FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
PROVISIONAL SPECIFICATION
(See section 10; rule 13)
1. TITLE OF THE INVENTION: – “PLANT BASED VEGAN LEATHER MADE
FROM BANANA CROP-WASTE”
2. APPLICANT:
a) NAME : ATMA LEATHER PRIVATE LIMITED
b) NATIONALITY : Indian
c) ADDRESS : 804, floor-8, Plot-3/301, 4/401, Lodha Supremus, Dr. E
Moses Road, Worli, Mumbai, Maharashtra, India
400018
3. PREAMBLE TO THE DESCRIPTION
The following specification describes the invention and the manner in which it is to be
performed.
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Plant based Vegan Leather made from banana crop-waste
Field of the invention
The present invention relates to compositions for preparing Vegan Leather and
5 Vegan Leather prepared from such compositions. This Vegan leather is a leather
like material completely free of any animal product. Particularly, the invention
relates to compositions for preparing Vegan Leather wherein such compositions
and Vegan Leather are prepared from Banana crop waste including banana
pseudostems. More particularly, compositions and Vegan Leather are prepared
10 from processed Banana crop waste such as Banana pulp. Compositions for
preparing Vegan Leather comprise of Banana pulp and at least one adhesive or
binder. Further, the invention also relates to processes for preparing compositions
and Vegan Leather from compositions containing Banana Pulp.
15 Objects of the invention
First object of the invention is to provide compositions to prepare Plant based
Vegan Leather wherein the compositions are completely free of animal product and
thus avoids animal cruelty of the leather industry.
Second object of the invention is to provide compositions to prepare Plant based
20 Vegan Leather wherein the compositions are employed in manufacturing Vegan
Leather by a tanning free process.
Third object of the present invention to provide a solution for leather manufacturing
that causes minimal or zero pollution and majority of the material (>50%) is natural.
Fourth object of the present invention is to provide a solution for leather
25 manufacturing that addresses the growing crop waste problem.
Fifth object of the invention is to use waste from the Banana crop after Harvest to
prepare compositions which can be further employed in Vegan Leather
manufacturing. Therefore, the Vegan Leather is prepared from compositions which
employ easily and abundantly available raw materials.
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Sixth object of the invention is to provide a simple, economical and environment
friendly process to prepare Plant based Vegan Leather from compositions of the
present invention containing processed waste from Banana crop.
Seventh object of the present invention is to provide a vegan leather material which
5 looks, feels, and performs like leather.
Eighth object of the present invention is to develop sustainable and environmentally
friendly alternatives which are significantly lower water intensive in comparison to
animal leather manufacturing and lower carbon emissions
Ninth object of the present invention is to develop plant leather alternative with
10 over 50% banana crop waste.
Summary of the invention
It is reported that leather is a by-product of animal slaughter for meat, however, in
reality, leather is a valuable co-product, and over one billion animals are slaughtered
15 for their skin worldwide every year.
Present invention provides Plant based Vegan Leather completely free of any
animal product.
Under the first aspect, the invention provides compositions to prepare Plant based
Vegan Leather wherein the compositions are completely free of animal product.
20 The said compositions incorporate plant based materials, particularly, plant based
waste material which is otherwise discarded. Using plant based materials for
manufacturing compositions of the present invention completely eliminates use of
animal skins or animal products in manufacturing of leather.
Tanning process used typically in manufacturing of leather employs harsh and toxic
25 chemicals that are largely deposited untreated into wastewater responsible for
polluting many water bodies. Various types of Tanning processes typically involve
use of basic chromium sulfate (BCS) and other toxic metals. Such use enhances
Carcinogenic compounds in the wastewater like Cr(VI), Cadmium, Arsenic etc.
which are known carcinogens. Additionally, chemicals like formaldehyde, lead,
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zinc, silicon are traced which are also hazardous. Therefore, stringent norms are
applicable for estimating presence or formation of Cr (VI) in the final leather.
Manufacturing leather without requiring tanning step offers several ecological and
environmental benefits such as reduction in water used, generation of toxic waste
5 and significant reduction in carbon emissions.
Under the second aspect, the invention provides compositions to prepare Plant
based Vegan Leather wherein the compositions are employed in manufacturing
Vegan Leather by a tanning free process.
Under the third aspect, the present invention uses easily and abundantly available
10 raw material to manufacture compositions which are further used to prepare Plant
based Vegan Leather.
Under this aspect, invention uses waste from the Banana crop after Harvest to
prepare compositions which can be further employed in Vegan Leather
manufacturing. Therefore, the Vegan Leather is prepared from compositions which
15 employ easily and abundantly available raw material such as Banana crop waste.
Leather manufacturing is a complex process. It involves a series of processes to
arrive at a leather having desirable characteristics. The processes involved are
soaking, liming, deliming, bating, pickling, tanning, dyeing, and finishing, and the
other machinery steps like splitting, sammying, staking, drumming etc. Each one
20 of these processes is complicated and requires multiple steps with immense water
and energy used.
Fourth object of the invention is to provide a simple, economical and environment
friendly process to prepare i) Compositions of the present invention containing
Banana pulp which is obtained by processed waste from Banana crop and ii) Plant
25 based Vegan Leather from compositions of the present invention. The process does
not involve use of any toxic or hazardous chemical and the product produced is free
of any such chemicals.
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Background of the Invention
The leather industry is responsible for significant environmental damage and puts
immense pressure on land, food, water resources and animal livestock too. A typical
cow leather bag requires 18,000 liters of water which is 25 years of drinking water
5 for a single person and the carbon equivalent of charging 12,000 smartphones. This
can also be looked at as the emissions from the manufacturing of 100K straws.
14% w/w of all emissions globally are attributed to livestock rearing an industry
that leather depends on. Additionally, 1 ton of raw material generates 20% w/w of
finished leather and 60-80% w/w of solid and liquid waste that includes
10 carcinogenic heavy metals, a by-product of the tanning processes. 90% w/w of
leather processed is tanned using chromium and other toxic chemicals that are
largely deposited untreated into wastewater responsible for polluting many water
bodies.
Countries like India are responsible for the most crop residue burning from any
15 other country, which is 18 Mn tons a year leading to some of the most polluted
cities in the world.
Specifically, the banana crop has more waste than most other crops as the plant only
bears fruit once, after which the stem becomes redundant. 80% w/w of the plant by
weight is wasted every harvest which amounts to about 120< tones generated
20 annually. And <10% w/w of this cellulose and fibre rich waste is utilized despite its
high value.
Indian Patent Application No. 202221054824 A provides a non-woven banana plant
leather made of banana fiber, which is extracted from banana stem. The extracted
banana fibers are opened, carded, cross-lapped and needle punched to obtain banana
25 fiber substrate which is a single layer non-woven substrate having density ranging
from 1.5 to 2 g/mm3. The banana fiber substrate is coated with adhesive coat to
form composite with bio polyurethane in ratio of range of 3:0.1:1 to 5:0.1:1 to give
desired leather finish to the banana fiber substrate. This prior art utilizes banana for
preparing backing material wherein strength of Banana stem is not fully utilized.
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There is a need for vegan leather in the market today, however, due to the vastly
different supply chains and production processes, it is not possible for traditional
manufacturers of animal leather to convert or switch to plant leather production.
Additionally, the majority of vegan leather alternatives are polyurethane, and PVC
5 based, both from petrochemical sources, which is not sustainable and
environmentally friendly. There are some new plant-based alternatives in the
market from cactus, mycelium, yeast and other raw materials, however such plantbased alternatives are also scarcely applicable.
10 Brief Description of figures
For a better understanding of the embodiments of the machine and methods
described herein, and to show more clearly how they may be carried into effect,
references will now be made, by way of example, to the accompanying drawings,
wherein like reference numerals represent like elements/components throughout
15 and wherein:
Fig.1 illustrates an exemplary flowchart that shows a plant-based method for
manufacturing plant based vegan leather material, in accordance with an
embodiment of the present invention.
20 Fig. 2 illustrates an exemplary view showing the plant-based panels of banana stem
leather, in accordance of the present invention.
Fig.3 provides a process diagram depicting all steps in preparing plant based vegan
leather of the present invention.
Fig. 4 provides different steps involved in the preparation for the plant based vegan
25 leather starting from harvesting banana tree to finished product.
Fig. 5 and Fig.6 provides plant based vegan leather prepared as per the present
invention.
Fig. 7A provides the composition containing banana pulp produced by processing
banana crop waste and other additives which is used for preparing plant based vegan
30 leather.
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Fig. 7B provides the coating of composition of Fig. 7A by way of spraying, on the
backing material to produce leather.
Fig. 7C provides the plant based vegan leather produced after coating of
composition containing banana pulp produced by processing banana crop waste and
5 other additives.
Fig. 8 provides the plant based vegan leather prepared as per the present invention.
Fig. 9 provides spraying of lacquering suspension.
Fig. 10 provides a wallet prepared as per the present invention.
Fig. 11A and Fig. 11B provides picture of bags prepared by using plant-based vegan
10 leather prepared as per the present invention.
Fig. 12A and Fig. 12B provides a test reports of banana content (%) and other
content (%) of the plant-based vegan leather prepared as per the present invention.
Fig. 13 A provides image of Vegan Leather wherein of composition o having 60%
Banana pulp + 30 % natural rubber + 10 % natural adhesive
15 Fig. 13 B provides image of Vegan Leather wherein of composition q having 60%
Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue
Fig. 14 A provides image of Vegan Leather wherein of composition U having 55%
Banana pulp + 26 % polyvinyl acetate + 14 % acrylic +5 % starch as filler.
Fig. 14 B provides image of Vegan Leather wherein of composition q having 60%
20 Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue.
Fig. 15A provides image of Vegan Leather wherein of composition R having 55%
Banana pulp + 25 % polyvinyl acetate + 20 % Magnopal IPF
Fig. 15B provides image of Vegan Leather wherein of composition V having 60%
Banana pulp + 30 % polyvinyl acetate + 10 % PEG.
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Detailed description of the invention
The invention provides compositions to produce plant based vegan leather and
Vegan leather produced from such compositions. Mainly, the invention provides
compositions containing processed banana crop waste which are further used to
5 produce vegan leather. Particularly, the invention covers compositions containing
i) Banana pulp produced by processing banana crop waste and ii) other additives.
More particularly, the invention covers compositions containing i) Banana pulp and
ii) at least one adhesive / binder and optionally other additives selected from fillers,
softeners / plasticizers, preservatives etc…
10 These compositions are coated on the backing material to produce leather. Hence
the compositions of the present invention are also referred as “coating
compositions”. These compositions are also referred as leather mixtures.
The invention further provides leather produced by depositing / spraying / applying
coating compositions / leather mixtures of the present invention on backing
15 material. The leather produced is further subjected through various processes to
enhance adhesion between backing material and coated composition and to enhance
look of a leather. These processes include plating, colour spraying, embossing and
lacquering and drying in between these steps whenever required.
The plant-based vegan leather material looks, feels and performs like leather.
20 The vegan leather and compositions from which it is prepared do not contain any
animal product. The processes to prepare compositions and Vegan Leather are
tanning free processes. The compositions and Vegan Leather are prepared from raw
materials which are easily and abundantly available and processes are simple,
economical and environment friendly.
25 Central to this innovations are the compositions that meld around 40 – 70 % w/w
of banana pulp, from 5 – 50 % w/w of adhesive and / or binder and optionally other
additives into a cohesive and versatile mixture. The amalgamation of these
components is a strategic endeavour aimed at crafting compositions with distinctive
properties. The abundant presence of banana pulp, constituting almost half of the
10
mixture serves as a foundational element. Its natural binding attributes, coupled
with inherent biodegradability, offer a sustainable adhesive quality.
