Location: Cotton Fiber Bioscience and Utilization Research
2024 Annual Report
Objectives
1. Enable, from a technological standpoint, new commercial products and market applications for cotton-containing nonwoven materials.
2. Enable new commercial varieties of cotton exhibiting non-conventional fiber properties for improved functionality and value of cotton-containing textiles.
3. Expand and develop novel metal-based nanotechnology to facilitate new value-added applications for cotton.
(Conduct original research to promote and enhance the use of cotton fibers in the nonwovens textile industry. Cotton fibers currently comprise ~2.4% of raw materials globally consumed for nonwovens, with the market dominated by synthetic petroleum-based fibers such as polyester (PET) and polypropylene (PP). However, the annual growth rate of cotton fiber use in nonwovens will surpass PET and PP over the next several years which present opportunities to replace petro-chemical fibers. The proposed research will include cotton fiber blending, processing, and bonding approaches, genetic selection of cotton varieties with unique fiber traits suitable for both broad use and specific nonwoven applications, and chemical modifications of cotton fibers for value added applications. Our previous cotton-based nonwovens project worked synergistically with projects in the unit and external collaborators to successfully patent and transfer cotton-based nonwoven technologies to commercially available products. These interactions will continue and will build on the success and accomplishments of our previous projects which have established a solid research foundation for cotton fiber use in nonwovens. Further investigations into the relationships between cotton fiber quality measurements and nonwovens fabric performance attributes will establish industry guidelines for cotton fiber selection, blending, and processing parameters for cotton-containing nonwovens destined for different end-use applications. This research is outlined in Objective 1 which allows for intimate stakeholder interaction and cooperative research for nonwoven prototype development toward the Agency goal of technology transfer. Objectives 2 and 3 will work together to examine value added attributes imparted by inherent genetic-based attributes and chemically added properties that enhance cotton fibers of selected varieties through nanotechnology, which ultimately relies on processing research conducted under Objective 1 for prototype development and textile functionality analyses. Cotton fiber functionalities in this research include but are not limited to inherent flame retardancy (FR) and hydrogen peroxide (H2O2) generation, high-yield nonwoven-specific cotton varieties, greige fiber color (whiteness and stability), nonwoven fabric tensile properties, stretch, drape and hand, moisture management, and new sanitization and disinfecting applications for cotton).
Approach
The increased use of cotton fibers in nonwovens textiles will be facilitated through innovative processing techniques, product prototype creation and testing, and close interaction with stakeholders at the fiber production, marketing, and manufacturing levels. Through fiber selection and blending combined with modification of nonwoven bonding processes, specialty and commodity cotton-based nonwoven fabrics can be produced which are suitable for new disposable or semi-durable applications. Raw materials will be procured from commercial sources and the in-house, commercial-grade production equipment and procedures, will be used to prepare fibrous batts for the downstream conversion of the fibers into nonwoven fabrics. The research products will be tested to assess their values for the targeted end-use products. The most promising research fabrics will be selected for confirmation before scaling to pilot operations. Selected fabrics will be offered to industrial partners for mutual cooperation and industrial trials.
Genetically diverse cotton lines will be screened to identify nonconventional fiber properties that could benefit the textile industry. Cotton fibers with specific inherent properties such as natural increased flame resistance (FR) were observed in the fibers of a cotton multiparent advanced generation intercross (MAGIC) population and will reduce the need for external applications of chemical additives to achieve the desired functionality. Additional unique fiber properties were observed in cotton fibers including elevated levels of hydrogen peroxide that would add beneficial properties to medical textiles for wound healing and infection mitigation. Other end-use properties include, but are not limited to, increased fiber elongation, enhanced absorbency and fluid handling characteristics, and development of high yield varieties specifically for nonwoven textiles. The genetic basis of the observed nontraditional fiber properties will be determined to facilitate the release of cotton varieties with properties for value-added, mostly nonwoven textile applications.
