TE/TT Senior Design 2013-2014
Introduction & Motivation Types of Processing
Sponsorship & Acknowledgements
Faculty Mentors: Dr. Jon Rust, Dr. Russell Gorga, & Dr. Jesse Jur
This project is sponsored by NIKE, inc.
Opportunities, Through Green Chemistry, for Improving Synthetic Leather Joseph DiCesare, Edgardo Lopez, Jackie Revels Spring 2014
Company Mentor: Samantha Shintay
Customer Needs
Conclusion & Next Steps
15 million kg of synthetic leather is used per year at Nike One line of production equals $18,625 in sewage treatment
costs (approximately 170 lines in Wenzhou China total of about $3,000,000) [1]
Nike is seeking to eliminate discharge of hazardous chemicals during the manufacturing of their products by 2020
Nike is constantly seeking to reduce…
Assess the current state of synthetic leather production Survey and catalog sustainable methods for improving
synthetic leather process and materials Rank and assess the quality, economic, and environmental
impact of each method in order to provide recommendations to Nike
Rank and quantify improvements based on Nike's Restricted Substances List (RSL) criteria and The 12 Principles of Green Chemistry
RSL is given to suppliers to promote the use of positive chemistry and processes
Use a selection of the 12 Principles of Green Chemistry
Rank individual processes rather than companies, based on sustainability
Customers should expect an increased cost for solvent free materials Vendors are making an effort towards more sustainable synthetic
leather manufacturing. Explore options to replace DMF and other harmful solvents with
environmentally friendly compounds.
Water Borne Polyurethane can be used in processes to eliminate or significantly reduce the use of harmful solvents (Table 1) (Figure 2).
TPU (thermoplastic polyurethane) is another option that allows for the elimination of harmful solvents. Only used with high density substrates, typically with some form of nonwoven [2].
Recycled polyester for use as a backer is a viable option. Little to no compromise of mechanical properties [3].
The reduction or elimination of harmful solvents highly reduces water and energy consumption.
Overall, vendors are working towards Nike’s goal of no harmful chemical discharge by 2020
Figure 1: Green Chemistry
[1] Xu Xu (2011). "Environmental Cost Analysis and Upgrading Research of Synthetic Leather Industry".Energy procedia, 5.
[2] Akuvali, Guneri (2008). "Advances in Polymer Coated Textiles“. [3] Documents obtained from Teijin. [4] Image from documents obtained from Clarino
1, 2, 3
Research Current Manufacturing
Processes
Landscape Methods &
Advancements
Rank & Quantify Improvements Based on Nike's Green Chemistry
Program
Project Process
Toxics Energy Consumption Waste
Water Consumption
Project Description
Project Criteria
ACS Chemistry for Life: http://www.acs.org/content/acs/en.html
Pocket Guide
Recommendation 1. Elimination of harmful solvents: (1) Prevention, (3)Less hazardous
chemical synthesis, (5) Safer solvents and auxiliaries 2. Reduced energy & water consumption: (1) Prevention 3. Recycled substrates & water: (1) Prevention, (7) Use of renewable
feed stocks 4. Non-woven composite could potentially improve mechanical
properties.
Results 2
Results 1
Selected Survey Responses How do you see the future of sustainable synthetic leather?
How does your company currently practice sustainable practices?
“The customer only cares about quality and price, not how it was made” “Using water based polyurethane” “No solvent usage, or toxic gas emission”
“We developed a way to make synthetic leather without using a solvent.” “We use a water based polyurethane resin” “Our company uses eco-friendly materials, such as recycled polyester”
Are there any emerging technologies that could improve the process?
“Expanding the use of recycled substrate material.” “Waste water recycling systems.”
Figure 2: Layers of a Water Based PU Synthetic Leather
Results 3
-Wet + Dry combination of the R/P dry process being laminated to the wet process backers
-Dry includes producing the finish on release papers and laminating to non wet process backers
-Wet impregnation and coating of the backer to give material body and cushioning and better roller emboss definition
Ideation Process -Eight question survey focusing on the companies solvents, methods, and processing with an emphasis on green chemistry and sustainability -Distributed to representatives of 6 individual companies -Responses helped formulate recommendation to addressed customer needs
• Wenzhou China would save $1,108,187.50 in water treatment if half their lines go solvent free.
Figure 3: Process Steps for Water Borne PU Synthetic Leather
Table 1