More particularly, compositions to produce Vegan Leather are made from
processed Banana crop waste. Banana crop generates significant waste than most
5 other crops as the plant only bears fruit once, post which the stem becomes
redundant and needs to be cut and discarded. Banana crop generates significant
waste than most other crops as the plant only bears fruit once, post which the stem
becomes redundant and needs to be cut and discarded. Thus 80% w/w of the plant
by weight is wasted every harvest which amounts to about over 120 million metric
10 < tones are generated annually globally. For India, which produces 25% w/w of the
world's bananas, the waste generated is 30 million metric tons. And <10% w/w of
this cellulose and fibre rich waste is utilized despite its high value. Thus, the present
invention utilizes abundantly and easily available raw materials which are usually
discarded as waste.
15 The present plant-based vegan leather is prepared from banana crop waste and thus
is a cruelty free alternative to animal leather. It also addresses the problems like the
crop waste, animal cruelty, pollution, natural resources depletion and the like.
Compositions of the present invention include processed Banana crop waste.
Banana crops can be processed in a number of ways. In a preferred way, Banana
20 crop waste is processed to obtain Banana pulp.
Compositions of the present invention for preparing vegan leather comprise of
Banana pulp. Particularly, compositions for preparing vegan leather comprise of
Banana pulp and at least one adhesive or binder. More particularly, compositions
contain Banana pulp, one or more adhesives or binders and other additive such as a
25 filler, softener / plasticizer, preservatives etc.
The Vegan leather prepared in accordance with the present invention comprises a
backing material coated with a composition containing Banana pulp and other
additives. Vegan leather prepared in accordance with the present invention
comprises Banana pulp and adhesives and / or binders, fillers, softeners,
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plasticizers, colours / pigments, preservatives, lacquers, chemicals to prevent colour
leakage, water repellents.
Backing material comprises up to 20 % w/w of the final leather, preferably up to 10
% w/w of final leather, and most preferably up to 5 % w/w of the final leather.
5 Since compositions of the present invention are coated on the backing material, they
are also referred to as coating compositions and coated backing material is called
panels. Coating compositions comprise at least 85 % w/w, preferably at least 90 %
w/w, more preferably at least 95 % w/w of the produced leather. Coating
compositions are also called leather mixtures.
10 After coating of backing material with compositions of the present invention and
plating which is done to enhance adhesion between backing material and coated
compositions, leather is subjected to several finishing processes. Finishing of
leather includes a series of steps to give buyers variety in the colours, embossing,
shiny or matt finishes etc. and include top coating, surface treatment and adding
15 chemicals to stop colour leakage and water proofing etc.
Upper coating contains colours / pigments, binders, preservatives, lacquers,
chemicals to prevent colour leakage and water repellents together up to 5 % w/w,
preferably, from 0.5 - 5 % w/w of final finished leather produced.
The Vegan leather prepared in accordance with the present invention comprises
20 from 1 – 15 % w/w of backing material, colours / pigments, binders, lacquers,
chemicals to prevent colour leakage and water repellents and 85 – 99 % w/w of
coating composition containing Banana pulp and at least one adhesive / binder and
optionally one or more of other additives such as fillers and softeners / plasticizers.
Additionally, from 0.001 to 0.1 % w/w of preservatives are present when required.
25
In addition to Banana pulp, other ingredients of compositions to prepare vegan
leather include at least one adhesive / binder and optionally other additives such as
fillers, softeners / plasticizers, preservatives, colours etc.
12
Filler provides structure and fullness to the leather. Starch is a preferred filler.
Preferably starch is added in liquid form prepared as provided below. Starch from
Tapioca, corn, potato and rice etc. can be used. Other fillers include polymer filler,
waxes such as bees wax, paraffin wax, carnauba wax, cork powder, veg oil, wheat
5 straw, rice husk etc.
Liquid Starch Preparation
● Grinding - The starch granules are first taken into a grinding machine to
make powder form. It will take 5 min to make it fully powder form.
● Straining- the powder starch will be strained by a strainer.
10 ● Boiling - Then the starch powder will be boiled for 30 minutes in the oven.
Here the ratio is 20g starch powder will mix into 200 ml water and mix it properly
and will take this for boiling.
● Straining- Then the liquid mixture will be strained again to make sure there
is no thick starch present in the mixture. Otherwise, it may make a spot on the
15 finished panel.
In an embodiment, starch is used as a filler. In another embodiment, polymer filler
is one or more from Magnopal IPF, Magnopal BP, Magnopal Pure-A is employed.
The compositions to prepare Vegan Leather preferably contain at least one adhesive
/ binder. Adhesives and binders can be selected from natural source hereinafter
20 natural adhesive or natural binder and chemical source hereinafter synthetic
adhesive or synthetic binder. Adhesives ensure that there is no peeling off of the
composition from backing material as well as it increases the intermolecular
attraction between the compound molecules.
Preferred synthetic adhesives include Ethylene vinyl acetate, Polyvinyl acetate,
25 Neoprene, plastic resin glue, epoxy glue etc. Preferred natural adhesives include
Natural rubber, guar gum, gum Arabic, gum rosin etc. Natural adhesives also
include some mixtures and glues prepared inhouse from arrowroot, gum rosin, gum
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Arabic, jackfruit, Guar gum, agar-agar powder etc. A preferred natural adhesive is
jackfruit glue, arrowroot glue, corn-starch glue.
Amongst binders, preferred are Polyvinyl chloride, Polyurethane Binders, Acrylic
Binders, Resin Binders, poly lactic acid, maleic anhydride, and Natural Binders
5 made from Rubber and Starch. Binders are present in the compositions as well as
in top colour coatings. Top coating binders include Protein binder, acrylic binder,
PU binder and other types of thermoplastic Binder, non-thermoplastic binders,
Butadiene Binder etc.
10 Plasticizers or softeners are added to obtain soft leather and include polyethylene
glycol, polypropylene glycol, glycerol, isopropyl alcohol, epoxidized soybean, and
other vegetable or fruit oils e.g., corn, sunflower, palm etc.
Additionally, preservatives such as fungicides and bactericides, natural colours
sourced from natural resources like charcoal black, beets, onion skins etc. can be
15 added.
Banana pulp content of the compositions is from 40 – 70 % w/w, preferably from
50 – 70 % w/w, more preferably from 50 – 65 % w/w, and most preferably from
55 – 65 % w/w. Adhesive / Binder content is from 5 – 50 % w/w.
20 More than one adhesives or binders are also present depending on the requirements
of final leather.
Additionally, from 5 - 35 % w/w of filler is present. When a soft leather is desired,
1 – 15 % w/w, preferably, 5 - 15% w/w of a softener / plasticizer such as
polyethylene glycol can be added.
25 Further, other additives are present in the vegan leather such as preservatives,
pigments, dyes, natural colours, binders for mixing with pigments etc.
Each of the compositions containing Banana pulp preferably contains at least 40 %
w/w, more preferably at least 50 % w/w and most preferably from 55 – 65 % w/w
of Banana pulp.
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Some of the Compositions of the present invention are as follows:
i) 40 % w/w banana pulp + 30 % w/w adhesive + 30 % w/w filler;
ii) 45 % w/w banana pulp + 30 % w/w adhesive + 25 % w/w filler;
iii) 52 % w/w banana pulp + 25 % w/w adhesive + 23 % w/w filler;
5 iv) 58 % w/w banana pulp + 21 % w/w adhesive + 21 % w/w filler;
v) 50 % w/w banana pulp + 25 % w/w adhesive + 25 % w/w binder;
vi) 58 % w/w banana pulp + 21 % w/w adhesive + 21 % w/w filler;
vii) 50 % w/w banana pulp + 25 % w/w adhesive + 15 % w/w binder + 10 % w/w
filler ;
10 viii) 55 % w/w banana pulp + 25 % w/w adhesive + 15 % w/w binder + 5 % w/w
filler;
ix) 55 % w/w banana pulp + 26 % w/w adhesive + 14 % w/w binder + 5 % w/w
filler;
x) 60 % w/w banana pulp + 30 % w/w adhesive +10 % w/w filler;
15 xi) 60 % w/w banana pulp + 30 % w/w adhesive +10 % w/w plasticizer / softener;
xii) 60 % w/w banana pulp + 20 % w/w adhesive +10 % w/w filler + 10 % w/w
plasticizer / softener;
xiii) 65 % w/w banana pulp + 20 % w/w adhesive +5 % w/w filler + 10 % w/w
plasticizer / softener;
20 xiv) 65 % w/w banana pulp + 15 % w/w adhesive +10 % w/w binder + 10 % w/w
plasticizer / softener;
xv) 70 % w/w banana pulp + 20 % w/w adhesive + 5 % w/w filler;
xvi) 60% w/w banana pulp + 20 % w/w binder 1 + 10% w/w binder 2 + 10%
w/w binder 3
25 xvii) 50% w/w banana pulp + 10% w/w softener 1 + 15 % w/w binder 1 + 10%
w/w binder 2 + 15% w/w softener 2;
xviii) 50% w/w banana pulp + 30% w/w natural adhesive + 20% w/w binder;
xix) 50% w/w banana pulp + 30% w/w synthetic adhesive + 20% w/w binder;
xx) 50% w/w banana pulp + 30% w/w filler+ 20% w/w binder;
15
xxi) 50% w/w banana pulp + 30% w/w Natural Rubber + 20% w/w Bio Poly
Urethane;
xxii) 50% w/w banana pulp + 30% w/w natural adhesive + 20% w/w binder;
xxiii) 50% w/w banana pulp + 30% w/w synthetic adhesive + 20% w/w binder;
5 xxiv) 50% w/w banana pulp + 30% w/w binder 1 + 20% w/w binder 2
xxv) 50% w/w banana pulp + 30% w/w Filler + 20% w/w binder
xxvi) 60% w/w banana pulp + 20% w/w Filler + 10% w/w binder + 10% w/w wax
softener
xxvii) 50% w/w banana pulp + 30% w/w Filler + 20% w/w binder
10 xxviii) 60% w/w banana pulp + 20% w/w Filler + 10% w/w binder + 10% w/w
wax softener
xxix) 50% w/w banana pulp + 15% w/w synthetic adhesive 1 + 20% w/w synthetic
binder + 15% w/w synthetic adhesive 2;
xxx) 50% w/w banana pulp + 15% w/w synthetic adhesive + 20% w/w Natural
15 binder + 15 % w/w synthetic adhesive 2;
xxxi) 60% w/w Banana pulp + 20 % w/w binder + 20% w/w plasticizer + 10%
w/w Oil softener
Following specific embodiments represent the compositions of the present
20 invention employing natural as well as synthetic adhesives and / binders, fillers, and
softeners / plasticizers etc.
Neoprene, ethylene vinyl acetate, polyvinyl acetate, natural rubber, gum Arabic,
gum rosin, agar-agar solution, arrowroot glue, solution are preferred adhesives.
Poly lactic acid, , polyvinyl chloride, maleic anhydride, polyurethane, Bio
25 polyurethane, acrylic binder, resin binders, jackfruit glue, Arrowroot flour or Glue
etc. act as binders.
Adhesives are used to cause adhesion between backing material and coating
compositions so no material gets separated / peeled off. Binders act as adhesion
bolsters. They enhance binding between backing material and compositions coated
30 on backing materials and also enhance binding within the compositions.
