Location: Cotton Fiber Bioscience and Utilization Research
2023 Annual Report
Objectives
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.
Objective 1: Enable, from a technological standpoint, new commercial products and market applications for cotton-containing nonwoven materials.
Objective 2: Enable new commercial varieties of cotton exhibiting non-conventional fiber properties for improved functionality and value of cotton-containing textiles.
Objective 3: Expand and develop novel metal-based nanotechnology to facilitate new value-added 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) nonwovens for medical and hygiene applications; (2) value added selection of cotton for nonwovens based on fiber classification; (3) determination of the genetic basis for cotton lines that produce inherently flame resistant fibers; (4) washable, reusable cotton antimicrobial wipes; (5) eco-friendly nanoparticle production for cotton-based textiles; and (6) hemostatic and antimicrobial cotton-based wound dressings.
In support of Objective 1, we made significant progress in producing pilot-scale nonwoven prototype wipe fabrics composed of raw and scoured/bleached cotton fibers that contained silver nanoparticles which imparted antimicrobial properties. The wipes were washable and reusable, maintaining antimicrobial properties after numerous launderings. Also, under Objective 1 and in collaboration with another of our research projects, we made significant progress in producing pilot-scale prototype hemostatic and antimicrobial wound dressings composed of greige cotton, polypropylene, and scoured/bleached cotton fibers that contained silver nanoparticles. We are currently using the dressing for evaluations in animal wound models. Also, under Objective 1 and in collaboration with ARS researchers in Stoneville and Starkville, Mississippi, we are cultivating the cotton lines previously identified as producing fiber with enhanced flame resistance (FR) at commercial-scale levels to harvest sufficient fibers for pilot scale fabric production and further characterization of the FR mechanism at the textile level. Also, under Objective 1, we subjected raw cotton hydroentangled nonwoven fabrics to ultrasonic welding treatments at varying power levels and processing speeds. The ultrasonic treatments resulted in significant changes in absorptive capacity and fluid handling characteristics of the fabrics, which could be a method for modifying moisture management properties of textiles including water repellency.
In support of Objective 2, we made significant progress in determining the genetic basis for inherent flame resistance (FR) previously discovered in fibers of select cotton lines from a genetically diverse population. The fiber FR was determined to be a genetically complex trait involving interactions between multiple genes. To better understand the genetics and mechanism of the FR, we conducted crosses with individual plants identified as having FR fibers, with plants that produce non-FR fibers. This generated a subsequent large mapping population that is currently being grown during the 2023 field season in collaboration with ARS researchers in Stoneville, Mississippi. This will allow for finer genetic mapping of the FR trait and development of associated genetic markers to facilitate the release of cotton lines with value-added fiber properties for producing flame resistant textiles. Also under Objective 2, cotton lines previously identified that have high fiber yields and superior fluid handling properties for disposable hygiene applications were cultivated at commercial-scale levels for further yield evaluations.
In support of Objective 3, we developed nanotech super-wipes that kill germs, save money, and reduce waste. By utilizing raw cotton fibers, a natural synthetic method for producing antimicrobial silver nanoparticles was devised. The remarkable finding was that raw cotton fibers can completely replace the need for reducing and stabilizing chemical agents typically used in conventional metallic nanoparticle syntheses. This sustainable nanotechnology not only eliminates the requirement for toxic and expensive chemicals but also enables the embedding of nanoparticles directly into cotton fibers. Building upon this breakthrough, ARS researchers produced the prototype of machine-washable antimicrobial wipes using blends of silver nanoparticle-embedded cotton fibers.
In support of Objective 3, we transformed cotton gin waste (also known as cotton gin trash) into a naturally occurring source material capable of synthesizing and hosting silver nanoparticles. Due to its abundant generation and limited disposal options, cotton gin waste poses a significant challenge in the cotton ginning industry. However, cotton gin waste has recently been gaining attention as a source for the development of new materials, such as composites, packaging, particleboard, and adsorbent materials. ARS researchers devised a simple heat treatment method that enables cotton gin waste to synthesize a remarkably high concentration of silver nanoparticles, reaching 14.7% based on the dry weight of the cotton gin waste. Electron microscopic images of cross-sections of cotton gin waste verified the formation of silver nanoparticles throughout the entire volume of cotton gin waste. By harnessing the biocidal properties of silver nanoparticles, the resulting cotton gin waste infused with silver nanoparticles can be utilized in innovative applications as antimicrobial and antifungal materials, opening new possibilities for the zero-waste strategy in the cotton ginning industry.
