork powder, veg oil, wheat straw, rice husk etc.
  • starch is used as a filler.
  • polymer filler is one or more from Magnopal IPF, Magnopal BP, Magnopal Pure-A is employed.
  • compositions to prepare vegan Leather preferably contain at least one adhesive / binder.
  • Adhesives and binders can be selected from natural source hereinafter natural adhesive or natural binder and chemical source hereinafter synthetic adhesive or synthetic binder. Adhesives ensure that there is no peeling off of the composition from backing material as well as it increases the intermolecular attraction between the compound molecules.
  • Preferred synthetic adhesives include Ethylene vinyl acetate, Polyvinyl acetate, Neoprene, plastic resin glue, epoxy glue etc.
  • Preferred natural adhesives include Natural rubber, guar gum, gum Arabic, gum rosin etc. Natural adhesives also include some mixtures and glues prepared inhouse from arrowroot, gum rosin, gum Arabic, jackfruit, Guar gum, agar-agar powder etc. A preferred natural adhesive is jackfruit glue, arrowroot glue, corn-starch glue.
  • binders preferred are Polyvinyl chloride, Polyurethane Binders, Acrylic Binders, Resin Binders, poly lactic acid, maleic anhydride, and Natural Binders made from Rubber and Starch. Binders are present in the compositions as well as in top colour coatings.
  • Top coating binders include Protein binder, acrylic binder, PU binder and other types of thermoplastic Binder, non-thermoplastic binders, Butadiene Binder etc.
  • Plasticizers or softeners are added to obtain soft leather and include polyethylene glycol, polypropylene glycol, glycerol, isopropyl alcohol, epoxidized soybean, and other vegetable or fruit oils e.g., com, sunflower, palm etc.
  • preservatives such as fungicides and bactericides, natural colours sourced from natural resources like charcoal black, beets, onion skins etc. can be added.
  • Banana pulp content of the compositions is from 40 - 70 % w/w, preferably from 50 - 70 % w/w, more preferably from 50 - 65 % w/w, and most preferably from 55 - 65 % w/w.
  • Adhesive / Binder content is from 5 - 50 % w/w.
  • More than one adhesives or binders are also present depending on the requirements of final leather.
  • filler from 5 - 35 % w/w of filler is present.
  • 1 - 15 % w/w, preferably, 5 - 15% w/w of a softener / plasticizer such as polyethylene glycol can be added.
  • additives are present in the vegan leather such as preservatives, pigments, dyes, natural colours, binders for mixing with pigments etc.
  • compositions containing Banana pulp preferably contains at least 40 % w/w, more preferably at least 50 % w/w and most preferably from 55 - 65 % w/w of Banana pulp.
  • Some of the Compositions of the present invention are as follows: i) 40 % w/w banana pulp + 30 % w/w adhesive + 30 % w/w filler; ii) 45 % w/w banana pulp + 30 % w/w adhesive + 25 % w/w filler; iii) 52 % w/w banana pulp + 25 % w/w adhesive + 23 % w/w filler; iv) 58 % w/w banana pulp + 21 % w/w adhesive + 21 % w/w filler; v) 50 % w/w banana pulp + 25 % w/w adhesive + 25 % w/w binder; vi) 58 % w/w banana pulp + 21 % w/
  • compositions of the present invention employing natural as well as synthetic adhesives and / binders, fillers, and softeners / plasticizers etc.
  • Neoprene ethylene vinyl acetate, polyvinyl acetate, natural rubber, gum Arabic, gum rosin, agar-agar solution, arrowroot glue, solution are preferred adhesives.
  • Adhesives are used to cause adhesion between backing material and coating compositions so no material gets separated / peeled off. Binders act as adhesion bolsters. They enhance binding between backing material and compositions coated on backing materials and also enhance binding within the compositions. Starch from tapioca, rice, corn, potato, rice husk, cork filler, polymer filler magnopal IPF, Magnopal BP, Magnopal Pure-A are added as fillers to give fullness and structure. Additional fillers include waxes such as Bees wax, paraffin wax, veg oil, Agri-waste filler like rice husk, wheat straw etc.
  • Glycerol, isopropyl alcohol, polyethylene glycol, polypropylene glycol etc. are added as softeners /plasticizers which impart desired softness to the leather.
  • compositions are specifically produced and suitable backing materials are coated with these compositions to produce vegan Leather.
  • Chloride M 60% w/w banana pulp + 20% w/w Cork Filler + 10% w/w Polyvinyl Chloride + 10% w/w wax
  • V 60% w/w Banana pulp + 30 % w/w polyvinyl acetate + 10 % w/w PEG (as softener and plasticizer).
  • compositions of the present invention employing natural adhesives such as natural rubber, jackfruit glue, Arrowroot Glue etc.
  • natural adhesives such as natural rubber, jackfruit glue, Arrowroot Glue etc.
  • d. 50% banana pulp + 30% Starch + 20% Guar Gum e.
  • dyes, pigments, colourants, binders for dyes and pigments and preservatives are part of these compositions and are added in amounts of up to 1 % w/w.
  • banana pulp, adhesives / binders, fillers, softeners / plasticizers are present around up to 99 % w/w and dyes, pigments, binders for dyes and pigments and preservatives are present around up to 1 % w/w.
  • compositions to prepare vegan Leather are also termed as leather mixtures.
  • a process of preparing compositions which are coated / sprayed on backing material to produce vegan Leather has following steps: (CHANGE AS PER CLAIM) i) Preparing banana pulp; ii) Mixing banana pulp and adhesive / binder in a blender; iii) Optionally adding any additional adhesive and / or binder; or adding filler and / or softener and blending; iv) Mixing dyes / pigments / synthetic colour with a binder and adding the mixture to above blend while mixing.
  • compositions of the present invention Banana pulp and adhesive and / or binder are mixed in a blender. Mixing is continued for 1 hr. Such mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying. If additional adhesive / binder is to be added, it is added at this stage and mixed. Filler and / or softener is added and mixed well. Dyes / pigments / Synthetic Colour is mixed with preferably double the quantity of Binder and such mixture is added to the above composition while mixing. Additionally, preservatives are added if needed.
  • Preparation of Banana pulp comprises i) Preparing or obtaining banana stem cuttings; ii) Subjecting banana stem cuttings to alkali treatment; iii) Boiling banana stem cuttings in a suitable equipment or digester causing them to melt and form banana pulp; iv) Washing and straining pulp to wash out left over alkali; v) Grinding pulp and washing ground pulp; vi) Optionally bleaching the pulp and washing pulp to wash out bleaching agent.