16
Starch from tapioca, rice, corn, potato, rice husk, cork filler, polymer filler
magnopal IPF, Magnopal BP, Magnopal Pure-A are added as fillers to give fullness
and structure. Additional fillers include waxes such as Bees wax, paraffin wax, veg
oil, Agri-waste filler like rice husk, wheat straw etc.
5 Glycerol, isopropyl alcohol, polyethylene glycol, polypropylene glycol etc. are
added as softeners /plasticizers which impart desired softness to the leather.
Following compositions are specifically produced and suitable backing materials
are coated with these compositions to produce Vegan Leather.
A. 60% w/w banana pulp + 10 % w/w Poly Lactic Acid + 10% w/w PVC +
10 20% w/w Bio Poly Urethane
B. 50% w/w banana pulp + 10% w/w Isopropyl alcohol + 15 % w/w Poly
Lactic Acid + 10% w/w Maleic anhydride + 15% w/w PVA
C. 50% w/w banana pulp + 30% w/w natural rubber + 20% w/w Polyvinyl
Chloride
15 D. 50% w/w banana pulp + 30% w/w neoprene + 20% w/w Acrylic binder
E. 50% w/w banana pulp + 30% w/w Starch + 20% w/w Polyvinyl Chloride
F. 50% w/w banana pulp + 30% w/w Natural Rubber + 20% w/w Bio Poly
Urethane
G. 50% w/w banana pulp + 30% w/w Gum Arabic solution + 20% w/wPVC
20 H. 50% w/w banana pulp + 30% w/w Polyvinyl acetate + 20% w/w Polyvinyl
Chloride
I. 50% w/w banana pulp + 30% w/w Poly Lactic Acid + 20% w/w Polyvinyl
Chloride
J. 50% w/w banana pulp + 30% w/w Cork Filler + 20% w/w Polyvinyl
25 Chloride
K. 60% w/w banana pulp + 10% w/w Cork Filler + 20% w/w Polyvinyl
Chloride + 10% w/w wax
L. 50% w/w banana pulp + 30% w/w Cork Filler + 20% w/w Polyvinyl
Chloride
17
M. 60% w/w banana pulp + 20% w/w Cork Filler + 10% w/w Polyvinyl
Chloride + 10% w/w wax
N. 50% w/w banana pulp + 15% w/w neoprene + 20% w/w Acrylic binder +
15% w/w Ethyl vinyl alcohol
5 O. 50% w/w banana pulp + 15% w/w neoprene + 20% w/w Resin binder + 15
% w/w Ethylene vinyl acetate
P. 60% w/w Banana pulp + 10% w/w Bio PU + 20% w/w PEG / glycerol as
plasticizer + 10% w/w Oil
Q. 60% w/w Banana pulp + 30 % w/w polyvinyl acetate + 10 % w/w starch;
10 R. 55% w/w Banana pulp + 25 % w/w polyvinyl acetate + 20 % w/w
Magnopal IPF as filler;
S. 58% w/w Banana pulp + 21 % w/w polyvinyl acetate + 21 % w/w bio
polyurethane as binder ;
T. 55% w/w Banana pulp + 25 % w/w polyvinyl acetate + 20 % w/w
15 Magnopal BP as filler;
U. 55% w/w Banana pulp + 26 % w/w polyvinyl acetate + 14 % w/w acrylic
+5 % w/w starch as filler;
V. 60% w/w Banana pulp + 30 % w/w polyvinyl acetate + 10 % w/w PEG (as
softener and plasticizer).
20 Following specific embodiments represent the compositions of the present
invention employing natural adhesives such as natural rubber, jackfruit glue,
Arrowroot Glue etc.
a. 60% banana pulp + 20 % Starch + 10% Cork filler + 10% Natural Rubber
25 b. 50% banana pulp + 10% Jackfruit Glue + 15 % Natural Rubber + 10% Gum
Arabic + 15% Softener
c. 50% banana pulp + 30% natural rubber + 20% Wheat Straw filler
d. 50% banana pulp + 30% Starch + 20% Guar Gum
e. 50% banana pulp + 30% Starch + 20% Veg oil
30 f. 50% banana pulp + 30% Natural Rubber + 20% wheat straw powder
g. 50% banana pulp + 30% Gum Arabic solution + 20% Citric acid
h. 50% banana pulp + 30% Talcum powder + 20% Rice husk powder
18
i. 50% banana pulp + 30% fruit wax + 20% Agar-agar solution
j. 50% banana pulp + 30% Cork Filler + 20%Natural Rubber
k. 60% banana pulp + 20% Cork Filler + 10% Natural Rubber + 10% wax
l. 60% banana pulp + 20 % Starch + 10% Cork filler + 10% Guar Gum
5 m. 60% Banana pulp + 30 % natural rubber + 10 % filler such as starch;
n. 60% Banana pulp + 40 % natural rubber;
o. 60% Banana pulp + 30 % natural rubber + 10 % natural adhesive;
p. 60% Banana pulp + 30 % natural rubber + 10 % jackfruit glue;
q. 60% Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue;
10 In addition to various above compositions, dyes, pigments, colourants, binders for
dyes and pigments and preservatives are part of these compositions and are added
in amounts of up to 1 % w/w.
In a coating composition or leather mixture, banana pulp, adhesives / binders,
fillers, softeners / plasticizers are present around up to 99 % w/w and dyes,
15 pigments, binders for dyes and pigments and preservatives are present around up to
1 % w/w.
Processes for preparing compositions to prepare Vegan Leather and
preparation of Vegan Leather therefrom
20 The compositions to prepare Vegan Leather are also termed as leather mixtures. A
process of preparing compositions which are coated / sprayed on backing material
to produce Vegan Leather has following steps: (CHANGE AS PER CLAIM)
i) Preparing banana pulp;
ii) Mixing banana pulp and adhesive / binder in a blender;
25 iii) Optionally adding any additional adhesive and / or binder; or adding
filler and / or softener and blending;
iv) Mixing dyes / pigments / synthetic colour with a binder and adding the
mixture to above blend while mixing.
30 Preparation of compositions of the present invention:
19
Banana pulp and adhesive and / or binder are mixed in a blender. Mixing is
continued for 1 hr. Such mixture has sufficient adhesiveness to ensure that the
composition does not peel off from the backing material after drying. If additional
adhesive / binder is to be added, it is added at this stage and mixed. Filler and / or
5 softener is added and mixed well. Dyes / pigments / Synthetic Colour is mixed with
preferably double the quantity of Binder and such mixture is added to the above
composition while mixing. Additionally, preservatives are added if needed.
Preparation of Banana pulp comprises
i) Preparing or obtaining banana stem cuttings;
10 ii) Subjecting banana stem cuttings to alkali treatment;
iii) Boiling banana stem cuttings in a suitable equipment or digester causing
them to melt and form banana pulp;
iv) Washing and straining pulp to wash out left over alkali;
v) Grinding pulp and washing ground pulp;
15 vi) Optionally bleaching the pulp and washing pulp to wash out bleaching
agent.
Detailed Preparation of Banana pulp
Banana pulp is prepared by carrying out a series of process steps including alkali
treatment, boiling, bleaching, ageing and intermittent washing in between these
20 steps when needed. Bleaching is mainly followed for obtaining white or whitish
shade and is an optional step when such shade is not required.
Banana stems are cut after trees give fruits. Upper surface of the stem is separated
from the inner and middle portions of the stem as it is harder. Long cuttings of Inner
and middle portions are collected and subjected to a banana shredder. Banana
25 shredder is a stem cutting machine having sharp rolling blades inside. The shredder
cuts the long cuttings of Inner and middle portions very quickly into small pieces
of banana.
Banana stem cuttings / banana fibres are subjected to an alkali treatment during
which 100 parts of Banana stem cuttings / banana fibres are mixed with around 1 –
30 2 parts of sodium sulfide and 2 – 3 parts of sodium hydroxide and 200 parts water
20
and mixed. Other combinations of alkalis that result in a pH of 11-12, can also be
employed like calcium hydroxide, aqueous ammonia, thiourea etc.
In the next step, the above mixture is subjected to boiling in a Digester. During
boiling, stem cuttings are melted. The melted stem cuttings are subjected to
5 grinding in a grinder for up to 15 – 30 mins., during which melted stem cuttings
produce banana pulp. This pulp is brown coloured. It is washed with water to wash
away alkali and strained in a strainer. After straining, pulp is subjected to grinding
and then washing.
After washing the pulp is optionally subjected to bleaching. Bleaching is optional
10 and done only when white / whitish leather is desired.
Bleaching process – 100 parts of pulp, around 6 – 7 parts of Bleaching powder
(Calcium Oxychloride [Ca(OCl)2] and 200 parts of water are mixed. The mixture
is kept overnight to lighten the original brown colour.
Bleaching chemicals like liquid bleach, hydrogen peroxide, sodium percarbonate,
15 sodium perborate etc. are basic in nature and washing is necessary if bleaching is
carried out to produce desired shade.
After bleaching the pulp, it is washed again. So, there involves 2-3 times
intermittent washings in the process.
During the above processing steps, initial weight is reduced to almost 20 – 60 %
20 w/w of the initial weight.
Preparation of Vegan Leather
A process of preparing Vegan leather comprises (As per the claim changes)
25 i) Selecting and cutting backing material in suitable dimensions;
ii) Preparing coating compositions;
iii) Applying or spraying coating compositions on the backing material of
suitable sizes to obtain panels;
iv) Trowelling panels or spreading even the coated composition on panels;
21
v) Drying panels under controlled temperature;
vi) Plating dried panels;
vii) Subjecting plated panels to colour spraying, drying and surface
treatments comprising one or more of, milling, embossing and
5 lacquering.
Additionally, the process of preparing Vegan Leather also comprises adding i)
chemicals to prevent colour leakage and / or ii) water repellents during surface
treatment.
Vegan leather from compositions of the present invention
10
The compositions of the present invention such as from compositions A to V or
compositions a to q are applied in the form of coating on a backing material in the
production of Vegan leather and hence the compositions are also termed as coating
compositions. One or more coats can be applied on the backing layer one after the
15 other.
A suitable backing material is selected from recycled plastic bottles, polyester,
rayon, nylon, velvet, cotton fabric from a locally grown cotton, vegan fabrics made
from banana, bamboo, jute, linen etc.
In an embodiment, backing material is obtained from recycled plastic bottles.
20 Backing material can be cotton fabric from a locally grown cotton known for its
suppleness and comfort. Organic cotton also enhances the biobased nature of the
product. In another embodiment, backing material is linen.
Thickness ratio of backing material to coatings is usually from 1:2 to 1:10. In terms
of weight, backing material is not more than 20 % w/w preferably not more than 10
25 % w/w of prepared leather.
The coated backing material is dried and subjected to a series of processes to
convert it into vegan leather. In a Vegan Leather prepared according to the present
invention, backing material or backing layer preferably comprises up to 10 % w/w,
more preferably up to 5 % w/w and most preferably up to 2.5 % w/w. Coating
22
compositions are preferably present in an amount of at least 90 % w/w, more
preferably at least 95 % w/w and most preferably at least 98 - 99 % w/w.
Drying and other processes do not materially affect the constitution of coating
compositions, backing material and therefore Vegan leather.
5
Preparation of Backing material
A suitable backing material is selected from recycled plastic bottles, polyester,
rayon, nylon, velvet, cotton fabric from a locally grown cotton, vegan fabrics made
from banana, bamboo, jute, linen etc..
10 Backing material is cut into various desired sizes as per the requirements and
available drying infrastructure. In an embodiment, preferably a size of 8 ft X 10 ft
has been employed. In another embodiment a smaller size of 27 inches X 40 inches
has been employed.
