APPAREL VIEWS / JULY 201134

Application ofcontemporaryfibres in apparels

History of coconut shell fibre

Cocona®, TrapTek LLC's patented innovative technology that incorporates

activated carbon derived from recycled coconut shells into fibres and yarns, has

received accolades as a natural, sustainable technology. The technology was

developed in 2002 by Gregory W Haggquist, Ph. D. the Longmont, Colo. based

company's founder and made its consumer market debut in 2006 in knitted cycling

apparel developed by United Knitting, Cleveland, Tenn., and Bethel, Conn.-based

Cannondale Bicycle Corp.

Technology of coconut shell fibre

Cocona’s outstanding features are due to the fact that the surface of the activated

carbon has a pore structure. The pores absorb odour molecules at the same

time as enabling the moisture to escape from the skin’s surface and absorb into

the sock more quickly than normal due to the large surface area. Yarn made with

Cocona® has a surface area that is upto 10 times larger than conventional

polyester yarn.

The Cocona® technology imbeds activated carbon from coconut shells into

polyester or nylon polymers. The coconut shells, recycled waste from the food

industry, are burned at 300°C followed by a 1,000°C steam-activation process.

The activated carbon is used for water and air filtration, wastewater treatment,

and other such industries. The microscopic, ultra-fine particles that are too

small for those applications are just what TrapTek needs to incorporate into its

fibre and yarn.

The coconut tree is known as “The tree of life.” Coconut meat, milk and oil have been widely used in products like

suntan lotion, cooking, oil, medicine, water and air filters. In textile also, coir is very popular which is extracted from

the husk of coconut and used in products such as floor mats, doormats, brushes, mattresses etc. Now, the finest

quality of activated carbon comes from coconut shells to provide superior dry times, odour adsorption and UV protection

on a wide range of product applications. The Cocona® material is a natural fabric enhancer that is produced from

activated carbon from coconut shells, which is infused into the textile fibre by Cocona Inc. patent method. The activated

carbon is derived from coconut husks; it is a “waste” product of the water filter industry and is known since immemorial

times to absorb poisons and odours. Activated carbon has a huge absorbing area — one gram of it has a surface area

the size of two tennis court. This activated carbon is infused into natural fibres like cotton, wool and synthetic fibres

like polyester, nylon, etc, which is then blended with other fibres to create performance fabrics

COCCOCCOCCOCCOCONUTONUTONUTONUTONUT SHELLSHELLSHELLSHELLSHELL

FIBREFIBREFIBREFIBREFIBRE - C - C - C - C - COCOCOCOCOCONAONAONAONAONA®®®®®

COCCOCCOCCOCCOCONUTONUTONUTONUTONUT SHELLSHELLSHELLSHELLSHELL

FIBREFIBREFIBREFIBREFIBRE - C - C - C - C - COCOCOCOCOCONAONAONAONAONA®®®®®

APPAREL VIEWS / JULY 2011 35

Characteristics of coconut shell fibre

Cocona® fabrics offer superior comfort and enhanced performance in a variety of

clothing applications. Cocona® fabric provides protection from harmful UV rays;

successfully manage odours, static, and moisture. Independent laboratory tests

measuring the amount of time a wet fabric takes to dry at room temperature,

fabrics made with Cocona® dried significantly faster than other leading moisture-

wicking fabrics including polyester (50 per cent faster), cotton (92 per cent faster),

and bamboo (96 per cent faster). Fabrics made with Cocona® yarns and fibres are

inherently lightweight, comfortable, and easy-care.

Activated carbon has been used for centuries to purify drinking water and to

absorb toxins. When incorporated into yarns and fibres, it creates a fabric that

provides highly effective evaporative cooling, odour control, and superior UV

protection, upto 50+UPF (the highest possible rating). Because Cocona®

technology is inside the fibre; it cannot wash off or wear out like ordinary surface

treatments to fabrics.