  • Banana pulp is prepared by carrying out a series of process steps including alkali treatment, boiling, bleaching, ageing and intermittent washing in between these steps when needed. Bleaching is mainly followed for obtaining white or whitish shade and is an optional step when such shade is not required.
  • Banana stems are cut after trees give fruits. Upper surface of the stem is separated from the inner and middle portions of the stem as it is harder. Long cuttings of Inner and middle portions are collected and subjected to a banana shredder.
  • Banana shredder is a stem cutting machine having sharp rolling blades inside. The shredder cuts the long cuttings of Inner and middle portions very quickly into small pieces of banana.
  • Banana stem cuttings / banana fibres are subjected to an alkali treatment during which 100 parts of Banana stem cuttings / banana fibres are mixed with around 1 - 2 parts of sodium sulfide and 2 - 3 parts of sodium hydroxide and 200 parts water and mixed.
  • alkali treatment 100 parts of Banana stem cuttings / banana fibres are mixed with around 1 - 2 parts of sodium sulfide and 2 - 3 parts of sodium hydroxide and 200 parts water and mixed.
  • Other combinations of alkalis that result in a pH of 11-12, can also be employed like calcium hydroxide, aqueous ammonia, thiourea etc.
  • the above mixture is subjected to boiling in a Digester.
  • stem cuttings are melted.
  • the melted stem cuttings are subjected to grinding in a grinder for up to 15 - 30 mins., during which melted stem cuttings produce banana pulp. This pulp is brown coloured. It is washed with water to wash away alkali and strained in a strainer. After straining, pulp is subjected to grinding and then washing.
  • Bleaching is optional and done only when white / whitish leather is desired.
  • Bleaching process 100 parts of pulp, around 6 - 7 parts of Bleaching powder (Calcium Oxychloride [Ca(OCl)2] and 200 parts of water are mixed. The mixture is kept overnight to lighten the original brown colour.
  • Bleaching chemicals like liquid bleach, hydrogen peroxide, sodium percarbonate, sodium perborate etc. are basic in nature and washing is necessary if bleaching is carried out to produce desired shade.
  • initial weight is reduced to almost 20 - 60 % w/w of the initial weight.
  • a process of preparing vegan leather comprises (As per the claim changes) i) Selecting and cutting backing material in suitable dimensions; ii) Preparing coating compositions; iii) Applying or spraying coating compositions on the backing material of suitable sizes to obtain panels; iv) Trowelling panels or spreading even the coated composition on panels; v) Drying panels under controlled temperature; vi) Plating dried panels; vii) Subjecting plated panels to colour spraying, drying and surface treatments comprising one or more of, milling, embossing and lacquering.
  • the process of preparing vegan Leather also comprises adding i) chemicals to prevent colour leakage and / or ii) water repellents during surface treatment.
  • compositions of the present invention such as from compositions A to V or compositions a to q are applied in the form of coating on a backing material in the production of vegan leather and hence the compositions are also termed as coating compositions.
  • One or more coats can be applied on the backing layer one after the other.
  • a suitable backing material is selected from recycled plastic bottles, polyester, rayon, nylon, velvet, cotton fabric from a locally grown cotton, vegan fabrics made from banana, bamboo, jute, linen etc.
  • backing material is obtained from recycled plastic bottles.
  • Backing material can be cotton fabric from a locally grown cotton known for its suppleness and comfort. Organic cotton also enhances the biobased nature of the product.
  • backing material is linen.
  • Thickness ratio of backing material to coatings is usually from 1:2 to 1:10.
  • backing material is not more than 20 % w/w preferably not more than 10 % w/w of prepared leather.
  • backing material or backing layer preferably comprises up to 10 % w/w, more preferably up to 5 % w/w and most preferably up to 2.5 % w/w.
  • Coating compositions are preferably present in an amount of at least 90 % w/w, more preferably at least 95 % w/w and most preferably at least 98 - 99 % w/w.
  • a suitable backing material is selected from recycled plastic bottles, polyester, rayon, nylon, velvet, cotton fabric from a locally grown cotton, vegan fabrics made from banana, bamboo, jute, linen etc..
  • Backing material is cut into various desired sizes as per the requirements and available drying infrastructure. In an embodiment, preferably a size of 8 ft X 10 ft has been employed. In another embodiment a smaller size of 27 inches X 40 inches has been employed.
  • cotton fabric is selected and cut into a size of 27 X 40 square inches. Fabric is ironed if it is creased or folded.
  • backing material is cut into desired dimensions.
  • the backing material is placed on a spraying table. Then 2 coats of any of the compositions are sequentially sprayed on the backing material using a spray gun to produce panels. Panel is backing material coated with compositions / leather mixtures. After first coat, panel is subjected to drying.
  • following coating compositions are preferably applied.
  • Next step is drying. After trowelling the panels, they are kept in drying racks and are subjected to drying at a specific temperature. Drying temperature is controlled and not allowed to exceed 60°C as it may burn upper soft portion of the coating. Panels are dried for at least 24 hrs., preferably for 48 hrs.
  • the dried coated panels are subjected sequentially to plating, colour spraying, embossing, and lacquering. Drying is needed after each of the steps involving colour spraying, embossing, and lacquering.
  • Plating Each panel is subjected to specific temperature and pressure and time.
  • pressure of from 200 - 300 MPa or Bar, preferably 250 MPa or Bar at 80°C for 1.5 sec. at a second in a hydraulic press machine.
  • Plating softens the upper surface and increases the bonding between fabric /backing material and the layers of coatings.
  • Finishing of leather includes a series of steps to give buyers variety in the colours, embossing, shiny or matt finishes etc. and include spray painting, surface treatment and adding chemicals to stop colour leakage and water proofing etc...
  • Finishing materials are up to 10 % w/w, preferably up to 5 % w/w of the leather, more preferably from 2% w/w to 4% w/w of the all coating and contains colours, binders, lacquers, and water resistant / water repellent coatings.
  • Eacquers include polyurethane lacquers, dyes lacquers, resin based lacquers, different types of nitrocellulose lacquers, Acrylic Lacquers, and also, water based silicone emulsions etc...
  • colours There are a variety of colours which can be employed in the compositions. Some of them are dyes, pigments & natural colours (made from organic compounds like coal tars, some petrochemicals i.e., benzene, toluene, xylene, oil & inorganic compounds like oxidation of metals i.e., titanium, iron etc).
  • binders Some of the colours are mixed with binders. There is a huge variety in binders. Most commonly, acrylic binders, polyurethane binders, Resin binders etc. are employed.