Preferably, cotton fabric is selected and cut into a size of 27 X 40 square inches.
15 Fabric is ironed if it is creased or folded.
Preparation of Vegan leather
In a first step, backing material is cut into desired dimensions.
In the second step, the backing material is placed on a spraying table. Then 2 coats
20 of any of the compositions are sequentially sprayed on the backing material using
a spray gun to produce panels. Panel is backing material coated with compositions
/ leather mixtures. After first coat, panel is subjected to drying.
For various approximate thickness, following coating compositions are preferably
applied.
Size of backing
material
Thickness
(overall)
Thickness
(backing)
Quantity Ratio of backing
material thickness to
Leather thicknes
40/27 inches 1.0mm 0.2mm 1.7 kg 1:5
40/27 inches 1.2 mm 0.2mm 2 kg 1:6
23
40/27 inches 1.4 mm 0.2mm 2.3 kg 1:7
40/27 inches 0.7 mm 0.2mm 1.3kg 1:3.5
Around 1.7 kg of compound is needed for one 27 by 40 inches fabric for overall
1mm thickness. Backing material of larger size such as 8 X 10 sq. feet or larger size
can be employed.
5 After spraying, panels are trowelled in which even spreading of coated material is
done.
Next step is drying. After trowelling the panels, they are kept in drying racks and
are subjected to drying at a specific temperature. Drying temperature is controlled
and not allowed to exceed 60°C as it may burn upper soft portion of the coating.
10 Panels are dried for at least 24 hrs., preferably for 48 hrs.
Further, the dried coated panels are subjected sequentially to plating, colour
spraying, embossing, and lacquering. Drying is needed after each of the steps
involving colour spraying, embossing, and lacquering.
These steps are described as follows:
15 Plating - Each panel is subjected to specific temperature and pressure and time.
Preferably, pressure of from 200 – 300 MPa or Bar, preferably 250 MPa or Bar at
80°C for 1.5 sec. at a second in a hydraulic press machine. Plating softens the upper
surface and increases the bonding between fabric /backing material and the layers
of coatings.
20 Further, leather is subjected through various finishing processes.
Finishing
Finishing of leather includes a series of steps to give buyers variety in the colours,
embossing, shiny or matt finishes etc. and include spray painting, surface treatment
and adding chemicals to stop colour leakage and water proofing etc...
25 Finishing materials are up to 10 % w/w, preferably up to 5 % w/w of the leather,
more preferably from 2% w/w to 4% w/w of the all coating and contains colours,
binders, lacquers, and water resistant / water repellent coatings. Lacquers include
24
polyurethane lacquers, dyes lacquers, resin based lacquers, different types of
nitrocellulose lacquers, Acrylic Lacquers, and also, water based silicone emulsions
etc...
There are a variety of colours which can be employed in the compositions. Some
5 of them are dyes, pigments & natural colours (made from organic compounds like
coal tars, some petrochemicals i.e., benzene, toluene, xylene, oil & inorganic
compounds like oxidation of metals i.e., titanium, iron etc).
Some of the colours are mixed with binders. There is a huge variety in binders.
Most commonly, acrylic binders, polyurethane binders, Resin binders etc. are
10 employed.
There is an alternative option of using 100 % w/w bio based binders. Here the binder
is made from Natural Rubber and Starch [the process of starch mixture has already
been mentioned in the above section] (1:3) or (1:4) or (1:5) or (1:6)
Embossing includes NDM embossed, PDM embossed, YDM embossed, Croco
15 embossed, Printing, Foiling and other types.
Colour Spraying / Spray coating
First coat of colour- After plating the next step is colour coating. Here the
Synthetic pigments that are made by some organic and inorganic compounds are
20 used for coating. The pigments used in colour coating are absolutely sustainable
and eco-friendly. The pigments are mixed with a binder in a ratio from 1:5 to 1:15,
preferably in 1:10 ratio.
Surface treatment
After one coat of spray, the panels are kept for drying for 24 hours for fixation of
25 colour. Next step is surface treatment and includes milling and embossing.
Milling
25
After colour coating and drying, the panels are subjected to a Milling process to
increase the softness. It is a drum operation where the panels are revolved in the
drum. Due to this operation the upper surface of the material gets creasing effects
like leather finishes.
5
Embossing
It is important to give vegan leather a look of leather. To emboss the upper surface
there are many types of plates in the leather industry. Embossing imparts a raised
pattern and enhances the look of the leather. There are many plates available in the
10 leather industry. A suitable plate is selected and embossing is done at specific
temperature and pressure.
After Embossing, the spray coating step is usually repeated if colours fade during
embossing.
15 Top coating treatment
The pigments are mixed with a suitable binder in specific ratio from 1:5 to 1:15
preferably, 1:10 and sprayed on the panel. After colour coating, panels are dried for
24 hrs, and then if desired, a second coating is done followed by drying.
Before lacquering the panel, it is mandatory to ensure the colour of the upper
20 surface has dried properly. So, a minimum 24 hours of drying time is needed.
Next step is Lacquering.
Lacquering is done to give desired finish to the prepared leather. Lacquering is done
using various types of lacquers including but not limited to nitrocellulose based or
cellulose acetate butyrate based which imparts gloss to the leather.
25 A nitrocellulose based lacquer is diluted using water. Additionally, a feeler that
modifies touch and feel of a leather such as plant based or silicon based coating
emulsion having properties like silicon coating is added to impart smooth touch.
26
49 % w/w shine lacquer is diluted with 49 % w/w with water and 2 % w/w plant
based or silicon based coating emulsion similar properties like silicon coating is
mixed in it to provide lacquer suspension. Lacquer suspension is applied as top coat
on the prepared leather.
5
Drying is essential after colour spraying, before and after lacquering. When colour
spraying is done multiple times, drying between each spray is essential. Minimum
24 hrs. drying time is used after each colour spraying and before and after
Lacquering.
10 The Vegan leather prepared in accordance with the present invention comprises a
backing material coated with a compositions containing Banana pulp and other
additives such as adhesives, binders, fillers, softeners / plasticizers, colours /
pigments, preservatives, lacquers, chemicals to prevent colour leakage and water
repellents. Backing material comprises up to 20 % w/w, preferably up to 15 %
15 w/w, more preferably up to 10 % w/w of the final leather, most preferably up to 5
% w/w of final leather. In most embodiments, backing material comprises
preferably up to 2.5 % w/w of the final leather.
Since compositions of the present invention are coated on the backing material, they
are also referred to as coating compositions. Coating compositions or leather
20 mixture along with top coatings comprise at least 85 % w/w, preferably at least 90
% w/w, more preferably at least 95 % w/w of the produced leather.
During finishing, colours / pigments, binders, preservatives, lacquers, chemicals to
prevent colour leakage and water repellents together not more than 5 % w/w are
added.
25 The Vegan leather prepared in accordance with the present invention comprises 1
– 15 % w/w of backing material, colours / pigments, binders, lacquers, chemicals
to prevent colour leakage and water repellents and 85 – 99 % w/w of coating
composition containing Banana pulp and one or more of additives such as
adhesives, binders, fillers, softeners / plasticizers. Additionally, from 0.001 to 0.1
30 % w/w preservatives are present when required.
27
Depending on the nature of the additives, the compositions are divided into those
containing synthetic adhesives and natural adhesives.
Arriving at the suitable compositions which can produce Vegan Leather was a
difficult task and inventors faced several challenges.
5 These challenges include
i) Colour Bleeding Problem;
ii) Creasing Problem;
iii) moisture retention problem or hygroscopic contents;
iv) Cracking Problem;
10 v) formation of air bubbles;
vi) fungal growth;
vii) Upper Surface peeling;
viii) durability problem.
Additionally, inventors faced few process related and machine related challenges.
15 Colour Bleeding
Colour Bleeding was one of the major problems faced. To solve the same, following
trials have been taken:
Used various type of pigments, dyes (different molecular size, different
composition, metal free) were tried. Dyes are chemicals with smaller molecular size
20 than pigments, and dyes are easily soluble while pigments are partially insoluble in
Various types of binders (acrylic, resin, PU etc.) were tried, that were mixed with
the colour in various concentrations;
Various types of lacquers were used to coat the top surface (NC based, Acetate
based, cellulose acetate butyrate (CAB) lacquer etc. from different sources) were
25 tried;
Top coating was made water repellent to prevent colour bleeding through ( silica
coating, wax finish etc).
Creasing Problem
28
This problem was one of the major problems found in vegan leather. Because vegan
leather does not contain collagen fibre like animal leather, it does not have the same
properties of elasticity and fullness. Either vegan leather is made of PU, PVC,
rubber or cellulosic materials. So, it is hard to make the same fullness, feel like
5 animal leather.
To solve the same, following trials are taken, various soft backings (cotton,
polyester etc.) were tried; filler material is added to enhance the softness ( wax,
starch, veg oil, agri-waste filler like rice husk, wheat straw, cork powder etc).
Moisture Problem
10 There are some chemicals which are hygroscopic in nature. They absorb moisture
from the environment. This moisture is retained on the upper surface and the
finishing chemicals cannot bind with the base material.
To solve the same, following trials are taken.
Treated the Banana pulp with Silane.
15 Added metal Silicate powder like magnesium silicate in the composition in 0.5%
w/w concentrations which is hydrophobic in nature; Drying is done at high
temperature;
Used dehumidifier;
Pulp is dried entirely in sun and stored for 2 weeks before being rehydrated again.
20 Cracking Problem
If the base compound is very hard or the upper surface is rough or the upper coating
is rough or the upper coating does not bind with the base surface it causes cracking.
To solve the same, following trials are taken.
Softener / plasticizers are employed whenever required such as veg oil, soft filler
25 etc.
Different upper coatings ( bio-based PU, Acrylic binder etc) are tried;
Softener is also employed in the upper coating like (silicon solution, crunchy wax
etc).
29
Bubble Problem
This is particularly observed when natural rubber was used in the composition, or
the material was made through a single extremely thick layer, instead of thinner
multilayers. Sometimes the natural rubber creates an air bubble in the composition
5 when it is heated by a little higher temperature like 80 degrees or mixing time.
Sometimes air bubbles are created on the upper surface for not mixing the
composition properly or during spraying from the gun.
To solve the same, following trials are taken.
Mixing time is increased;
10 Mixing is done in a suitable blender;
Added defoaming agent ( hydrogen peroxide, Sodium percarbonate, peracetic acid,
sodium perborate);
Adhesives with good binding property are employed.
15 Fungus Problem
Fungus growth is observed after five to six months in the panels. To avoid bacteria
and fungal activity in the panel, spraying Antifungal, Antibacterial was tried. Most
of the Vegan Leathers now employ a suitable preservative.
Upper Surface peeling
20 Due to the moisture, the upper surface can peel off easily. Because the upper coating
does not bind on the base compound if there is moisture. So, the base material
should be moist free.
To solve the same, following trials are taken.
Treated the pulp with Silane;
25 Added metal Silicate powder in the base compound which is hydrophobic in nature;
Drying in high temperature;
Used dehumidifier;
Pulp is dried and hydrated again while making the compositions.
30
Durability Problem
The most important thing is durability of a material, initially the durability was not
so good due to many reasons like Fungus, Peeling problem, cracking problem,
moisture problem. So, the material went through a lot of trials to get this perfection.