New or modified nanotechnology for cotton-based materials will be developed that increase the existing market share and create new markets. The unique chemistry and structure of various cotton varieties will be identified and utilized as a scaffold on which to build a technology enabling nanoengineered cotton products. The advantages of developing this customized nanotechnology over applying the currently available nanotechnology include comfortable and washable metal-based nanotextile products; newer functionalities; conversion of inferior or valueless cotton varieties into value-added products; decrease ecological/environmental footprints; and facilitate industry to efficiently and economically produce functional products. Based on our successful realization of cotton as a nanoengineering tool that is self-generating antibacterial silver nanoparticles, the cotton-oriented nanotechnology will be further expanded for nano-enhanced applications and the improved quality of processes and products in a sustainable manner.
Progress Report
Progress was made on all three objectives, all of which fall under National Program 306, Component 2, Quality and Utilization of Agricultural Products, Non-Food. Progress on this project focuses on Problem 2A to increase or protect the market demand for (or increase the value of) existing U.S.-produced non-food bio-based products derived from agricultural products and byproducts. ARS researchers in New Orleans, Louisiana, developed new products, applications, and processes for expansion of domestic cotton in the areas of: (1) cotton-based components for disposable hygiene products such diapers, feminine care, etc; (2) cotton and polylactic acid fiber blends for nonwoven disposable products with improved sustainability; (3) determination of the genetic and molecular basis for cotton lines that produce inherently flame retardant fibers; (4) eco-friendly nanoparticle production for cotton-based textiles; (6) conversion of agricultural waste, including cotton ginning byproducts, into nanotemplates for functional chemistries and value-added products.
In support of Objective 1, progress was made by ARS researchers in New Orleans, Louisiana, in developing nonwoven fabrics by blending cotton fiber and polylactic acid (PLA) fibers in different ratios. PLA fibers are biodegradable fibers derived from fermented natural plant starch such as corn, sugarcane, and sugar beets. The ARS scientists fabricated the nonwoven fabrics using both raw and scoured and bleached cotton fibers in five different blend ratios for each type of cotton. Tensile properties of the fabrics were determined as well as biodegradation efficiency in marine, fresh water, and activated sludge from a sewage treatment plant. The cotton/PLA fabrics were also subjected to hot roll thermal bonding under pressure through two metal rolls heated to the melting point of the PLA fibers. Changes in physical properties and air permeability were determined for potential utilization as filtration media. This research is a collaboration with a university and funded in part by a grant from a major cotton stakeholder.
In support of Objective 1, progress was made by ARS researchers in New Orleans, Louisiana, in developing sustainable and biodegradable nonwoven components for use in diapers. ARS scientists optimized cotton blends and textile processing parameters to develop prototype diaper topsheets and backsheets that can transport liquid efficiently to the diaper absorbent core and keep the liquid from escaping back to the skin or through the back of the diaper. A Cooperative Research and Development Agreement (CRADA) is currently being established with a major stakeholder to develop a cotton-based, completely biodegradable diaper that is also readily available and affordable for lower income families. This research addresses unmet needs in mitigating plastic and microplastic environmental contamination by replacing petrochemical derived fibers with more sustainable natural fibers.
In support of Objective 2, progress was made by ARS researchers in New Orleans, Louisiana, in determining the genetic and molecular basis for previously identified cotton fibers with enhanced flame retardance. Fibers from a newly developed mapping population derived from a cross of cotton lines with and without the flame retardance (FR) trait were harvested and are being used to produce nonwoven fabrics using a laboratory scale needle-loom. Flammability properties were determined using a microscale combustion calorimeter instrument as a proxy for fabric testing. This will guide selection of cotton fibers from individual plants for producing nonwoven fabrics. Cotton lines with and without the FR trait are being grown in New Orleans for further gene expression analysis of developing fibers as well as a comprehensive metabolite analysis to identify the molecular basis for the FR trait.
In support of Objective 3, progress was made by ARS researchers in New Orleans, Louisiana, in developing a cotton-supported copper catalyst that showed significant activity in the chemical degradation of dyes in water while retaining performance over consecutive cycles. The durability of the cotton biocomposite catalyst is the result of the copper catalyst being produced in the interior of the cotton fabric fibers, which mechanically immobilize the catalyst while still allowing chemical access to the dye molecules. This material, which had been previously published for its antibacterial, antifungal and antiviral properties, was highlighted in ARS news podcast “Science in Your Shopping Cart,” and has received significant attention from researchers and stakeholders. This has resulted in the conception of cooperative research projects and interest in commercialization.