  • the binder is made from Natural Rubber and Starch [the process of starch mixture has already been mentioned in the above section] (1:3) or (1:4) or (1:5) or (1:6)
  • Embossing includes NDM embossed, PDM embossed, YDM embossed, Croco embossed, Printing, Foiling and other types.
  • the pigments used in colour coating are absolutely sustainable and eco-friendly.
  • the pigments are mixed with a binder in a ratio from 1:5 to 1:15, preferably in 1:10 ratio.
  • Next step is surface treatment and includes milling and embossing.
  • Milling After colour coating and drying, the panels are subjected to a Milling process to increase the softness. It is a drum operation where the panels are revolved in the drum. Due to this operation the upper surface of the material gets creasing effects like leather finishes.
  • the spray coating step is usually repeated if colours fade during embossing.
  • the pigments are mixed with a suitable binder in specific ratio from 1:5 to 1:15 preferably, 1:10 and sprayed on the panel. After colour coating, panels are dried for 24 hrs, and then if desired, a second coating is done followed by drying.
  • Lacquering is done to give desired finish to the prepared leather. Lacquering is done using various types of lacquers including but not limited to nitrocellulose based or cellulose acetate butyrate based which imparts gloss to the leather.
  • a nitrocellulose based lacquer is diluted using water. Additionally, a feeler that modifies touch and feel of a leather such as plant based or silicon based coating emulsion having properties like silicon coating is added to impart smooth touch. 49 % w/w shine lacquer is diluted with 49 % w/w with water and 2 % w/w plant based or silicon based coating emulsion similar properties like silicon coating is mixed in it to provide lacquer suspension. Lacquer suspension is applied as top coat on the prepared leather.
  • Drying is essential after colour spraying, before and after lacquering. When colour spraying is done multiple times, drying between each spray is essential. Minimum 24 hrs. drying time is used after each colour spraying and before and after Lacquering.
  • the vegan leather prepared in accordance with the present invention comprises a backing material coated with a compositions containing Banana pulp and other additives such as adhesives, binders, fillers, softeners / plasticizers, colours / pigments, preservatives, lacquers, chemicals to prevent colour leakage and water repellents.
  • Backing material comprises up to 20 % w/w, preferably up to 15 % w/w, more preferably up to 10 % w/w of the final leather, most preferably up to 5 % w/w of final leather. In most embodiments, backing material comprises preferably up to 2.5 % w/w of the final leather.
  • compositions of the present invention are coated on the backing material, they are also referred to as coating compositions.
  • Coating compositions or leather mixture along with top coatings comprise at least 85 % w/w, preferably at least 90 % w/w, more preferably at least 95 % w/w of the produced leather.
  • the vegan leather prepared in accordance with the present invention comprises 1 - 15 % w/w of backing material, colours / pigments, binders, lacquers, chemicals to prevent colour leakage and water repellents and 85 - 99 % w/w of coating composition containing Banana pulp and one or more of additives such as adhesives, binders, fillers, softeners / plasticizers. Additionally, from 0.001 to 0.1 % w/w preservatives are present when required. Depending on the nature of the additives, the compositions are divided into those containing synthetic adhesives and natural adhesives.
  • dyes used various type of pigments, dyes (different molecular size, different composition, metal free) were tried. Dyes are chemicals with smaller molecular size than pigments, and dyes are easily soluble while pigments are partially insoluble in Various types of binders (acrylic, resin, PU etc.) were tried, that were mixed with the colour in various concentrations;
  • lacquers were used to coat the top surface (NC based, Acetate based, cellulose acetate butyrate (CAB) lacquer etc. from different sources) were tried;
  • Top coating was made water repellent to prevent colour bleeding through ( silica coating, wax finish etc).
  • vegan leather does not contain collagen fibre like animal leather, it does not have the same properties of elasticity and fullness.
  • Either vegan leather is made of PU, PVC, rubber or cellulosic materials. So, it is hard to make the same fullness, feel like animal leather.
  • Added metal Silicate powder like magnesium silicate in the composition in 0.5% w/w concentrations which is hydrophobic in nature; Drying is done at high temperature;
  • Pulp is dried entirely in sun and stored for 2 weeks before being rehydrated again.
  • the base compound is very hard or the upper surface is rough or the upper coating is rough or the upper coating does not bind with the base surface it causes cracking. To solve the same, following trials are taken.
  • Softener / plasticizers are employed whenever required such as veg oil, soft filler etc.
  • Softener is also employed in the upper coating like (silicon solution, crunchy wax etc). Bubble Problem
  • Added defoaming agent hydrogen peroxide, Sodium percarbonate, peracetic acid, sodium perborate
  • Adhesives with good binding property are employed.
  • the upper surface can peel off easily. Because the upper coating does not bind on the base compound if there is moisture. So, the base material should be moist free.
  • Natural Adhesive are sourced like natural rubber, gum rosin, gum Arabic, jackfruit glue, arrowroot glue, agar-agar solution, banyan sap glue, com starch adhesive etc. Natural Adhesive are prepared inhouse from many different sources like jackfruit, arrowroot, gum rosin, gum-arabic, banyan sap, com starch, guar gum etc. Natural Binders are used such as Starch from rice or tapioca with a great binding capacity and arrowroot and rubber.
  • Natural fillers such as starch from tapioca, rice, corn, cork filler, rice husk, wheat straw, talcum powder etc. are employed.
  • Natural softener such as veg oil, fruit oil, citric acid, fruit waxes etc.
  • Natural colours are employed such as colours from charcoal black, beets, onion skins etc.
  • FIGS 1 and 3 also provide details of all process steps followed in manufacturing of vegan Leather according to the present invention.
  • the plant-based vegan method 100 includes a step 102 of pulp extraction.
  • the pulp from the raw banana stem is extracted.
  • the stem becomes redundant.
  • the present method 100 can utilize this banana stem for pulp extraction, at step 102.
  • the banana stem is cut into fine pieces and boiled with chemicals, such as including and not limited to NaOH, Na2S, NaHClO and common salt. Thereafter, the chemically treated pulp is drained and rinsed. It may be apparent to a person skilled in the art that the pulp extraction from banana stem may implement any conventionally used methods and processes, without deviating from the meaning and scope of the present invention.
  • step 104 tapioca starch is powdered and then boiled with water to reach a jelly like consistency. It may be apparent to a person skilled in the art that the present plant-based vegan method 100 may use any other starch extracted from the plants, without deviating from the meaning and scope of the present invention.
  • the plant-based vegan method 100 also includes a step 106 for creating a leather mixture.
  • the step 106 further includes mixing the pulp obtained in the step 102 and the tapioca obtained in the step 104 with additional chemicals (such as including and not limited to adhesives, PU, polyvinyl acetate, and other plasticizers) to then create a leather mixture.