5 Initial Procedure problems
Alkali Treatment
Initially developed process did not include alkali treatment. It was done only by
boiling and mixing. So, the panel made from that pulp is much harder. So, chemicals
that can dissolve the stem into a pulp homogenously were used such as some
10 hydroxides like sodium hydroxide and sulphide compounds like sodium sulphide
along with sodium hypochlorite that are finalized for alkali treatment.
Adhesives
The adhesive used in previous conditions made the panel harder and less ecofriendly. So, there are a lot of trials to choose the appropriate adhesives.
15 Natural additives
It was hard to find 100% w/w natural adhesive, so it was decided to create a natural
adhesives that is made from arrowroot, gum rosin, gum Arabic, jackfruit glue etc.
Filler
There are many options for a filler. To find a good filler, many trials are undertaken.
20 Inventors had undertaken many trials in various concentrations like starch, wax,
cork powder, polymer filler, veg oil, rice husk, wheat straw, etc.
Machinery problems
31
Initially all the machinery steps were done manually due to small scale. So, there
were always many problems like the thickness variation , the compound
consistency variation, colour variation . This was fixed by specific measurement
of applied coating, constant measuring of variation after each lot to provide
5 feedback and improve consistency.
Accordingly, following machinery is added now to eliminate manual variation:
- Roller coating machine
- Hydraulic press
- Spraying booth with spray gun and compressor
10 - Milling drum
- Digester
- Grinding Machine
- Dehumidifier
- Hot air oven
15 Finally, the inventors arrived at the compositions of the present invention and a
good quality Vegan Leather is produced using the same.
Another problem was on panel softness variation due to hand milling. The molisa
and milling steps through machinery were added which can be effectively done.
Producing 100% w/w natural Vegan Leather
20 Usually, marketed Vegan leathers contain at least 10% w/w of Polyurethane or
polyvinyl chloride etc. It was very much challenging to make leather which has
zero plastic and is made of 100% w/w natural materials. In the present invention,
inventors carried out several trials to produce 100 % w/w natural, vegan, durable
and soft leather suitable for several goods or products.
25 To solve the same, following trials are taken.
Natural Adhesive are sourced like natural rubber, gum rosin, gum Arabic, jackfruit
glue, arrowroot glue, agar-agar solution, banyan sap glue, corn starch adhesive etc.
Natural Adhesive are prepared inhouse from many different sources like jackfruit,
arrowroot, gum rosin, gum-arabic, banyan sap, corn starch, guar gum etc.
32
Natural Binders are used such as Starch from rice or tapioca with a great binding
capacity and arrowroot and rubber.
Natural fillers such as starch from tapioca, rice, corn, cork filler, rice husk, wheat
straw, talcum powder etc. are employed.
5 Natural softener such as veg oil, fruit oil, citric acid, fruit waxes etc.
Natural colours are employed such as colours from charcoal black, beets, onion
skins etc.
Following examples without limiting the scope of the invention provide,
i) preparation of Banana pulp (example 1)
10 ii) preparation of compositions of the present invention containing from 40
– 70 % Banana pulp (example 2);
iii) preparation of Vegan Leather (example 3).
Figures 1 and 3 also provide details of all process steps followed in manufacturing
of Vegan Leather according to the present invention.
15
Referring to FIG. 1, the plant-based vegan method 100 includes a step 102 of pulp
extraction. At this step, the pulp from the raw banana stem is extracted. As
mentioned above, after the banana plant bears fruit, the stem becomes redundant.
The present method 100 can utilize this banana stem for pulp extraction, at step 102.
20 For pulp extraction, the banana stem is cut into fine pieces and boiled with
chemicals, such as including and not limited to NaOH, Na2S, NaHClO and common
salt. Thereafter, the chemically treated pulp is drained and rinsed. It may be
apparent to a person skilled in the art that the pulp extraction from banana stem may
implement any conventionally used methods and processes, without deviating from
25 the meaning and scope of the present invention.
At a step 104, tapioca starch is powdered and then boiled with water to reach a jelly
like consistency. It may be apparent to a person skilled in the art that the present
plant-based vegan method 100 may use any other starch extracted from the plants,
without deviating from the meaning and scope of the present invention.
30 The plant-based vegan method 100 also includes a step 106 for creating a leather
mixture.
33
The step 106 further includes mixing the pulp obtained in the step 102 and the
tapioca obtained in the step 104 with additional chemicals (such as including and
not limited to adhesives, PU, polyvinyl acetate, and other plasticizers) to then create
a leather mixture.
5 Further, the method includes a step 108 of spraying / pouring or screen printing the
leather mixture obtained in the step 106 onto a fabric backing. The fabric backing
can be for example made from recycled PET bottles. The sprayed leather mixture
in the step 108 is then air dried, at a step 110.
The air-dried leather material is then spray painted for smooth finishing, at a step
10 112. The spray painting includes coating the leather material with a smooth
material, as a finishing process for the material.
At a step 114, the spray-painted leather undergoes sub-processes like plating and
pressing.
In an embodiment, this sub- process of plating and pressing includes putting the
15 leather under a hot plate and pressed. Plating is a finishing process that can be very
useful as it makes leather more uniform and smoother, and at the same time more
lucid.
Further, at a step 116, the pressed leather material at step 114, undergoes a surface
treatment process, which includes and is not limited to creasing the leather material
20 for a creased look, adding chemicals to improve flexibility, water resistance, fire
resistance.
It may be apparent to a person skilled in the art that the present plant-based vegan
method 100 may use any suitable and conventionally available chemicals for
improving the flexibility of the leather material, without deviating from the
25 meaning and scope of the present invention. It may be apparent to a person skilled
in the art that the present plant-based vegan method 100 may use any other
conventionally used surface treatment processes also at step 116, without deviating
from the meaning and scope of the present invention.
Further, in an embodiment, the method 100 may also include a step 118 of repeating
30 the spray-painting process to further finish the material. The step 118 of repeating
34
the spray painting may be optional step, and can be implemented as and when
needed.
Further, the method 100 includes a step 120 where some suitable chemicals can be
added to stop color leakage from the finished leather material. It may be apparent
5 to a person skilled in the art that the present plant-based vegan method 100 may use
any suitable and conventionally available chemicals for stopping the color leakage
from the finished leather material, without deviating from the meaning and scope
of the present invention.
10 Example 1 – Preparation of Banana pulp
Banana stems are cut after trees give fruits. Upper surface of the stem is separated
from the inner and middle portions of the stem as it is harder. Long cuttings of inner
and middle portions are collected and subjected to a banana shredder. Banana
shredder is a stem cutting machine having sharp rolling blades inside. The shredder
15 cuts the long cuttings of inner and middle portions very quickly into small pieces
of banana.
Banana stem cuttings / banana fibres are subjected to an alkali treatment during
which 100 parts of Banana stem cuttings / banana fibres are mixed with 2.6 parts
Sodium Hydroxide, 1.6 parts Sodium Sulphide and 200 parts water and mixed.
20 In the next step, the above mixture is subjected to boiling in a Digester for 45
minutes. During boiling, stem cuttings are melted. The melted stem cuttings are
subjected to grinding in a grinder for 15 mins., during which melted stem cuttings
produce banana pulp. This pulp is brown coloured. It is washed with water to wash
away alkali and strained in a strainer. After straining, pulp is subjected to grinding
25 and then washing.
After washing the pulp is optionally subjected to bleaching. Bleaching is optional
and done only when white / whitish leather is desired.
Bleaching process – Weighed 100 parts of pulp and added 6.6 parts of Bleaching
powder (Calcium Oxychloride [Ca(OCl)2] and 200 parts of water and are mixed.
30 The mixture is kept overnight to lighten the original brown colour.
35
Bleaching chemicals like liquid bleach, hydrogen peroxide, sodium percarbonate,
sodium perborate etc. are basic in nature and washing is necessary if bleaching is
carried out to produce desired shade.
After bleaching the pulp, it is washed again. So, there involves 2-3 times
5 intermittent washings in the process.
During the above processing steps, initial weight is reduced to almost 25 % w/w of
the initial weight.
Example 2 - Preparation of compositions A to W of the present invention:
A. 60% w/w banana pulp + 20 % w/w Poly Lactic Acid + 10% w/w PVC +
10 10% w/w Bio Poly Urethane
Poly lactic acid (PLA) is mixed with Banana pulp in a blender with a blunt spiral
structure. Mixing is continued for up to 1 hr with. This mixture has sufficient
adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
15 Polyvinyl chloride (PVC) and polyurethane (PU) in liquid form are added and
mixed for another 15 minutes. PVC and PU mainly work in this compound as a
filler to give fullness and structure to the leather.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
20 while mixing.
Because of moisture release tendency of the Banana pulp, there is a high chance of
fungal growth. So, preservatives such as fungicides and bactericide are added.
B. 50% w/w banana pulp + 10% w/w IPA + 15 % w/w PLA + 10% w/w
Maleic anhydrous + 15% w/w glycerol
25 10% w/w IPA and 15% w/w PLA are mixed with 50% w/w banana pulp in a blender
with a blunt spiral structure. Mixing is continued for up to 1 hr with mixing
36
compound elements one by one. This mixture has sufficient adhesiveness to ensure
that the composition does not peel off from the backing material after drying.
10% w/w Maleic anhydride and 15% w/w glycerol are added and mixed for another
15 minutes. Glycerol mainly works in this compound as a filler to give fullness and
5 structure to the leather.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
Because of the moisture release tendency of the banana pulp, there is a high chance
10 of fungal growth. So, preservatives such as fungicides and bactericide are added.
C. 50% w/w banana pulp + 30% w/w natural rubber + 20% w/w Polyvinyl
Chloride
30% w/w Natural Rubber is mixed with 50% w/w Banana pulp in a blender with a
blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound
15 elements one by one. This mixture has sufficient adhesiveness to ensure that the
composition does not peel off from the backing material after drying.
20% w/w PVC in liquid form is added and mixed for another 15 minutes. PVC
mainly works in this compound as a filler to give fullness and structure to the
leather.
20 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
25 D. 50% w/w banana pulp + 30% w/w neoprene + 20% w/w acrylic binder
37
30% w/w Neoprene is mixed with 50% w/w Banana pulp in a blender with a blunt
spiral structure. Mixing is continued for up to 1 hr with mixing compound elements
one by one. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
5 20% w/w acrylic binder in liquid form is added and mixed for another 15 minutes.
Acrylic binder mainly works in this compound as a filler to give fullness and
structure to the leather.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
10 while mixing. Because of the moisture release tendency of the Banana pulp, there
is a high chance of fungal growth. So, preservatives such as fungicides and
bactericide are added.
E. 50% w/w banana pulp + 30% w/w Starch + 20% w/w Polyvinyl
Chloride
15 20% w/w PVC is mixed with 50% w/w Banana pulp in a blender with a blunt spiral
structure. Mixing is continued for up to 1 hr with mixing compound elements one
by one. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
30% w/w starch in liquid form is added and mixed for another 15 minutes. Starch
20 mainly works in this compound as a filler to give fullness and structure to the
leather.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
25 Because of the moisture absorption capacity of starch and moisture release tendency
of the Banana pulp, there is a high chance of fungal growth. So, preservatives such
as fungicides and bactericide are added.
38
99. 50% w/w banana pulp + 30% w/w Natural Rubber + 20% w/w Bio Poly
Urethane
30% w/w Natural Rubber is mixed with 50% w/w Banana pulp in a blender with a
blunt spiral structure. Mixing is continued for up to 1 hr This mixture has sufficient
5 adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
20 % w/w Bio PU in liquid form is added and mixed for another 15 minutes. Bio
PU mainly works in this compound as a filler to give fullness and structure to the
leather.
