Probiotics solutions for sustainable leather

Probiotics solutions for sustainable leather

XXXIV IULTCS Congress, CHENNAI (India) 2017 Claus Reineking, Joan Carles Castell

XXXIV IULTCS Congress, CHENNAI/INDIA 2017

R3 environment responsibility Background

35 m3 water 200 kg chemicals 300 kg chemical aux. Energy

Reduce Reuse Recycle

1 ton raw hide

250 kg leather

250 Kg O2 (COD) 100 Kg O2 (BOD) 150 Kg SS 5 Kg Cr 10 Kg Sulfide

35 m3 water

500 Kg sludge from WWTP

600 Kg solid process residues

5 kg volatiles

■  Probiotics: live microorganisms that confer health benefits

■  A natural technology to repopulate environments with healthy microorganisms

Based on probiotics: Technical Fundamentals


Probiotic biochemicals from proprietary fermentation and formulation technology using probiotic mother culture and particular natural raw ingredients.

Based on probiotics: Technical Fundamentals


Probiotics Natural raw ingredients

Metabolites Fermentation

■  Natural bioreaction → Low carbon footprint

■  No toxic, no hazardous, no corrosive

■  From renewable resources

■  100 % Biodegradable

Technical Fundamentals


Sustainability based on probiotics:


Hydrotropic properties:

■  Increase solubility of sparingly soluble organic molecules:

  Substances in the leather:

§  Dirt, dung, waxes, phospholipids,…

§  Soluble proteins (hyaluronic acid, dermatan sulfate, GAG, globulins… )

  Processing chemicals

■  Water transfer from particle to particle:

Probiotic biochemicals

Properties (1)



Properties (1)

Fibra de colágeno

Fibras de colágeno vistas con microscopio

Fibrilla

Microfibrilla

Cadenas de tropocolágeno

Cadenas de aminoacidos

Estructura de una fibra de colágeno

■  Are compatible with all chemicals used in the leather making process and do not require to adjust the conditions (pH, temperature,…) beyond those required in the manufacturing operations.

■  Except under unusual conditions1, the soaking operation using Proviera products is free of bactericides and can reduce bad odors or putrefaction.

1 deficient preservation, long soaking time, water conditions,….



Properties (2)


Material & methods Probiotic Degreasing Agent PG Effects:

§  Strip off fats §  Degrease auxiliary

Operations:

§  Presoaking fatty hides/skins §  Degreasing sheepskins

Probiotic Soaking Agent PK Effects:

§  Soaking fresh hides & skins/hydrating §  Removal of non-structured proteins

Probiotic Dispersing Agent PS Effects:

§  Dispersing organic material §  Dispersing process chemicals §  Cleaning

Operations:

§  Pre soaking, esp. salted hides §  Liming §  Retanning, fatliquoring, dying

DRY

FAT DIRT

Operations: §  Main soaking, esp. fresh hides §  Washing wet blue/wetting back


Material & methods Beamhouse: (% on raw weight of hides/skins)

Washing: 0.1% PK + 0%-0.05% PD (No pH adjustments)

Pre-soaking: 0.2%-0.5% PS + 0%-0.05% PG (No pH adjustments) Replacing soaking agents (surfactants, enzymes) and degreasers. No bactericides.

Main soaking: 0.3%-0.5% PK + 0%-0.3% PS (Adjust pH to 8.5-9.5 for liming)

Replacing soaking agents (surfactants, enzymes) No bactericides.

Unhairing / liming: 0.2% PD Eliminate or reducing amines, organic reductive agents, polyphosphates


Material & methods Degreasing: (Sheepskins % on pickled weight of skins)

0.5%-3% PS + 3%-6% PG (1 up to 3 washes) Combined with degreasing agents.

Tanning: % on limed weight

0.2%-0.5% PS Replacing dispersing agents


Material & methods Wet end: (% on shaved weight of hides/skins)

Wetting back / Washing: 0.5%-2% PS + 0%-1% PK + 0%-1% PG Replacing surfactants, ammonia, oxalic acid

Retanning / Fatliquoring / Dyeing: 0.5%-2% PS or PG Replacing surfactants, ammonia, dyeing auxiliaries (naphthalene sulphonic derivatives, ethoxilate amines


Results & discussions Beamhouse:

Washing / Pre-soaking / Main soaking:

■  Clean / degreased hide / skin surface

■  Uniform rehydration. Slight lyotropic swelling (fiber sponginess + relaxation)

■  No putrefacting odors and hide/skin bacterial damages

■  No foaming

■  Reduction of COD (from 25-35 to 15-25 Kg O2/tonne of hide)

■  Increase of BOD/COD ratio


Results & discussions Beamhouse:

Unhairing / liming:

■  Improve dispersion of lime and open wrinkles

■  Lowe draw marks, pelts more relaxed and flatter

■  Easier removal of hair roots

Standard Proviera

Standard Proviera

Standard

Proviera

Potential better sorting and increase of area and area yield


Results & discussions Degreasing: ■  Improve efficiency of the degreasing process

0

20

40

60

80

100

120

Double Face Nappa

Ini6al fat content

Standard: commercial degreasing agent

2/3 commercial degreasing +1/3 PG


Results & discussions Wet end: Washing / wetting back:

■  Clean and uniform surface on the leather

■  No impact on waterproofing

■  No foaming

Retanning / fatliquoring / dyeing

■  Improves dispersion and exhaustion of chemicals

■  Better fault coverage

Ammonia Ethoxilate Amine

Naphthalene Sulf.

Probiotic Aux.


Results & discussions Potential reduction of COD (mg O2 / ton of raw hide, brine cured)1:

1 Based on standards which are widely applied and found generally acceptable (i.e. tends to ignore specific individual situations). Variables that influence the results are the chemicals already used in the tannery, origin of raw hides, preservation methods, mechanical action, etc.

0

50

100

150

200

250

Finishing

Post tanning

Tanning opera6ons

Rest beamhouse

Soaking

Up to 24% all process


Conclusions ■  Path breaking technology with no impact on environment

■  Natural biochemicals from renewable resources. 100% biodegradable

■  Characterized by hydrotropic properties

■  Delay damages caused by bacteria and bad odors

■  Replace or combine chemical auxiliaries

■  Improve leather quality, save water consumption and costs


Acknowledgements STAHL HOLDINGS B.V. Waalwijk. Netherlands

SCD PROBIOTICS. Kansas City. MO. USA

PROVIERA BIOTECH. Kansas City. MO. USA

PROKLEAN TECHNOLOGIES, PVT LTD. Chennai. India

Probiotics solutions for sustainable leather

Environment

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