  • additional chemicals such as including and not limited to adhesives, PU, polyvinyl acetate, and other plasticizers
  • the method includes a step 108 of spraying / pouring or screen printing the leather mixture obtained in the step 106 onto a fabric backing.
  • the fabric backing can be for example made from recycled PET bottles.
  • the sprayed leather mixture in the step 108 is then air dried, at a step 110.
  • the air-dried leather material is then spray painted for smooth finishing, at a step 112.
  • the spray painting includes coating the leather material with a smooth material, as a finishing process for the material.
  • the spray-painted leather undergoes sub-processes like plating and pressing.
  • this sub- process of plating and pressing includes putting the leather under a hot plate and pressed.
  • Plating is a finishing process that can be very useful as it makes leather more uniform and smoother, and at the same time more lucid.
  • the pressed leather material at step 114 undergoes a surface treatment process, which includes and is not limited to creasing the leather material for a creased look, adding chemicals to improve flexibility, water resistance, fire resistance.
  • the present plant-based vegan method 100 may use any suitable and conventionally available chemicals for improving the flexibility of the leather material, without deviating from the meaning and scope of the present invention. It may be apparent to a person skilled in the art that the present plant-based vegan method 100 may use any other conventionally used surface treatment processes also at step 116, without deviating from the meaning and scope of the present invention.
  • the method 100 may also include a step 118 of repeating the spray-painting process to further finish the material.
  • the step 118 of repeating the spray painting may be optional step, and can be implemented as and when needed.
  • the method 100 includes a step 120 where some suitable chemicals can be added to stop color leakage from the finished leather material. It may be apparent to a person skilled in the art that the present plant-based vegan method 100 may use any suitable and conventionally available chemicals for stopping the color leakage from the finished leather material, without deviating from the meaning and scope of the present invention.
  • Banana stems are cut after trees give fruits. Upper surface of the stem is separated from the inner and middle portions of the stem as it is harder. Long cuttings of inner and middle portions are collected and subjected to a banana shredder.
  • Banana shredder is a stem cutting machine having sharp rolling blades inside. The shredder cuts the long cuttings of inner and middle portions very quickly into small pieces of banana.
  • Banana stem cuttings / banana fibres are subjected to an alkali treatment during which 100 parts of Banana stem cuttings / banana fibres are mixed with 2.6 parts Sodium Hydroxide, 1.6 parts Sodium Sulphide and 200 parts water and mixed.
  • the above mixture is subjected to boiling in a Digester for 45 minutes. During boiling, stem cuttings are melted. The melted stem cuttings are subjected to grinding in a grinder for 15 mins., during which melted stem cuttings produce banana pulp. This pulp is brown coloured. It is washed with water to wash away alkali and strained in a strainer. After straining, pulp is subjected to grinding and then washing.
  • Bleaching is optional and done only when white / whitish leather is desired.
  • Bleaching process Weighed 100 parts of pulp and added 6.6 parts of Bleaching powder (Calcium Oxychloride [Ca(OCl)2] and 200 parts of water and are mixed. The mixture is kept overnight to lighten the original brown colour. Bleaching chemicals like liquid bleach, hydrogen peroxide, sodium percarbonate, sodium perborate etc. are basic in nature and washing is necessary if bleaching is carried out to produce desired shade.
  • initial weight is reduced to almost 25 % w/w of the initial weight.
  • Poly lactic acid (PLA) is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr with. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • PVC Polyvinyl chloride
  • PU polyurethane
  • 10% w/w IPA and 15% w/w PLA are mixed with 50% w/w banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound elements one by one. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Glycerol mainly works in this compound as a filler to give fullness and structure to the leather.
  • PVC mainly works in this compound as a filler to give fullness and structure to the leather.
  • Acrylic binder mainly works in this compound as a filler to give fullness and structure to the leather.
  • 20% w/w PVC is mixed with 50% w/w Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound elements one by one. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Bio PU mainly works in this compound as a filler to give fullness and structure to the leather.
  • 20% w/w PVC is mixed with 50% w/w Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound elements one by one. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Gum Arabic s colloidal properties, when solubilized, create a viscous solution that contributes to the cohesion of the composition and its adhesion with backing material. Its natural origin aligns with the increasing demand for eco-friendly adhesive alternatives.
  • the innovation lies in the meticulous combination of 50% w/w banana pulp, 30% w/w Gum Arabic solution, and 20% w/w PVC.
  • This fusion embodies the advantages of each component, resulting in a well-rounded adhesive composition that merges the strengths of natural binding, colloidal adhesion enhancement, and synthetic durability.
  • the final composition is poised to cater to a diverse range of applications, presenting a promising direction in adhesive technology.
  • the composition comprises 50% w/w banana pulp, 30% w/w Polyvinyl Acetate (PVA), and 20% w/w Polyvinyl Chloride (PVC).
  • Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes. 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing. Because of the moisture release tendency of the Banana pulp, there is a high chance of fungal growth. So, preservatives such as fungicides and bactericide are added.
  • This innovative formulation underscores the combination of 50% w/w banana pulp, 30% w/w Polyvinyl Acetate (PVA), and 20% w/w Polyvinyl Chloride (PVC) to create a composition with multifaceted attributes.
  • banana pulp contributes both natural adhesion properties and environmental sustainability to the mixture.
  • Banana pulp's inherent adhesiveness stemming from its organic composition, lays the foundation for a strong bonding capability.
  • the introduction of 30% w/w PVA amplifies the adhesive potential of the composition.
  • PVA renowned for its versatility and adhesive qualities, enhances the cohesion between the components, further bolstering the adhesion properties of the mixture. Balancing the equation, 20% w/w PVC adds a dimension of durability and resilience to the composition.
  • PVC's synthetic nature imparts mechanical strength and longevity to the adhesive, ensuring its effectiveness over time. This meticulously composed mixture not only taps into the innate adhesion strengths of natural elements but also integrates synthetic durability for a well-rounded solution poised to cater to a spectrum of applications.
  • Poly Lactic Acid is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr with. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes. 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • This formulation epitomizes the synergy between 50% w/w banana pulp, 30% w/w Polylactic Acid (PLA), and 20% w/w Polyvinyl Chloride (PVC), yielding a composition designed to bridge the realms of sustainability and performance.
  • PVA Polylactic Acid
  • PVC Polyvinyl Chloride
  • the eco-friendly attributes of banana pulp align with the growing demand for sustainable materials in adhesive applications.
  • 30% w/w PLA a biodegradable polymer derived from renewable resources, amplifies the environmentally conscious profile of the composite. PLA's adhesive capabilities, combined with its biodegradability, contribute to the cohesive strength of the mixture.
  • Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes. 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • Banana pulp Because of the moisture release tendency of the Banana pulp, there is a high chance of fungal growth. So, preservatives such as fungicides and bactericide are added.
  • This distinctive formulation brings together 50% w/w banana pulp, 30% w/w cork filler, and 20% w/w Polyvinyl Chloride (PVC) to create an adhesive composite with a well-balanced blend of natural and synthetic components.
  • PVC Polyvinyl Chloride
  • the significant inclusion of banana pulp, constituting half of the composition contributes inherent adhesion properties along with a touch of environmental sustainability. Banana pulp's natural adhesiveness serves as a foundation for strong bonding capabilities within the mixture.
  • the introduction of 30% w/w cork filler enhances the texture and resilience of the composite.
  • the porous nature of cork functions as an effective filler, promoting cohesion and structural strength in the adhesive.
  • the balance is achieved with the incorporation of 20% w/w PVC, which imparts mechanical strength and endurance to the composition.
  • the synthetic properties of PVC ensure the adhesive's stability and longevity, making it effective over time. In harmony, these elements create a cohesive and well-rounded adhesive composite that capitalizes on the adhesion strengths of natural components while integrating the durability of synthetic materials.
  • Wax is melted.
  • Polyvinyl chloride (PVC) in liquid form and Wax in molten form are added and mixed for another 15 minutes.
  • This innovative formulation art fully combines 60% w/w banana pulp, 20% w/w cork filler, 10% w/w Polyvinyl Chloride (PVC), and 10% w/w wax, creating an adhesive composition that blends diverse attributes for a multifaceted solution.
  • the prominent presence of banana pulp, constituting a majority of the composition introduces inherent adhesion strengths coupled with an environmental consciousness.
  • the natural adhesive qualities of banana pulp paired with its biodegradability, form a strong foundation for robust bonding capabilities within the adhesive.
  • the incorporation of 20% w/w cork filler further enriches the composition's texture and resilience. Cork's porous and flexible structure contributes to the overall cohesion and mechanical integrity of the adhesive.
  • 10% w/w PVC provides the composition with mechanical durability and longevity.
  • PVC's synthetic attributes enhance the adhesive's stability, ensuring its effectiveness in various conditions.
  • 10% w/w wax is introduced. This component contributes to the adhesive's malleability, allowing it to adapt to different surfaces and contours.
  • the composition draws from the natural adhesive strengths of banana pulp, the reinforcing properties of cork and PVC, and the flexibility offered by wax, resulting in a versatile adhesive solution poised to meet diverse industrial demands.
  • Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes. 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • the innovative blend of 50% w/w banana pulp, 30% w/w cork filler, and 20% w/w Polyvinyl Chloride (PVC) forms a composite that uniquely fuses natural and synthetic elements.
  • the substantial incorporation of banana pulp contributes both eco-friendliness and inherent adhesion properties to the composite.
  • T'his natural component adds an element of biodegradability and sustainability to the adhesive. aligning with environmentally conscious demands.
  • the introduction of 30% w/w cork filler amplifies the composite’s texture and resilience.
  • Cork’s porous nature serves as an effective filler, enhancing the overall structural integrity and adhesive properties of the mixture. Balancing the equation, 20% w/w PVC provides the composite with mechanical strength and durability.
  • PVC’s synthetic characteristics offer stability and longevity to the adhesive, ensuring its effectiveness over time. In synergy, these elements create a cohesive blend that draws from the strengths of each constituent, resulting in an adhesive composition with attributes poised to meet a range of industry requirements.
  • Wax is melted.
  • Polyvinyl chloride (PVC) in liquid form and Wax in molten form are added and mixed for another 15 minutes.
  • This composition strategically combines 60% w/w banana pulp, 20% w/w cork filler, !()% w/w Polyvinyl Chloride (PVC), and 10% w/w wax to engineer an adhesive composite with a nuanced balance of properties.
  • the substantial presence of banana pulp as the primary component introduces inherent adhesion strengths and environmental sustainability to the mixture.
  • Banana pulp s natural adhesive qualities, combined with its biodegradability, form a foundation for strong bonding capabilities.
  • the incorporation of 20% w/w cork filler enhances the composite's texture and resilience.
  • the cork’ s unique porous structure contributes to the overall cohesion and structural robustness of the adhesive. Introducing 10% w/w PVC adds a synthetic element that imparts mechanical durability and longevity.
  • 30% w/w Neoprene and 15 % w/w ethylene vinyl acetate are mixed with 50% w/w Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound elements one by one. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Acrylic binder in liquid form is added and mixed for another 15 minutes.
  • Acrylic binder mainly works in this compound as a filler to give fullness and structure to the leather.
  • the innovative blend comprising 50% w/w banana pulp, 15% w/w neoprene, 20% w/w Acrylic Binder, and 15% w/w Ethylene Vinyl Acetate (EVA) brings together diverse elements to create an adhesive composite that stands at the crossroads of natural and synthetic characteristics.
  • the prominent inclusion of banana pulp introduces inherent adhesion properties and ecological consciousness to the blend.
  • This natural component offers biodegradability and environmental sustainability, aligning with the growing demand for eco-friendly solutions.
  • Incorporating 15% w/w neoprene enhances the composite's flexibility and resilience.
  • Neoprene's elastomeric nature contributes to the adhesive's adaptability to varying conditions.
  • the introduction of 20% w/w Acrylic Binder enhances adhesion and cohesion.
  • Acrylic binders are known for their strong bonding capabilities, fortifying the adhesive's overall performance.
  • the addition of 15% w/w EVA adds a synthetic dimension that imparts mechanical stability and durability to the mixture. EVA's properties ensure the composite's longevity and robustness over time. In harmony, these components form a composite that merges the natural adhesion strengths of banana pulp, the flexibility of neoprene, the binding capabilities of acrylic, and the durability of EVA, yielding an adhesive solution tailored to diverse applications.
  • the inventive formulation featuring 50% w/w banana pulp, 15% w/w neoprene, 20% w/w Resin Binder, and 15% w/w Ethylene Vinyl Acetate (EVA) showcases a strategic combination of natural and synthetic elements.
  • the substantial integration of banana pulp imparts inherent adhesion strengths and environmental sustainability to the composite.
  • This natural component delivers both robust bonding capabilities and biodegradability, aligning with eco-friendly standards.
  • the inclusion of 15% w/w neoprene augments the adhesive's elasticity and resilience. Neoprene's flexible nature ensures the adhesive can adapt to various conditions while maintaining cohesion. Incorporating 20% w/w Resin Binder bolsters the adhesive's binding properties and structural integrity.
