Number

364-EN

Section

General Section

Use

Abstract

Nonwoven polyurethane and polyester/polyamide based microfibers (generally known as suede) are increasingly used in many fields of application and in a diversity of products. The most used and popular technology for the production of nonwoven is a method involving different solvents and processing aids during the production in order to give the fibres the physical and mechanical characteristics required. This case story describes an alternative technology to produce microfibers using water as the only solvent. The technology, called Dinamica®, developed by Miko and patented by the Japanese partner Asahi Kasei also gives the materials flame retardant properties without the addition of chemical flame retardants.

Substituted substances

Reliability of information

Evidence of implementation: there is evidence that the solution was implemented and in use at time of publication

Reason substitution

CMR
ED
other toxic effects
ecotoxicity

Other type of alternative

An alternative technology allowing complete substitution and/or elimination of different organic solvents normally used in this process.

Hazard Assessment

Substances to be substituted: This technology allows the elimination of organic solvents traditionally used for production of microfibers. Solvents commonly used: tri-and tetrachloroethylene and dimethylformamide (DMF). The material also allows the replacement of chemical flame retardants such as antimony trioxide, pentabromophenyl, decabromodiphenyloxide and other halogenated compounds. All of these chemicals are well known for having hazardous properties posing risk to workers and to the environment. Trichloroethylene may cause cancer, is suspected of causing genetic defects, may cause drowsiness or dizziness, causes skin irritation and is harmful to aquatic life with long lasting effects. Tetrachloroethylene is suspected of causing cancer and is toxic to aquatic life with long lasting effects The substance is also an endocrine disruptor (SIN List) and an endocrine disruptor category 2 (EU EDC database) as listed in the Substance Database according to SUBSPORTplus Screening Criteria (SDSC). N,N-dimethylformamide may damage the unborn child, is harmful if inhaled, harmful in contact with skin and causes serious eye irritation. Antimony trioxide is suspected of causing cancer. Alternative substance: Waterbased technology with non-hazardous substances that have no harmonised classification according to Annex VI of Regulation (EC) No 1272/2008 (CLP Regulation ).

Description of Substitution

Nonwoven polyurethane and polyester/polyamide based microfibers (generally known as suede) are increasingly used in the following fields of application: - home application (furnishing and upholstery) - car interiors - contract - airplane seating The most used and popular technology for the production of nonwoven is the traditional method (carding and needle punching) in which the microfibers are produced with the sea island technology. Islands of microfibers (PES/PA) are spun in a matrix (sea) of another polymer, which protects the microfiber during machining. Such a matrix is then dissolved in a later stage. The matrix that ensures the best performances in terms of hardwearing resistance is polystyrene or its copolymers. Trichloroethylene is normally used for dissolution of polystyrene and its copolymers. The needle punched TNT is then impregnated with polyurethane, which besides giving particularly appreciated tactile features, acts as a binder and provides the resistance to wear. Polyurethanes are normally used for these applications and usually dissolved in DMF and applied through the process widely used for manufacturing of manmade leather called coagulation. The application areas mentioned requires fire retardant properties of the material. To obtain this, the material is typically coated with compounds based on antimony oxide and decabromodiphenyloxide = pentabromophenyl ether or other halogenated compounds. Miko has developed a new line of products called Dinamica®, which eliminates all the harmful chemicals mentioned above. The microfiber used in the product comes from recycled PES (reducing CO2 emissions and increasing energy savings) through a technology known as direct spinning. Therefore, there is no need to dissolve the sea component with trichloroethylene. The nonwoven production process is called wet laid combined with spun lace (water needling). This technology is less invasive than conventional microfiber and does not need the use of protective matrix. The product uses waterborne PU or, in some cases, is exempt from PU. Therefore also the DMF is not used in the production cycle. The company has solved the problem of fire resistance making the product inherently flame retardant without the need to use harmful products. This is due the structure of the product which consists of three layers (surface, inner scrim and back). Specific products have been developed to meet the fire safety requirements for each of the different applications described in the beginning. Miko is an Italian company founded in 1997, Dinamica® by Miko is an ecological microfiber made from recycled polyester. The product was the winner of the Italian Environmental Business Award 2011 for Best Product. Miko is partner of Asahi Kasei, a Japanese company, which provides the raw base for the production of Dinamica®. The company offers products for different types of applications. For the production the company does not use harmful solvents and uses only neutral and nontoxic dyes. Its production cycle is based on a unique water process in order to guarantee fully respect for human health and the environment.

Case/substitution evaluation

This case story describes a new technology developed to eliminate a number of hazardous chemicals used in the production of microfibers. The technology also uses recyclable materials which is favourable also from a resource efficiency point of view. The use of water instead of hazardous solvents is a great example for substitution.

State of implementation

Full capacity

Date and place of implementation

Italy 2005

Availability ofAlternative

On the market

Producer/Provider

www.dinamicamiko.it

Type of information supplier

Producer / distributor

Contact

www.dinamicamiko.it

Further information

Product website

Product for automotive

Date, reviewed

November 26, 2021