10 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
15 G. 50% w/w banana pulp + 30% w/w Gum Arabic solution + 20% w/w
PVC
20% w/w PVC is mixed with 50% w/w Banana pulp in a blender with a blunt spiral
structure. Mixing is continued for up to 1 hr with mixing compound elements one
by one. This mixture has sufficient adhesiveness to ensure that the composition
20 does not peel off from the backing material after drying.
30% w/w Gum Arabic solution in liquid form is added and mixed for another 15
minutes.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
25 while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
39
The introduction of a 30% w/w Gum Arabic solution further enriches the
formulation. This addition plays a crucial role in enhancing the adhesive
capabilities of the mixture. Gum Arabic’s colloidal properties, when solubilized,
create a viscous solution that contributes to the cohesion of the composition and its
5 adhesion with backing material. Its natural origin aligns with the increasing demand
for eco-friendly adhesive alternatives.
Complementing the natural elements, 20% w/w PVC is incorporated into the
mixture. PVC’s synthetic nature imparts durability and resilience to the
formulation, elevating its mechanical properties. This synergy of natural and
10 synthetic constituents is orchestrated to yield a balanced composition that bridges
the gap between sustainability and performance.
In summary, the innovation lies in the meticulous combination of 50% w/w banana
pulp, 30% w/w Gum Arabic solution, and 20% w/w PVC. This fusion embodies the
advantages of each component, resulting in a well-rounded adhesive composition
15 that merges the strengths of natural binding, colloidal adhesion enhancement, and
synthetic durability. The final composition is poised to cater to a diverse range of
applications, presenting a promising direction in adhesive technology.
H. 50% w/w banana pulp + 30% w/w PVA + 20% w/w PVC
20 The composition comprises 50% w/w banana pulp, 30% w/w Polyvinyl Acetate
(PVA), and 20% w/w Polyvinyl Chloride (PVC).
30% w/w Polyvinyl Acetate is mixed with 50% w/w Banana pulp in a blender with
a blunt spiral structure. Mixing is continued for up to 1 hr with mixing compound
elements one by one. This mixture has sufficient adhesiveness to ensure that the
25 composition does not peel off from the backing material after drying.
Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
30 while mixing.
40
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
This innovative formulation underscores the combination of 50% w/w banana pulp,
30% w/w Polyvinyl Acetate (PVA), and 20% w/w Polyvinyl Chloride (PVC) to
5 create a composition with multifaceted attributes. The substantial inclusion of
banana pulp as the primary component contributes both natural adhesion properties
and environmental sustainability to the mixture. Banana pulp's inherent
adhesiveness, stemming from its organic composition, lays the foundation for a
strong bonding capability. The introduction of 30% w/w PVA amplifies the
10 adhesive potential of the composition. PVA, renowned for its versatility and
adhesive qualities, enhances the cohesion between the components, further
bolstering the adhesion properties of the mixture. Balancing the equation, 20% w/w
PVC adds a dimension of durability and resilience to the composition. PVC's
synthetic nature imparts mechanical strength and longevity to the adhesive,
15 ensuring its effectiveness over time. This meticulously composed mixture not only
taps into the innate adhesion strengths of natural elements but also integrates
synthetic durability for a well-rounded solution poised to cater to a spectrum of
applications.
20 I. 50% w/w Banana Pulp + 30% w/w Poly Lactic Acid + 20% w/w
PVC
Poly Lactic Acid is mixed with Banana pulp in a blender with a blunt spiral
structure. Mixing is continued for up to 1 hr with. This mixture has sufficient
adhesiveness to ensure that the composition does not peel off from the backing
25 material after drying.
Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
30 This formulation epitomizes the synergy between 50% w/w banana pulp, 30% w/w
Polylactic Acid (PLA), and 20% w/w Polyvinyl Chloride (PVC), yielding a
41
composition designed to bridge the realms of sustainability and performance. The
substantial incorporation of banana pulp, constituting half of the composite, infuses
the mixture with inherent natural adhesion properties. The eco-friendly attributes
of banana pulp align with the growing demand for sustainable materials in adhesive
5 applications. The introduction of 30% w/w PLA, a biodegradable polymer derived
from renewable resources, amplifies the environmentally conscious profile of the
composite. PLA's adhesive capabilities, combined with its biodegradability,
contribute to the cohesive strength of the mixture. Balancing the equation, 20% w/w
PVC introduces a synthetic dimension that enhances the composite's mechanical
10 integrity and resilience. PVC's robustness augments the durability of the adhesive,
ensuring its stability under varying conditions. In amalgamating these components,
this composition not only harnesses the natural adhesive strengths of banana pulp
and the ecological benefits of PLA but also integrates the durability of PVC,
presenting a well-rounded adhesive solution poised to address contemporary
15 sustainability and performance requirements.
J. 50% w/w Banana Pulp + 30% w/w Cork Filler + 20% w/w PVC
30% w/w Cork filler is mixed with 50% w/w Banana pulp in a blender with a blunt
spiral structure. Mixing is continued for up to 1 hr with mixing compound elements
20 one by one. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
25 while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
This distinctive formulation brings together 50% w/w banana pulp, 30% w/w cork
filler, and 20% w/w Polyvinyl Chloride (PVC) to create an adhesive composite with
30 a well-balanced blend of natural and synthetic components. The significant
inclusion of banana pulp, constituting half of the composition, contributes inherent
42
adhesion properties along with a touch of environmental sustainability. Banana
pulp's natural adhesiveness serves as a foundation for strong bonding capabilities
within the mixture. The introduction of 30% w/w cork filler enhances the texture
and resilience of the composite. The porous nature of cork functions as an effective
5 filler, promoting cohesion and structural strength in the adhesive. The balance is
achieved with the incorporation of 20% w/w PVC, which imparts mechanical
strength and endurance to the composition. The synthetic properties of PVC ensure
the adhesive's stability and longevity, making it effective over time. In harmony,
these elements create a cohesive and well-rounded adhesive composite that
10 capitalizes on the adhesion strengths of natural components while integrating the
durability of synthetic materials.
K. 60% w/w Banana Pulp + 20% w/w Cork Filler + 10% w/w PVC +
10% w/w Wax
20% w/w Cork filler is mixed with 60% w/w Banana pulp in a blender with a blunt
15 spiral structure. Mixing is continued for up to 1 hr with mixing compound elements
one by one. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
Wax is melted. Polyvinyl chloride (PVC) in liquid form and Wax in molten form
are added and mixed for another 15 minutes.
20 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
25 This innovative formulation artfully combines 60% w/w banana pulp, 20% w/w
cork filler, 10% w/w Polyvinyl Chloride (PVC), and 10% w/w wax, creating an
adhesive composition that blends diverse attributes for a multifaceted solution. The
prominent presence of banana pulp, constituting a majority of the composition,
introduces inherent adhesion strengths coupled with an environmental
30 consciousness. The natural adhesive qualities of banana pulp, paired with its
43
biodegradability, form a strong foundation for robust bonding capabilities within
the adhesive. The incorporation of 20% w/w cork filler further enriches the
composition's texture and resilience. Cork's porous and flexible structure
contributes to the overall cohesion and mechanical integrity of the adhesive. The
5 inclusion of 10% w/w PVC provides the composition with mechanical durability
and longevity. PVC's synthetic attributes enhance the adhesive's stability, ensuring
its effectiveness in various conditions. To add a layer of flexibility and pliability,
10% w/w wax is introduced. This component contributes to the adhesive's
malleability, allowing it to adapt to different surfaces and contours. In this
10 orchestrated union, the composition draws from the natural adhesive strengths of
banana pulp, the reinforcing properties of cork and PVC, and the flexibility offered
by wax, resulting in a versatile adhesive solution poised to meet diverse industrial
demands.
L: 50% w/w Banana Pulp + 30% w/w Cork Filler + 20% w/w PVC
15 30% w/w Cork filler is mixed with 50% w/w Banana pulp in a blender with a blunt
spiral structure. Mixing is continued for up to 1 hr with mixing compound elements
one by one. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
Polyvinyl chloride (PVC) in liquid form is added and mixed for another 15 minutes.
20 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
25 The innovative blend of 50% w/w banana pulp, 30% w/w cork filler, and 20% w/w
Polyvinyl Chloride (PVC) forms a composite that uniquely fuses natural and
synthetic elements. The substantial incorporation of banana pulp contributes both
eco-friendliness and inherent adhesion properties to the composite. This natural
component adds an element of biodegradability and sustainability to the adhesive,
44
aligning with environmentally conscious demands. The introduction of 30% w/w
cork filler amplifies the composite's texture and resilience. Cork's porous nature
serves as an effective filler, enhancing the overall structural integrity and adhesive
properties of the mixture. Balancing the equation, 20% w/w PVC provides the
5 composite with mechanical strength and durability. PVC's synthetic characteristics
offer stability and longevity to the adhesive, ensuring its effectiveness over time. In
synergy, these elements create a cohesive blend that draws from the strengths of
each constituent, resulting in an adhesive composition with attributes poised to meet
a range of industry requirements.
10 M: 60% w/w Banana Pulp + 20% w/w Cork Filler + 10% w/w PVC + 10%
w/w Wax
20% w/w Cork filler is mixed with 60% w/w Banana pulp in a blender with a blunt
spiral structure. Mixing is continued for up to 1 hr with mixing compound elements
one by one. This mixture has sufficient adhesiveness to ensure that the composition
15 does not peel off from the backing material after drying.
Wax is melted. Polyvinyl chloride (PVC) in liquid form and Wax in molten form
are added and mixed for another 15 minutes.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
20 while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
This composition strategically combines 60% w/w banana pulp, 20% w/w cork
filler, 10% w/w Polyvinyl Chloride (PVC), and 10% w/w wax to engineer an
25 adhesive composite with a nuanced balance of properties. The substantial presence
of banana pulp as the primary component introduces inherent adhesion strengths
and environmental sustainability to the mixture. Banana pulp's natural adhesive
qualities, combined with its biodegradability, form a foundation for strong bonding
capabilities. The incorporation of 20% w/w cork filler enhances the composite's
45
texture and resilience. The cork's unique porous structure contributes to the overall
cohesion and structural robustness of the adhesive. Introducing 10% w/w PVC adds
a synthetic element that imparts mechanical durability and longevity. PVC's
strength augments the composite's resilience, ensuring its stability under varying
5 conditions. Further, the inclusion of 10% w/w wax contributes to the adhesive's
pliability and flexibility. This synergistic amalgamation blends the eco-friendly and
adhesive attributes of banana pulp with the reinforcement of cork, PVC, and wax,
resulting in a versatile adhesive solution poised to address diverse industry needs.
10 N: 50% w/w Banana Pulp + 15% w/w Neoprene + 20% w/w Acrylic Binder +
15% w/w EVA
30% w/w Neoprene and 15 % w/w ethylene vinyl acetate are mixed with 50% w/w
Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up
to 1 hr with mixing compound elements one by one. This mixture has sufficient
15 adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
20% w/w Acrylic binder in liquid form is added and mixed for another 15 minutes.
Acrylic binder mainly works in this compound as a filler to give fullness and
structure to the leather.
20 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing. Because of the moisture release tendency of the Banana pulp, there
is a high chance of fungal growth. So, preservatives such as fungicides and
bactericide are added.
25 The innovative blend comprising 50% w/w banana pulp, 15% w/w neoprene, 20%
w/w Acrylic Binder, and 15% w/w Ethylene Vinyl Acetate (EVA) brings together
diverse elements to create an adhesive composite that stands at the crossroads of
46
natural and synthetic characteristics. The prominent inclusion of banana pulp
introduces inherent adhesion properties and ecological consciousness to the blend.
