To implement Textilfabrik 7.0 in a sustainable, energy-efficient, and economically viable way, it is necessary to develop biotechnological solutions and utilize natural resources. While on-demand production is scaled down, the Biosphere module is intended to scale up and demonstrate how textile production can also operate fossil-free. By combining microbiological processes, material flow analyses, and recycling processes, forward-looking concepts are created for fashion, sportswear, and technical textiles. Like all modules, Biosphere is strongly interconnected with other modules to address these topics holistically and translate them into practical applications. The Biosphere module focuses on three key areas:
- Circular economy
- Microplastics
- Green textile finishing
Circular Economy
To implement a circular economy, biotechnological methods for fiber (re)generation are being explored. Currently, the use of natural fibers consumes significant resources. Cotton, for example, requires large amounts of water, and transporting fibers to production sites generates a considerable CO₂ footprint. Therefore, the module aims to use not only cellulose sources from domestic natural fibers but also biotechnological processes for fiber production, either originally or in a secondary cycle. For instance, cellulose could be isolated from plants, produced de novo using bacterial cultures, or synthesized from monomers via enzymatic polymerization.
In addition to developing new fibers, the module also aims to recycle old textiles and use waste materials and textile wastewater as a carbon source for circular value creation. Another challenge is separating mixed materials (e.g., cotton and polyester) in recycling processes. Here, biotechnological methods are being investigated to recover individual materials from blended fabrics. This is preceded by sorting and mechanical, and optionally chemical, recycling before the actual biological degradation begins. While the primary goal is textile reuse, circular applications, such as providing nutrients for the growth of production microorganisms, are also pursued.
Microplastics
Microplastics represent a serious environmental problem because they are very slow to degrade and therefore remain in the environment for long periods, posing health risks to humans and animals. Since part of the microplastics enters the environment through textiles, a key focus is to investigate how this textile-related impact can be minimized.
The project is establishing detailed microplastic analytics to quantify and identify microplastics in wastewater from household laundry and textile production processes. In addition, the release of microplastics into nature during the wearing of textiles is being studied. This allows investigation of the effects of textile design parameters and processing methods. The goal is to develop prototypes with low microplastic emissions. To address the issue comprehensively, wastewater treatment methods, such as textile filter materials for microplastic removal, are also being developed.
Green Textile Finishing
Especially in textile finishing, such as dyeing or functionalization, chemicals are often used that pose significant risks to humans and the environment. Therefore, the third focus of the Biosphere module is to replace existing chemical auxiliaries with bio-based alternatives, as well as to isolate natural dyes or produce microbial dyes for textile coloring.
To maintain a circular approach, waste materials are also utilized as raw materials for the biotechnological synthesis of enzymes for sustainable textile finishing or for natural dyes (e.g., for dyeing viscose/lyocell).