In support of Objective 3, and Agreement 58-6054-4-35, progress was made by ARS researchers in New Orleans, Louisiana, in developing and characterizing silver metal-cotton products. ARS researchers fabricated cotton fibers doped with nanosilver, both on the exterior and interior, and tested their resistance to soil biodegradation. This nanosilver-cotton fabric demonstrated remarkable stability during a 16-week soil burial test, while pristine cotton deteriorated. ARS researchers attributed such stability to the fiber’s antifungal properties through testing against the soil-borne fungus Aspergillus flavus and revealed the leaching-proof of interior nanosilver in the soil, suggesting its potential for seedling, planting, or geotextile applications. This groundbreaking technology has advanced further with a CRADA established between ARS and a stakeholder to explore new opportunities for commercializing the nanometal embedding technology.
In support of Objective 3, ARS researchers in New Orleans, Louisiana, made progress in understanding the crystalline structure of cotton fibers, which is crucial for the development of new cotton technologies. ARS researchers measured crystallinity indices (CIs) of cotton fibers between 20 and 60 days post anthesis, revealing that the popularly used Segal method based on X-ray diffraction data overestimated CIs for these developing cotton fibers and indicated a more rapid crystallinity development compared to other methods. These findings motivated the need for a more accurate CI measurement method to better assess the crystallinity of cotton fibers during their development.
Accomplishments
1. Finding the "silver lining" in cotton gin trash. 1. Finding the "silver lining" in cotton gin trash. ARS researchers in New Orleans, Louisiana, have transformed cotton gin trash, an abundant agricultural waste with limited disposal options, into value-added materials. The team has unlocked the hidden values of cotton gin trash for the natural synthesis of nanosilver, extraction of nanofibers, creation of nanofiber-silver hybrid, and production of silver-infused ultralight aerogel. This innovative repurposing is made possible by utilizing cotton gin trash and its derivatives as multifunctional nanotemplates. Supported by the ARS Innovation Fund, the findings have been highlighted in ARS news, journal websites, and social media. Extending the technology to other biomass sources has led to a patent application. This research contributes to multiple benefits, including reduced disposal costs, new agricultural waste applications, additional revenue sources for cotton ginners, sustainable and cost-effective nanotechnology solutions, and eco-friendly alternatives for antimicrobial and antifungal products [NP306, C2, PS2B].
Review Publications
Nam, S., Tewolde, H., He, Z., Rajasekaran, K., Cary, J.W., Thyssen, G.N., Zhang, H., Sickler, C.M., Islam, M. 2024. Biodegradation Resistance of Cotton Fiber Doped with Interior and Exterior Silver Nanoparticles in Soil. ACS Omega. 9(11): 13017-13027. https://doi.org/10.1021/acsomega.3c09390.
Hinchliffe, D.J., Naoumkina, M.A., Thyssen, G.N., Nam, S., Chang, S., McCarty, J.C., Jenkins, J.N. 2024. Multi-omics analysis of pigmentation related to proanthocyanidin biosynthesis in brown cotton (Gossypium hirsutum L.). Frontiers in Plant Science. 15. Article 1372232. https://doi.org/10.3389/fpls.2024.1372232.
Nam, S., Easson, M., Jordan, J.H., He, Z., Zhang, H., Santiago Cintron, M., Chang, S. Unveiling the hidden value of cotton gin waste: natural synthesis and hosting of silver nanoparticles. ACS Omega. 2023:8(34):31281–31292. https://doi.org/10.1021/acsomega.3c03653.
Edwards, J.V., Prevost, N.T., Hinchliffe, D.J, Nam, S., Chang, S., Hron, R.J., Madison, C.A., Smith, J.N., Poffenberger, C.N., Taylor, M.M., Martin, E.J.,Dixon, K.J., 2023. Preparation and Activity of Hemostatic and Antibacterial Dressings with Greige Cotton/Zeolite Formularies Having Silver and Ascorbic Acid Finishes. International Journal of Molecular Sciences. https://doi.org/10.3390/ijms242317115.
Nam, S., Liu, Y., He, Z., Hinchliffe, D.J., Fang, D. 2024. Assessment of the Segal method for identifying crystallinity evolution in developing cotton fibers. Agricultural and Environmental Letters. 9(1). Article e201138. https://doi.org/10.1002/ael2.20138.