This natural component offers biodegradability and environmental sustainability,
aligning with the growing demand for eco-friendly solutions. Incorporating 15%
5 w/w neoprene enhances the composite's flexibility and resilience. Neoprene's
elastomeric nature contributes to the adhesive's adaptability to varying conditions.
The introduction of 20% w/w Acrylic Binder enhances adhesion and cohesion.
Acrylic binders are known for their strong bonding capabilities, fortifying the
adhesive's overall performance. The addition of 15% w/w EVA adds a synthetic
10 dimension that imparts mechanical stability and durability to the mixture. EVA's
properties ensure the composite's longevity and robustness over time. In harmony,
these components form a composite that merges the natural adhesion strengths of
banana pulp, the flexibility of neoprene, the binding capabilities of acrylic, and the
durability of EVA, yielding an adhesive solution tailored to diverse applications.
15 O. 50% w/w Banana Pulp + 15% w/w Neoprene + 20% w/w Resin Binder +
15% w/w EVA
15% w/w Neoprene and 15 % w/w ethylene vinyl acetate are mixed with 50% w/w
Banana pulp in a blender with a blunt spiral structure. Mixing is continued for up
to 1 hr with mixing compound elements one by one. This mixture has sufficient
20 adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
20% w/w Resin binder in liquid form is added and mixed for another 15 minutes.
Acrylic binder mainly works in this compound as a filler to give fullness and
structure to the leather.
25 99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing. Because of the moisture release tendency of the Banana pulp, there
47
is a high chance of fungal growth. So, preservatives such as fungicides and
bactericide are added.
The inventive formulation featuring 50% w/w banana pulp, 15% w/w neoprene,
20% w/w Resin Binder, and 15% w/w Ethylene Vinyl Acetate (EVA) showcases a
5 strategic combination of natural and synthetic elements. The substantial integration
of banana pulp imparts inherent adhesion strengths and environmental
sustainability to the composite. This natural component delivers both robust
bonding capabilities and biodegradability, aligning with eco-friendly standards.
The inclusion of 15% w/w neoprene augments the adhesive's elasticity and
10 resilience. Neoprene's flexible nature ensures the adhesive can adapt to various
conditions while maintaining cohesion. Incorporating 20% w/w Resin Binder
bolsters the adhesive's binding properties and structural integrity. Resin binders are
recognized for their robust adhesion characteristics, enhancing the overall
performance of the mixture. The introduction of 15% w/w EVA introduces
15 synthetic durability and mechanical stability to the composite. EVA's attributes
contribute to the adhesive's lasting strength and reliability. In unison, these
constituents create a composite that synergistically leverages the natural adhesion
properties of banana pulp, the flexibility of neoprene, the binding efficacy of resin,
and the durability of EVA, yielding a versatile adhesive solution suitable for an
20 array of applications.
P. 60% w/w Banana pulp + 10% w/w Bio PU + 20% w/w Plasticizer + 10%
w/w Oil
20 % w/w plasticizer selected from Glycerol or PEG and 10 % w/w oil are mixed
with Banana pulp in a blender with a blunt spiral structure. Mixing is continued for
25 up to 1 hr. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
Bio polyurethane (Bio PU) in liquid form is added and mixed for another 15
minutes.
48
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
Because of moisture release tendency of the Banana pulp, there is a high chance of
5 fungal growth. So, preservatives such as fungicides and bactericide are added.
This composition is a result of combining 60% w/w Banana pulp, 10% w/w
Biodegradable Polyurethane (Bio PU), 20% w/w Plasticizer, and 10% w/w Oil to
create a specialized adhesive composite. The substantial incorporation of 60% w/w
EVA contributes mechanical stability and durability to the blend. EVA's synthetic
10 nature ensures resilience and longevity, enhancing the overall adhesive properties.
The introduction of 10% w/w Bio PU adds a biodegradable element to the
composite. Bio PU, derived from renewable sources, aligns with eco-conscious
goals and introduces environmental sustainability to the adhesive. Incorporating
20% w/w plasticizer enhances the adhesive's flexibility and adaptability.
15 Plasticizers contribute to the composite's ability to conform to varying surfaces and
conditions. The addition of 10% w/w oil imparts pliability and fluidity to the
mixture. The oil content enhances the adhesive's application ease and ensures its
spreadability. The culmination of these components results in a composite that
harnesses the mechanical strength of EVA, the eco-friendliness of Bio PU, the
20 flexibility of plasticizers, and the application ease provided by oil, yielding an
adhesive solution tailored to specific industry needs.
Q. 60% Banana pulp + 30 % polyvinyl acetate + 10 % starch;
Synthetic adhesive like Ethylene Vinyl Acetate, Poly vinyl acetate, Neoprene,
25 plastic resin glue, epoxy glue is mixed with Banana pulp in a blender with a blunt
spiral structure. Mixing is continued for up to 1 hr with mixing compound elemnets
one by one. This mixture has sufficient adhesiveness to ensure that the composition
does not peel off from the backing material after drying.
49
Starch in liquid form is added and mixed for another 15 minutes. Starch mainly
works in this compound as a filler to give fullness and structure to the leather.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
5 while mixing.
Because of moisture absorption tendency of starch and moisture release tendency
of the Banana pulp, there is a high chance of fungal growth. So, preservatives such
as fungicides and bactericide are added.
R. 55% Banana pulp + 25 % polyvinyl acetate + 20 % Polymer filler
10 PVA (polyvinyl acetate) / Ethylene vinyl acetate / Neoprene is mixed with Banana
pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr.
This mixture has sufficient adhesiveness to ensure that the composition does not
peel off from the backing material after drying.
Magnopal IPF is a polymer filler which is added to the above mixture in an amount
15 of 20% w/w of the weight of the composition and mixed for another 30 minutes.
This filler imparts fullness and structure to the leather.
Synthetic Colour mixed with double the quantity of suitable Binder is added to the
above composition while mixing and mixed for an hour.
Because of the moisture release tendency of the Banana pulp, there is a high chance
20 of fungal growth. So, preservatives such as fungicides and bactericide are added.
S. 58% Banana pulp + 21 % polyvinyl acetate + 21 % bio polyurethane
as binder ;
PVA (polyvinyl acetate) / Ethylene vinyl acetate / Neoprene is mixed with Banana
pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr.
25 This mixture has sufficient adhesiveness to ensure that the composition does not
peel off from the backing material after drying.
Bio Polyurethane is added and mixed for another 15 minutes.
50
Synthetic Colour mixed with double the quantity of suitable Binder is added to the
above composition while mixing.
Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
5
T. 55% Banana pulp + 25 % polyvinyl acetate + 20 % Magnopal as
filler;
PVA (polyvinyl acetate) / Ethylene vinyl acetate / Neoprene is mixed with Banana
pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr.
10 This mixture has sufficient adhesiveness to ensure that the composition does not
peel off from the backing material after drying.
Polymer filler Magnopal is added and mixed for another 15 minutes.
Synthetic Colour mixed with double the quantity of suitable Binder is added to the
above composition while mixing.
15 Because of the moisture release tendency of the Banana pulp, there is a high chance
of fungal growth. So, preservatives such as fungicides and bactericide are added.
U. 60% Banana pulp + 30 % polyvinyl acetate + 10 % starch as filler;
20 PVA (polyvinyl acetate) / Ethylene vinyl acetate / Neoprene is mixed with Banana
pulp in a blender with a blunt spiral structure. Mixing is continued for up to 1 hr.
This mixture has sufficient adhesiveness to ensure that the composition does not
peel off from the backing material after drying.
Starch in liquid form is added and mixed for another 15 minutes. Starch mainly
25 works in this compound as a filler to give fullness and structure to the leather.
99 % w/w of the above mixture and up to 1 % w/w of mixture of Synthetic Colour
mixed with double the quantity of suitable Binder is added to the above composition
while mixing.
51
Because of moisture absorption tendency of starch and moisture release tendency
of the Banana pulp, there is a high chance of fungal growth. So, preservatives such
as fungicides and bactericide are added.
Softener / plasticizer PEG in liquid form is added to the above mixture and mixed
5 for another 15 minutes. Softener / plasticizer imparts softness to the leather.
Synthetic Colour mixed with double the quantity of suitable Binder is added to the
above composition while mixing.
For compositions comprising natural adhesives, processes described below are
employed.
10
First step is preparing natural adhesives. Various natural adhesives are natural
rubber, Corn starch adhesive, jackfruit glue, Arrowroot Glue etc.
Cornstarch Adhesive - Cornstarch is diluted in hot water in a preferred weight
ratio of 1: 6 and mixed properly. Agar agar powder is mixed with hot water in a
15 preferred weight ratio of 1: 5 and gum arabic and gum rosin are also mixed
separately with water in a preferred weight ratio of 1: 6.
Further, 60 parts cornstarch solution, 20 parts Agar-agar solution, 10 parts Gum
Arabic solution and 5 parts Gum Rosin solution are mixed and heated. Further, from
0.3 to 1.5 parts glycerol, 1 - 2 parts acetic acid, 1 - 1.5 parts Ferrous sulphate are
20 added to above mixture and stirred for 30 min.
Corn starch adhesive is ready for incorporation into the compositions of the present
invention for preparing Vegan Leather.
Jackfruit Glue
Jackfruit seeds are dried at a temperature of 80°C till they are fully dried. The dried
25 seeds are powdered in a grinder to form dried seed powder.
52
Around 300 - 400 g dried seed powder is mixed with 5 - 8 g of borax and around 2
litres of water. This mixture is subjected to 70-80°C for 10 - 30 minutes after which
1 litre of water is added and mixed and kept aside for 5 - 10 minutes. Jackfruit glue
is ready to use.
5 Arrowroot Glue
Around 40 – 60 g of arrowroot is added to 0.6 – 1 g borax and 180 ml water and
mixed properly. The mixture is kept in the hot air oven at a temp of 70- 80°C for
around 10 min.
Then 10 -12g NaOH is added to the above mixture and stirred for 15 minutes.
10 Arrowroot Glue is ready to use.
Preparation of compositions comprising natural adhesives
a. 60% banana pulp + 20 % Starch + 10% Cork filler + 10% Natural Rubber
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
15 ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture cork filler and starch are added together
for 10 - 30 minutes. The high banana pulp content provides sustainability, potential
biodegradability, and a connection to agriculture. Starch enhances the blend's
20 binding and adhesive properties, while cork filler introduces lightweight and
insulating qualities. Natural rubber imparts flexibility and durability. This blend can
be tailored for applications like eco-friendly packaging materials or even insulating
and cushioning materials with agricultural and natural rubber components.
b. 50% banana pulp + 10% Jackfruit Glue + 15 % Natural Rubber + 10%
25 Gum Arabic + 15% waxes
53
Comprising 50% banana pulp, 10% jackfruit glue, 15% natural rubber, 10% gum
arabic, and 15% softener, this composition strikes a balance between natural and
synthetic components.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
5 Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above jackfruit glue, gum Arabic, waxes are mixed
together for 10 - 30 minutes.
10 Banana pulp adds sustainability and biodegradability, while jackfruit glue and
natural rubber provide adhesive and elastic properties. Gum arabic contributes to
viscosity, and the softener enhances flexibility. This blend can be utilized for
applications ranging from bio-based adhesives to coatings, combining natural and
synthetic attributes for versatile use.