  • Resin binders are recognized for their robust adhesion characteristics, enhancing the overall performance of the mixture.
  • the introduction of 15% w/w EVA introduces synthetic durability and mechanical stability to the composite.
  • EVA's attributes contribute to the adhesive's lasting strength and reliability. In unison, these constituents create a composite that synergistically leverages the natural adhesion properties of banana pulp, the flexibility of neoprene, the binding efficacy of resin, and the durability of EVA, yielding a versatile adhesive solution suitable for an array of applications.
  • % w/w plasticizer selected from Glycerol or PEG and 10 % w/w oil are mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Bio polyurethane (Bio PU) in liquid form is added and mixed for another 15 minutes. 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • This composition is a result of combining 60% w/w Banana pulp, 10% w/w Biodegradable Polyurethane (Bio PU), 20% w/w Plasticizer, and 10% w/w Oil to create a specialized adhesive composite.
  • the substantial incorporation of 60% w/w EVA contributes mechanical stability and durability to the blend. EVA's synthetic nature ensures resilience and longevity, enhancing the overall adhesive properties.
  • the introduction of 10% w/w Bio PU adds a biodegradable element to the composite. Bio PU, derived from renewable sources, aligns with eco-conscious goals and introduces environmental sustainability to the adhesive. Incorporating 20% w/w plasticizer enhances the adhesive's flexibility and adaptability.
  • Plasticizers contribute to the composite's ability to conform to varying surfaces and conditions.
  • the addition of 10% w/w oil imparts pliability and fluidity to the mixture.
  • the oil content enhances the adhesive's application ease and ensures its spreadability.
  • the culmination of these components results in a composite that harnesses the mechanical strength of EVA, the eco-friendliness of Bio PU, the flexibility of plasticizers, and the application ease provided by oil, yielding an adhesive solution tailored to specific industry needs.
  • Synthetic adhesive like Ethylene Vinyl Acetate, Poly vinyl acetate, Neoprene, plastic resin glue, epoxy glue is mixed with Banana pulp in a_ blender with a blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound elemnets one by one. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying. Starch in liquid form is added and mixed for another 15 minutes. Starch mainly works in this compound as a filler to give fullness and structure to the leather.
  • PVA polyvinyl acetate
  • Ethylene vinyl acetate / Neoprene is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Magnopal IPF is a polymer filler which is added to the above mixture in an amount of 20% w/w of the weight of the composition and mixed for another 30 minutes. This filler imparts fullness and structure to the leather.
  • Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing and mixed for an hour.
  • PVA polyvinyl acetate
  • Ethylene vinyl acetate / Neoprene is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Bio Polyurethane is added and mixed for another 15 minutes.
  • Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • PVA polyvinyl acetate
  • Ethylene vinyl acetate / Neoprene is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • PVA polyvinyl acetate
  • Ethylene vinyl acetate / Neoprene is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Starch in liquid form is added and mixed for another 15 minutes.
  • Starch mainly works in this compound as a filler to give fullness and structure to the leather.
  • Softener / plasticizer PEG in liquid form is added to the above mixture and mixed for another 15 minutes. Softener / plasticizer imparts softness to the leather.
  • Synthetic Colour mixed with double the quantity of suitable Binder is added to the above composition while mixing.
  • compositions comprising natural adhesives For compositions comprising natural adhesives, processes described below are employed.
  • First step is preparing natural adhesives.
  • Various natural adhesives are natural rubber, Com starch adhesive, jackfruit glue, Arrowroot Glue etc.
  • Cornstarch Adhesive - Cornstarch is diluted in hot water in a preferred weight ratio of 1: 6 and mixed properly.
  • Agar agar powder is mixed with hot water in a preferred weight ratio of 1: 5 and gum arabic and gum rosin are also mixed separately with water in a preferred weight ratio of 1: 6.
  • Com starch adhesive is ready for incorporation into the compositions of the present invention for preparing vegan Feather.
  • Jackfruit seeds are dried at a temperature of 80°C till they are fully dried.
  • the dried seeds are powdered in a grinder to form dried seed powder.
  • Around 300 - 400 g dried seed powder is mixed with 5 - 8 g of borax and around 2 litres of water. This mixture is subjected to 70-80°C for 10 - 30 minutes after which 1 litre of water is added and mixed and kept aside for 5 - 10 minutes.
  • Jackfruit glue is ready to use.
  • compositions comprising natural adhesives a. 60% banana pulp + 20 % Starch + 10% Cork filler + 10% Natural Rubber
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Gum Arabic + 15 % waxes Comprising 50% banana pulp, 10% jackfruit glue, 15% natural rubber, 10% gum arabic, and 15% softener, this composition strikes a balance between natural and synthetic components.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp adds sustainability and biodegradability, while jackfruit glue and natural rubber provide adhesive and elastic properties. Gum arabic contributes to viscosity, and the softener enhances flexibility. This blend can be utilized for applications ranging from bio-based adhesives to coatings, combining natural and synthetic attributes for versatile use. c. 50% banana pulp + 30% natural rubber + 20% Wheat Straw filler
  • the mixture of 50% banana pulp, 30% natural rubber, and 20% wheat straw filler creates a composite that combines the sustainability of banana pulp with the durability of natural rubber and the lightweight properties of wheat straw filler.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • this composition emphasizes natural and plant-based materials.
  • Guar gum is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp offers sustainability, while starch and guar gum enhance the blend's binding and thickening properties.
  • This mixture can be used in the creation of environmentally friendly adhesives or biodegradable materials, reflecting a commitment to sustainable alternatives. e. 50% banana pulp + 30% Starch + 20% Veg oil
  • composition of 50% banana pulp, 30% starch, and 20% vegetable oil blends natural and plant-based materials to create a versatile mixture.
  • Starch is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • this composition combines natural and sustainable materials.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp adds eco-friendliness, natural rubber imparts durability, and wheat straw powder introduces lightweight properties.
  • This blend can be employed in applications such as eco-friendly construction materials or as a base for biodegradable composites. g. 50% banana pulp + 30% Gum Arabic solution + 20% Citric acid
  • the mixture of 50% banana pulp, 30% gum arabic solution, and 20% citric acid emphasizes natural and water-soluble components.
  • Gum arabic solution is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • citric acid acts as a natural preservative and pH adjuster.
  • This composition can be used in the formulation of eco-friendly adhesives or as a base for biodegradable solutions, highlighting the use of natural and environmentally conscious materials. h. 50% banana pulp + 30% Talcum powder + 20% natural rubber
  • this composition combines natural materials with mineral fillers.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp brings sustainability, talcum powder offers texture and softness.