Accomplishments
1. Introducing sustainable machine-washable antimicrobial cotton wipes. With the growing emphasis on personal health protection, the use of antimicrobial wipes has soared. However, most wipes on the market are made of nonbiodegradable synthetic fibers and designed for single use, leading to environmental pollution. To address this issue, ARS researchers in New Orleans, Louisiana, have developed commercially viable nanotechnology that harnesses the natural ability of raw cotton fibers to capture antimicrobial silver nanoparticles and devised machine-washable antimicrobial cotton wipes. This innovative approach offers several advantages. It omits energy-intensive pretreatments of cotton fibers and eliminates the requirement for toxic and expensive chemical agents typically used in nanoparticle synthesis. Moreover, instead of serving as carriers of antimicrobial agents, these cotton wipes themselves act as antimicrobial agents, and can be washed up to 30 times without loosing its power. This minimizes the potential negative effects associated with the leaching of nanoparticles and reduces environmental microplastic pollution. The technology has been highlighted in ARS Tellus and News and received keen interest from companies. Currently, a commercial evaluation license agreement has been applied.
Review Publications
Thyssen, G.N., Condon, B.D., Hinchliffe, D.J., Zeng, L., Naoumkina, M., Jenkins, J.N., Mccarty,J.C., Sui, R., Madison, C., Li, P., Fang, D.D. Flame resistant cotton lines generated by synergistic epistasis in a MAGIC population. PLOS ONE. 18:e0278696.2023. https://doi.org/10.1371/journal.pone.0278696.
Hillyer, M.B., Nam, S., Condon, B.D. 2022. Intrafibrillar dispersion of cuprous oxide (Cu2O) nanoflowers within cotton cellulose fabrics for permanent antibacterial, antifungal and antiviral activity. Molecules. 27:7706. https://doi.org/10.3390/molecules27227706.
Nam, S., Hillyer, M.B., He, Z., Chang, S., Edwards, J.V. 2022. Self-induced transformation of raw cotton to a nanostructured primary cell wall for a renewable antimicrobial surface. Nanoscale Advances. 4(24):5404-5416. https://doi.org/10.1039/D2NA00665K.
Nam, S., Hinchliffe, D.J., Hillyer, M.B., Gary, L., He, Z. 2023. Washable antimicrobial wipes fabricated from a blend of nanocomposite raw cotton fiber. Molecules. 28(3). Article 1051. https://doi.org/10.3390/molecules28031051.
Hron, R.J., Hinchliffe, D.J., Thyssen, G.N., Condon, B.D., Zeng, L., Santiago Cintron, M., Jenkins, J.N., Mccarty Jr, J.C., Sui, R. 2023. Interrelationships between cotton fiber quality traits and fluid handling and moisture management properties of nonwoven textiles. Textile Research Journal. https://doi.org/10.1177/00405175221132011.
Hinchliffe, D.J., Thyssen, G.N., Condon, B.D., Zeng, L., Hron, R.J., Madison, C.A., Jenkins, J.N., Mccarty Jr, J.C., Delhom, C.D., Sui, R. 2023. Interrelationships between cotton fiber quality traits and tensile properties of hydroentangled nonwoven fabrics. Journal of Industrial Textiles. https://doi.org/10.1177/15280837231171312.
He, Z., Nam, S., Klasson, K.T. 2023. Oxidative stability of cottonseed butter products under accelerated storage conditions. Molecules. 28(4). Article 1599. https://doi.org/10.3390/molecules28041599.
He, Z., Nam, S., Liu, S., Zhao, Q. 2023. Characterization of the nonpolar and polar extractable components of glanded cottonseed for its valorization. Molecules. 28(10). Article 4181. https://doi.org/10.3390/molecules28104181
He, Z., Liu, S., Nam, S., Klasson, K.T., Cheng, H.N. 2022. Molecular level characterization of the effect of roasting on the extractable components of glandless cottonseed by Fourier transform ion cyclotron resonance mass spectrometry. Journal of Food Chemistry. 403. Article 134404. https://doi.org/10.1016/j.foodchem.2022.134404.
