How our fiber is produced
At TreeToTextile we have developed a groundbreaking fiber technology for the broader textile fiber market. This unique process creates versatile, low environmental impact fibers at a competitive production cost. Using a system with a high degree of chemical recovery, our method involves dissolving cellulose without harmful by-products. This innovative approach ensures responsible resource stewardship. The result is a game-changing solution for the textile and nonwoven industry, offering an attractive alternative and complement to traditional fibers like cotton, viscose, and polyester.
The TreeToTextile technology focuses on achieving a low environmental impact and has consistently refined the process through third-party life cycle assessments. This bio-based method requires low amounts of chemicals, energy, and water, resulting in a low CO₂ footprint.
It’s a win-win-win scenario benefitting our planet, the textile industry, and consumers.
From pulp to staple fiber
Pulp sheet
Dissolving pulp from (FSC/PEFC) certified forests.
In the future when the market provides circular and alternative pulps, these can also be introduced.
Spin dope
The spin dope is prepared by letting pulp sheets dissolve in a cold alkaline solution.
Tow
The spin dope is extruded through nozzles with thousands of small holes (spinnerets) into an alkaline spin bath, where the extruded spin dope coagulates and forms the tow.
Crimped tow
The tow is washed and after that crimped, to give it texture and bulk.
Staple fiber
Finally, the crimped tow is cut into a specific length, normally 38 mm, called staple fiber.
Dissolving pulp from (FSC/PEFC) certified forests.
In the spin dope preparation step, the pulp sheets are dissolved in an alkaline solution. The resulting “syrup” is called spin dope.
The spin dope is extruded through nozzles with thousands of small holes (spinnerets) into an alkaline spin bath, where the extruded spin dope coagulates and forms the tow.
The tow is washed and after that crimped, to give it texture and bulk.
Finally the crimped tow is cut into a specific length, normally 38 mm. Called staple fiber.
Chemical recovery
Since the pH levels in both spin dope and spin bath are alkaline, the alkali is not neutralized and lost. This allows for the alkali in the tow to be washed out and recovered. In the chemical recovery process, the alkali is concentrated, and the additives are reclaimed and reintroduced to the spin dope preparation step.
Chemical recovery
Since the pH levels in both spin dope and spin bath are alkaline, the alkali is not neutralized and lost. This allows for the alkali in the tow to be washed out and recovered. In the chemical recovery process, the alkali is concentrated, and the additives are reclaimed and reintroduced to the spin dope preparation step.
Environmental performance
The TreeToTextile process was specifically designed to minimize its environmental footprint. Rather than just transitioning from fossil raw material, and/or energy, to renewable, we completely changed the chemical system.
By using environmentally friendly process chemicals with high recovery rates, the environmental footprint of the TreeToTextile technology process is exceptionally low. Switching to TreeToTextile fibers would result in 70–90% lower emissions for the key textile materials (compared to industry averages) according to internal calculation and assumptions made.
Thus, by switching to our more sustainable fiber, 1 ton of TreeToTextile fiber produced will remove 2 tons of CO2 equivalents from the textile industry, and significantly contributing to a decarbonized textile and nonwoven industry.