The distinctive benefits of Cocona® fabric include:

• Evaporative cooling - Cocona® fabrics dry faster providing increased comfort

while reducing the amount of time and energy required drying garments after

washing. Activated carbon embedded within the yarn of woven and knitted

fabrics wicks moisture away from the skin and transports it to the fabric surface

for rapid evaporation. Cocona® fabric’s powerful moisture management

properties provide a 50 per cent increase in moisture transfer compared to

standard polyester

• Odour adsorption - Activated carbon embedded within the yarns and fibres

absorbs a wide range of odour molecules. Odours emanating from the wearer,

inherent in the fabric, and present in the surrounding environment are attracted

to and trapped within the pores of the carbon, to keep the clothing fresher

longer, and reducing the need for daily washing. Odour molecules are released

and the carbon renewed when the fabric is washed and dried

• Durable - Cocona® performance is permanently embedded in the yarn and will

not wash out. Cocona® clothing lasts longer than items made from other organic

fabrics such as pure cotton or bamboo

• Comfort - Clothes made using Cocona® yarn are available in all weights for items

that feel softer, stay fresher, and wear more comfortably than other fabrics

Environmental benefits of coconut shell fibre

Cocona® technology utilises recycled coconut shells that would have gone to

landfills. Suppliers convert the coconut shells into activated carbon, primarily for

the air and water filtration industries. Cocona® uses the particles that are too

small to use in water and air filters, apply their processes and then combine it

with other fabrics. While this is not a completely “green” process it is much

better than using chemicals to treat the materials.

Applications of coconut shell fibre

Apparel made from the fibre helps spread and evaporate surface moisture rapidly,

making it perfect for sportswear, undergarments, golf apparel and other active

applications. Cocona® fibres are used in garments ranging from shirts, pants,

shorts, outerwear, underwear, footwear, travel wear and tank tops.

MoistureManagement

OdourResistant

UVProtection

WashDurable

Wide comfortRange

Active NaturalParticles

Cocona - activated carbon

• Activated carbon is usually derived from charcoal.

• Cocona is derived from coconut husk.

• There are 20 billion coconuts produced annually.

• Activated carbon has a huge surface area, and is highly porous.

• One gram has a surface area of around 500 m2/g or the size of two tennis courts.

• It grabs stole odours through adsorption to its porous surface.

• It uses evaporative cooling to move moisture (sweat) away from the skin.

• Activated carbon also blocks out harmful UV radiation.

• Carbon is activated either chemically or steam. It can be reactivated in

tumble drying.

• The activated carbon finish is locked into the fibre polymer prior to spinning.

Garments made with Cocona TM fabric provide up to50UPF, 2.5x more protection than ordinary polyester!

UV Test

UV protection

Fig: Cocona® enhances the performance of above products largely

Antimicrobial/antibacterial fabrics Cocona® fabrics

Treatments wash out over time and Carbon is renewed during regular

lose their effectiveness machine wash and dry cycle

Not effective against existing odours Odour molecules are adsorbed onto

(smoke odours, body odours, etc.) the surface of the activated carbon

Strict government regulations Activated carbon is free of all

(FIFRA, EPA) government regulations

Chemicals kill all bacteria; good All natural - activated carbon is

and bad made from coconut shells

Products vary in effectiveness All fabrics are tested and certified

Comparison with antimicrobial/antibacterial fabrics

APPAREL VIEWS / JULY 201136

Conclusion

Nowadays everyone is becoming more environmentally aware, trying to be

carbon neutral, buying organic, and minimising their impact on the

environment. Using the active carbon is a new concept of using a natural

technology in order to give sport fabrics several new features without adding

chemicals. By working innovatively and provide the market with new and

exciting concept creates more business opportunities for retailers, while

allowing users to better clothes

Caring for coconut shell fibre

Cocona’s good features can never wash out from garment as these are natural

features from the activated carbon. In fact, with every wash, the features of

garment will be reactivated. It’s important not to use scented products as

well as softener as these clogs the pores. To achieve the highest performance,

wash these garments over 40 degrees and use tumble drying. The drying time

in a tumble drier decrease with 35 per cent with a Cocona® garment compared

to a similar material in polyester, this will save 22 per cent in energy. As

compare to cotton or a bamboo product, a Cocona® product use 52 per cent

less energy to dry the garment.

Brands using coconut shell fibre for their products

Over 50 brands are utilising Cocona® fibres in sports and active wear including

Eddie Bauer, Cutter & Buck, Izod, New Balance, Marmot, GoLite, Oakley, Patagonia

and Cannondale.

By Vasant R Kothari Assistant Professor, NIFT, Bangalore (Authorcan be contacted @ www.vasantkothari.com)

Productsmade fromCocona® fibre