ReCeWTAG - Regenerated Cellulose from Waste Textiles for Artifical Grass

Artificial grass is much more durable and easily maintained than natural grass and therefore finds use in a wide range of applications. The artificial grass system consists of various components which are currently predominantly made of non-biodegradable plastics derived from fossil fuels. Consequently, it has a large environmental impact and is a significant contributor to the world’s (micro)plastic problem.
Simultaneously, the world is suffering from a textile waste problem. In the EU only, 12.6 million tons of textile waste is produced annually. Most of this post-consumer textile waste ends up in landfills or incinerators. Striving for a circular economy, new regulations like the Extended Producer Responsibility (EPR) define goals for the collection and recycling of this textile waste. A dominant textile-waste stream is cotton, which consists of the biodegradable biopolymer cellulose. Cotton can be eco-friendly chemically recycled into regenerated cellulose fibres using the lyocell wet-spin process.
The ReCeWTAG proposal will explore regenerating cellulose pulp from textile waste into natural artificial grass-like fibres. Currently cellulosic fibres do not have the same properties as synthetic fibres. This applied project will explore how regenerated cellulose grass fibres can be produced with the properties required by varying parameters on Saxion’s recently installed wet-spinning line. SaXcell BV will supply cellulose pulp generated from various cotton-containing textile waste-streams. TenCate Thiolon BV will advise on the required properties. bAwear will assess the environmental impact benefits.

The aim is to follow-up this project to replace all synthetic components in artificial grass with cellulose creating a circular system as well as expanding the concept to other technical textiles. It will also assess waste streams like agricultural residues for cellulose regeneration, supporting the circular economy by reducing microplastics, waste and environmental impact.

Eindrapportage

Artificial grass is widely used because it is durable and easy to maintain. However, most artificial grass systems are made from fossil-based plastics, contributing to environmental impacts and the growing problem of (micro)plastic pollution. At the same time, large amounts of textile waste are generated each year, much of which is still incinerated or landfilled. Cotton, one of the main textile waste streams, consists of cellulose, a natural and biodegradable polymer that can be chemically recycled into regenerated cellulose fibres through the lyocell process.

The ReCeWTAG project investigated whether cellulose pulp derived from textile waste could be used to produce fibres suitable for artificial grass applications. In collaboration with TenCate Grass, the performance requirements for artificial grass fibres were defined, and a dedicated spinneret was developed for wet-spinning trials carried out at Saxion University of Applied Sciences with support from SaXcell. Multiple spinning trials were conducted using different process settings to produce fibres with a range of properties.

The project demonstrated that regenerated cellulose fibres with characteristics relevant for artificial grass can be produced. However, challenges in process control resulted in variations in fibre quality, limiting fibre characterisation and making it difficult to draw definitive conclusions. Further research is needed to optimise and stabilise the production process.

Project partner bAwear performed a limited life cycle assessment covering raw materials, transport, and yarn spinning. The regenerated cellulose fibres showed a higher environmental impact than the conventional fibres, mainly due to the raw material use. Potential benefits during the end-of-life phase could not yet be assessed and may significantly influence the overall sustainability profile. In addition, the cellulose-based fibres displayed unique surface properties not found in existing artificial grass products. Based on these findings, further research into hybrid artificial grass systems combining conventional and regenerated cellulose fibres is recommended.