  • This blend can be employed in applications like eco-friendly fillers for various products or as a base for biodegradable materials. i. 50% banana pulp + 30% fruit wax + 20% Agar-agar solution
  • composition of 50% banana pulp, 30% fruit wax, and 20% agar-agar solution integrates natural and plant-based materials.
  • Agar-agar solution is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • this composition emphasizes a balance between natural and synthetic materials.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp adds sustainability, cork filler introduces lightweight and insulating qualities, and natural rubber imparts flexibility and durability.
  • This blend can be tailored for applications like eco-friendly packaging materials or cushioning materials with a blend of natural and synthetic components. k. 60% banana pulp + 20% Cork Filler + 10% Natural Rubber + 10% wax
  • composition of 60% banana pulp, 20% cork filler, 10% natural rubber, and 10% wax offers a blend that combines natural and synthetic materials with a focus on flexibility and texture.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying. Specific concentration of the above mixture wax and cork filler are mixed together for 10 - 30 minutes.
  • Banana pulp provides sustainability, cork filler introduces lightweight properties, natural rubber imparts flexibility and durability, and wax enhances texture and moisture resistance. This blend can be used for applications such as bio-based coatings or as a base for environmentally conscious sealants.
  • Guar gum is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp provides sustainability, starch and guar gum enhance the blend's binding and thickening properties, and cork filler introduces lightweight and insulating qualities. This mixture can be utilized for applications like eco-friendly adhesives or as a base for biodegradable materials, reflecting a commitment to sustainable alternatives.
  • m 60% Banana pulp + 30 % natural rubber + 10 % filler like tapioca starch
  • the mixture of 60% banana pulp, 30% natural rubber, and 10% filler such as starch showcases a blend that combines natural and synthetic components with a focus on sustainability and flexibility.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp offers sustainability, while natural rubber introduces flexibility and durability. This blend can be used for various applications, such as eco-friendly rubber products or materials with a predominantly natural composition. o. 60% Banana pulp + 30 % natural rubber + 10 % citric acid
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying.
  • Banana pulp provides sustainability, natural rubber imparts flexibility and durability, and jackfruit glue enhances adhesive qualities. This blend can be used for applications such as bio-based adhesives or as a base for environmentally friendly coatings, showcasing the synergy between natural and synthetic components. q. 60% Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue
  • Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition does not peel off from the backing material after drying. Specific concentration of the above mixture (mixture of Banana pulp and natural rubber) such as 70 - 90 parts and 10 - 30 parts of Arrowroot glue are mixed together for 10 - 30 minutes.
  • Banana pulp offers sustainability, natural rubber provides flexibility and durability, and arrowroot glue enhances adhesive characteristics.
  • This composition can be utilized for applications like eco-friendly adhesives or as a base for biodegradable materials with a focus on natural and adhesive components.
  • Example 3 Preparation of vegan leather
  • backing material is cut into desired dimensions.
  • the backing material is placed on a spraying table. Then 2 coats of any of the compositions are sequentially sprayed on the backing material using a spray gun to produce panels.
  • Panel is backing material coated with compositions / leather mixtures. After first coat, panel is subjected to drying. For various approximate thickness, following coating compositions are preferably applied.
  • Next step is drying. After trowelling the panels, they are kept in drying racks and are subjected to drying at a specific temperature. Drying temperature is controlled and not allowed to exceed 60°C as it may burn upper soft portion of the coating. Panels are dried for at least 24 hrs., preferably for 48 hrs.
  • the dried coated panels are subjected sequentially to plating, colour spraying, embossing and lacquering. Drying is needed after each of the steps involving colour spraying, embossing and lacquering.
  • Each panel is subjected to specific temperature and pressure and time.
  • pressure Preferably, pressure of 250 MPa or Bar at 80°C for 1.5 sec. at a second in a hydraulic press machine.
  • Plating softens the upper surface and increases the bonding between fabric /backing material and the layers of coatings.
  • Finishing of leather includes a series of steps to give buyers variety in the colours, embossing, shiny or matt finishes etc. and include spray painting, surface treatment and adding chemicals to stop colour leakage and water proofing etc...
  • Finishing materials are up to 10 % w/w, preferably up to 5 % w/w of the leather, more preferably from 2% w/w to 4% w/w of the all coating and contains colours, binders, lacquers and water resistant / water repellent coatings.
  • Eacquers include polyurethane lacquers, dyes lacquers, resin based lacquers, different types of Nitrocellulose lacquers, Acrylic Lacquers, and also, water based silicone emulsions etc...
  • colours which can be employed in the compositions. Some of them are dyes, pigments & natural colours (made from organic compounds like coal tars, some petrochemicals i.e. benzene, toluene, xylene, oil & inorganic compounds like oxidation of metals i.e. titanium, iron etc). Some of the colours are mixed with binders. There is a huge variety in binders. Most commonly, acrylic binders, polyurethane binders, Resin binders etc. are employed.
  • the binder is made from Natural Rubber and Starch in ratios such as (1:3) or (1:4) or (1:5) or (1:6).
  • Embossing includes NDM embossed, PDM embossed, YDM embossed, Croco embossed, Printing, Foiling and other types.
  • colour coating First coat of colour- After plating the next step is colour coating.
  • Synthetic pigments that are made by some organic and inorganic compounds are used for coating.
  • the pigments used in colour coating are absolutely sustainable and eco friendly.
  • the pigments are mixed with a binder in a ratio from 1:5 to 1:15, preferably in 1:10 ratio.
  • the panels After one coat of spray, the panels are kept for drying for 24 hours for fixation of colour.
  • Next step is surface treatment and includes milling and embossing.
  • the panels are subjected to a Milling process to increase the softness. It is a drum operation where the panels are revolved in the drum. Due to this operation the upper surface of the material gets creasing effects like leather finishes.
  • Embossing It is important to give vegan leather a look of leather. To emboss the upper surface there are many types of plates in the leather industry. Embossing imparts a raised pattern and enhances the look of the leather. There are many plates available in the leather industry. A suitable plate is selected and embossing is done at specific temperature and pressure.
  • the spray coating step is usually repeated if colours fade during embossing.
  • the pigments are mixed with a suitable binder in specific ratio from 1:5 to 1:15 preferably, 1:10 and sprayed on the panel. After colour coating, panels are dried for 24 hrs, and then if desired, a second coating is done followed by drying.
  • a specific nitrocellulose based lacquer is diluted using water. Additionally, a feeler that modifies touch and feel of a leather such as plant based or silicon based coating emulsion having properties like silicon coating is added to impart smooth touch.
  • 49 % w/w EC lacquer is diluted with 49 % w/w with water and 2 % w/w plant based or silicon based coating emulsion similar properties like silicon coating is mixed in it to provide lacquer suspension. Lacquer suspension is applied as top coat on the prepared leather.
  • Drying is essential after colour spraying, before and after lacquering. When colour spraying is done multiple times, drying between each spray is essential. Minimum 24 hrs. drying time is used after each colour spraying and before and after Lacquering. During finishing, colours / pigments, binders, preservatives, lacquers, chemicals to prevent colour leakage and water repellents together not more than 5 % w/w are added.
  • the vegan leather prepared in accordance with the present invention comprises 1 - 15 % w/w of backing material, colours / pigments, binders, lacquers, chemicals to prevent colour leakage and water repellents and 85 - 99 % w/w of coating composition containing Banana pulp and one or more of additives such as adhesives, binders, fillers, softeners / plasticizers. Additionally, from 0.001 to 0.1 % w/w preservatives are present when required.
  • compositions and suitable backing materials By using and selecting suitable compositions and suitable backing materials, various vegan leathers of desired properties can be prepared. For example, by choosing tougher backing material, tearing strength can be enhanced. By choosing softer material and adding softeners, tensile strength can be enhanced.
  • Thickness- The thickness of animal leather is between 1.2mm to 1.8mm. But the thickness of the present vegan leather can vary between a large range i.e. from 0.7mm to 1.4mm.
  • Tensile Strength The tensile strength of leather is 8 to 40 N/mm 2 whereas the tensile of the present Vegan leather is 10- 20 N/ mm 2 . Tearing Strength - The tearing strength of animal leather is 82.9 N/mm.
  • Various vegan leathers prepared in accordance with the present invention exhibit tearing strength range from 25 - 105 N/mm. Within this range, tensile strength depends on the nature of backing material. For non-woven backing materials made of cotton, polyester and others, tearing strength is 50-105 N/mm and for soft backing material such as woven materials made of cotton, polyester and recycled material, the tearing strength is 30-50N /mm based on the process selected.
  • Abrasion - The present vegan leather has water resistance. In dry condition the vegan leather does not find any coating removal up to 500 revolutions (standard abrasion testing parameter). Waterproofing can further enhance resistance to abrasion.
  • the present vegan leather material has moisture content up to 3 % w/w and therefore there are no chances of peeling or the coating removal like other vegan leathers. Additionally hydrophilic bacteria cannot affect the panel.
  • the present vegan leather material has low water vapour permeability of up to 0.5 mg/cm 2 /h, preferably up to 0.2 mg/cm 2 /h.
  • the present vegan leather material has water vapour absorption of up to 2 mg/cm 2 .
  • the present vegan leather has passed all the chemical tests conducted for absence of hazardous / toxic substances and no such compounds are found in the vegan Leather produced in accordance with the present invention.
  • vegan Leather of the present invention is Phthalate free, lead free, chrome free, cadmium free. These are toxic heavy metals found in animal leather due to the tanning process.
  • the vegan leather is also free of various banned amines, organotin compounds, Polycyclic Aromatic Hydrocarbons (PAHs), Alkylphenols and Alkylphenol Ethoxylates, Short Chain Chlorinated Paraffins, pentachloro phenol.
  • the pH of the present vegan leather is 7.5 + 0.2 i.e. almost equal to neutral pH.
  • banana based leather material is consistent.
  • a suitable backing material is selected from recycled plastic bottles, polyester, rayon, nylon, velvet, cotton fabric from a locally grown cotton, vegan fabrics made from banana, bamboo, jute, linen etc..
  • the thickness of the backing material in the overall panel is up to 40 % w/w, preferably up to 30 % w/w, more preferably from 5 - 30 % w/w and most preferably from 10 - 30 % w/w and the rest of the coated material is from 60 - 95 % w/w.
  • backing material is up to 20 % w/w, preferably up to 10 % w/w and more preferably up to 5 % w/w.
  • coating composition make from 85 - 99 % w/w of the vegan Leather; and colours / pigments, binders, preservatives, lacquers, chemicals to prevent colour leakage and water repellents together up to 5 % w/w, preferably, from 0.5 - 5 % w/w of final finished leather produced .
  • vegan leather prepared using compositions of the present invention has employed various natural and synthetic compounds to make the material most effective, usable and suitable for manufacturing various products.
  • Coating compositions / leather mixtures contain Banana pulp having banana fibres and natural additives like rubber, gums, saps and additional small quantities of substances like PVA, resins, polyurethane, waxes, fillers, starch powder (like Tapioca, corn, potato, rice etc), cork, PEG, Glycerol, IPA, PVC etc is used. It is important to make the leather fungus free, so trace amounts of antifungals, bactericides are used in the manufacturing process.
  • the plant-based method of the present invention has at least the following benefits on the environment and livestock.
  • This plant based leather has wide spread uses across fashion (bags, shoes, belts, wallets), furniture (sofas), and automotive (seats) being the major areas. It is an alternative to a more polluting alternative and also doesn’t harm any animals.
  • waste reduction is achieved including crop waste from banana stems.
  • Air pollution reduction is achieved by this invention, for example, crop waste that is used is typically burned or degrades on fields.
  • the present invention also helps in water resource management.
  • the plant-based leather produced in the present invention uses 90% w/w less water than animal leather. Further, the present inventive method is also impactful to avoid animal pollution.
  • the leather industry is responsible for shelter to animals (cows, crocodiles, snakes, sheep, goat, buffalo) many of them killed only for their skin, whereas this method completely avoids this.

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  • Treatment And Processing Of Natural Fur Or Leather (AREA)

Abstract

La présente invention concerne des compositions destinées à préparer un cuir végan et un cuir végan préparé à partir de telles compositions, de telles compositions comprenant de la pulpe de banane et au moins un adhésif ou un liant. En outre, l'invention concerne également des procédés de préparation de compositions et d'un cuir végan à partir de compositions contenant de la pulpe de banane. Ce cuir végan est un matériau de type cuir complètement exempt de tout produit animal.
PCT/IN2023/050788 2022-08-20 2023-08-21 Cuir végan à base de plante fabriqué à partir de déchets de culture de banane WO2024042538A1 (fr)

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CN118241494A (zh) * 2024-05-28 2024-06-25 旭川化学（苏州）有限公司 一种具有皮皱感的聚氨酯合成革及其制备方法和应用
CN118241494B (zh) * 2024-05-28 2024-09-24 旭川化学（苏州）有限公司 一种具有皮皱感的聚氨酯合成革及其制备方法和应用

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