15 c. 50% banana pulp + 30% natural rubber + 20% Wheat Straw filler
The mixture of 50% banana pulp, 30% natural rubber, and 20% wheat straw filler
creates a composite that combines the sustainability of banana pulp with the
durability of natural rubber and the lightweight properties of wheat straw filler.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
20 Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture wheat straw filler is mixed together for
10 - 30 minutes.
54
This blend can be employed in applications like eco-friendly construction materials
or as a base for biodegradable composites, offering a balanced approach to natural
and synthetic components.
d. 50% banana pulp + 30% Starch + 20% Guar Gum
5 Comprising 50% banana pulp, 30% starch, and 20% guar gum, this composition
emphasizes natural and plant-based materials.
Guar gum is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
10 drying.
Specific concentration of the above mixture starch is mixed together for 10 - 30
minutes.
Banana pulp offers sustainability, while starch and guar gum enhance the blend's
binding and thickening properties. This mixture can be used in the creation of
15 environmentally friendly adhesives or biodegradable materials, reflecting a
commitment to sustainable alternatives.
e. 50% banana pulp + 30% Starch + 20% Veg oil
The composition of 50% banana pulp, 30% starch, and 20% vegetable oil blends
natural and plant-based materials to create a versatile mixture.
20 Starch is mixed with Banana pulp in a blender with a blunt spiral structure. Mixing
is continued for up to 1 hr. This mixture has sufficient adhesiveness to ensure that
the composition does not peel off from the backing material after drying.
Specific concentration of the above mixture veg oil is mixed together for 10 - 30
minutes.
55
Banana pulp provides sustainability, starch offers binding properties, and vegetable
oil introduces lubrication and moisture resistance. This blend can be suitable for
applications like biodegradable coatings or as a base for environmentally conscious
lubricants.
5 f. 50% banana pulp + 30% Natural Rubber + 20% wheat straw powder
Comprising 50% banana pulp, 30% natural rubber, and 20% wheat straw powder,
this composition combines natural and sustainable materials.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
10 ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture wheat straw is mixed together for 10 -
30 minutes.
Banana pulp adds eco-friendliness, natural rubber imparts durability, and wheat
15 straw powder introduces lightweight properties. This blend can be employed in
applications such as eco-friendly construction materials or as a base for
biodegradable composites.
g. 50% banana pulp + 30% Gum Arabic solution + 20% Citric acid
The mixture of 50% banana pulp, 30% gum arabic solution, and 20% citric acid
20 emphasizes natural and water-soluble components.
Gum arabic solution is mixed with Banana pulp in a blender with a blunt spiral
structure. Mixing is continued for up to 1 hr. This mixture has sufficient
adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
25 Specific concentration of the above mixture citric acid is mixed together for 10 - 30
minutes.
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Banana pulp provides sustainability, gum arabic offers viscosity, and citric acid acts
as a natural preservative and pH adjuster. This composition can be used in the
formulation of eco-friendly adhesives or as a base for biodegradable solutions,
highlighting the use of natural and environmentally conscious materials.
5 h. 50% banana pulp + 30% Talcum powder + 20% natural rubber
Comprising 50% banana pulp, 30% talcum powder, and 20% natural rubber , this
composition combines natural materials with mineral fillers.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
10 ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture talcum powder is mixed together for
10 - 30 minutes.
Banana pulp brings sustainability, talcum powder offers texture and softness. This
15 blend can be employed in applications like eco-friendly fillers for various products
or as a base for biodegradable materials.
i. 50% banana pulp + 30% fruit wax + 20% Agar-agar solution
The composition of 50% banana pulp, 30% fruit wax, and 20% agar-agar solution
integrates natural and plant-based materials.
20 Agar-agar solution is mixed with Banana pulp in a blender with a blunt spiral
structure. Mixing is continued for up to 1 hr. This mixture has sufficient
adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
Specific concentration of the above mixture 30% is mixed together for 10 - 30
25 minutes.
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Banana pulp provides sustainability, fruit wax introduces texture and protection,
and agar-agar solution offers a gelling agent. This blend can be used in applications
such as eco-friendly coatings or as a base for biodegradable products, showcasing
the versatility of natural components.
5 j. 50% banana pulp + 30% Cork Filler + 20%Natural Rubber
Comprising 50% banana pulp, 30% cork filler, and 20% natural rubber, this
composition emphasizes a balance between natural and synthetic materials.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
10 ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture cork filler is mixed together for 10 - 30
minutes.
Banana pulp adds sustainability, cork filler introduces lightweight and insulating
15 qualities, and natural rubber imparts flexibility and durability. This blend can be
tailored for applications like eco-friendly packaging materials or cushioning
materials with a blend of natural and synthetic components.
k. 60% banana pulp + 20% Cork Filler + 10% Natural Rubber + 10% wax
The composition of 60% banana pulp, 20% cork filler, 10% natural rubber, and
20 10% wax offers a blend that combines natural and synthetic materials with a focus
on flexibility and texture.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
25 drying.
58
Specific concentration of the above mixture wax and cork filler are mixed together
for 10 - 30 minutes.
Banana pulp provides sustainability, cork filler introduces lightweight properties,
natural rubber imparts flexibility and durability, and wax enhances texture and
5 moisture resistance. This blend can be used for applications such as bio-based
coatings or as a base for environmentally conscious sealants.
l. 60% banana pulp + 20 % Starch + 10% Cork filler + 10% Guar Gum
Comprising 60% banana pulp, 20% starch, 10% cork filler, and 10% guar gum, this
composition balances natural and plant-based materials.
10 Guar gum is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture starch and cork filler are mixed together
15 for 10 - 30 minutes.
Banana pulp provides sustainability, starch and guar gum enhance the blend's
binding and thickening properties, and cork filler introduces lightweight and
insulating qualities. This mixture can be utilized for applications like eco-friendly
adhesives or as a base for biodegradable materials, reflecting a commitment to
20 sustainable alternatives.
m. 60% Banana pulp + 30 % natural rubber + 10 % filler like tapioca starch
The mixture of 60% banana pulp, 30% natural rubber, and 10% filler such as starch
showcases a blend that combines natural and synthetic components with a focus on
sustainability and flexibility.
25 Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
59
ensure that the composition does not peel off from the backing material after
drying.
Specific concentration of the above mixture starch filler are mixed together for 10
- 30 minutes.
5
n. 60% Banana pulp + 40 % natural rubber
Comprising 60% banana pulp and 40% natural rubber, this composition places a
strong emphasis on natural and sustainable components.
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral
10 structure. Mixing is continued for up to 1 hr. This mixture has sufficient
adhesiveness to ensure that the composition does not peel off from the backing
material after drying.
Banana pulp offers sustainability, while natural rubber introduces flexibility and
durability. This blend can be used for various applications, such as eco-friendly
15 rubber products or materials with a predominantly natural composition.
o. 60% Banana pulp + 30 % natural rubber + 10 % citric acid
20 Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
drying.
10 parts of citric acid is mixed together for 10 - 30 minutes.
60
p. 60% Banana pulp + 30 % natural rubber + 10 % jackfruit glue
5 Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
drying.
Specific amounts of the above mixture (mixture of Banana pulp and natural rubber)
10 such as 70 – 90 parts and 10 – 30 parts of jackfruit glue are mixed together for 10
- 30 minutes.
Banana pulp provides sustainability, natural rubber imparts flexibility and
durability, and jackfruit glue enhances adhesive qualities. This blend can be used
for applications such as bio-based adhesives or as a base for environmentally
15 friendly coatings, showcasing the synergy between natural and synthetic
components.
q. 60% Banana pulp + 30 % natural rubber + 10 % Arrowroot Glue
20
Natural rubber is mixed with Banana pulp in a blender with a blunt spiral structure.
Mixing is continued for up to 1 hr. This mixture has sufficient adhesiveness to
ensure that the composition does not peel off from the backing material after
drying.
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Specific concentration of the above mixture (mixture of Banana pulp and natural
rubber) such as 70 – 90 parts and 10 – 30 parts of Arrowroot glue are mixed together
for 10 - 30 minutes.
Banana pulp offers sustainability, natural rubber provides flexibility and durability,
5 and arrowroot glue enhances adhesive characteristics. This composition can be
utilized for applications like eco-friendly adhesives or as a base for biodegradable
materials with a focus on natural and adhesive components.
Example 3 - Preparation of Vegan leather
10 In a first step, backing material is cut into desired dimensions.
In the second step, the backing material is placed on a spraying table. Then 2 coats
of any of the compositions are sequentially sprayed on the backing material using
a spray gun to produce panels. Panel is backing material coated with compositions
/ leather mixtures. After first coat, panel is subjected to drying.
15 For various approximate thickness, following coating compositions are preferably
applied.
Size of backing
material
Thickness
(overall)
Thickness
(backing)
Quantity Ratio of backing
material thickness to
Leather thicknes
40/27 inches 1.0mm 0.2mm 1.7 kg 1:5
40/27 inches 1.2 mm 0.2mm 2 kg 1:6
40/27 inches 1.4 mm 0.2mm 2.3 kg 1:7
40/27 inches 0.7 mm 0.2mm 1.3kg 1:3.5
Around 1.7 kg of compound is needed for one 27 by 40 inches fabric for overall
1mm thickness. Backing material of larger size such as 8 X 10 sq. feet or larger
20 larger size can be employed.
62
After spraying, panels are trowelled in which even spreading of coated material is
done.
Next step is drying. After trowelling the panels, they are kept in drying racks and
are subjected to drying at a specific temperature. Drying temperature is controlled
5 and not allowed to exceed 60°C as it may burn upper soft portion of the coating.
Panels are dried for at least 24 hrs., preferably for 48 hrs.
Further, the dried coated panels are subjected sequentially to plating, colour
spraying, embossing and lacquering. Drying is needed after each of the steps
involving colour spraying, embossing and lacquering.
10 These steps are described as follows:
Plating
Each panel is subjected to specific temperature and pressure and time. Preferably,
pressure of 250 MPa or Bar at 80°C for 1.5 sec. at a second in a hydraulic press
machine. Plating softens the upper surface and increases the bonding between
15 fabric /backing material and the layers of coatings.
Further, leather is subjected through various finishing processes.
Finishing
Finishing of leather includes a series of steps to give buyers variety in the colours,
embossing, shiny or matt finishes etc. and include spray painting, surface treatment
20 and adding chemicals to stop colour leakage and water proofing etc...
Finishing materials are up to 10 % w/w, preferably up to 5 % w/w of the leather,
more preferably from 2% w/w to 4% w/w of the all coating and contains colours,
binders, lacquers and water resistant / water repellent coatings. Lacquers include
polyurethane lacquers, dyes lacquers, resin based lacquers, different types of
25 Nitrocellulose lacquers, Acrylic Lacquers, and also, water based silicone emulsions
etc...
There are a variety of colours which can be employed in the compositions. Some
of them are dyes, pigments & natural colours (made from organic compounds like
coal tars, some petrochemicals i.e. benzene, toluene, xylene, oil & inorganic
30 compounds like oxidation of metals i.e. titanium, iron etc).
63
Some of the colours are mixed with binders. There is a huge variety in binders.
Most commonly, acrylic binders, polyurethane binders, Resin binders etc. are
employed.
There is an alternative option of using 100 % w/w bio based binders. Here the binder
5 is made from Natural Rubber and Starch in ratios such as (1:3) or (1:4) or (1:5) or
(1:6).
Embossing includes NDM embossed, PDM embossed, YDM embossed, Croco
embossed, Printing, Foiling and other types.
10 Colour Spraying / Spray coating
First coat of colour- After plating the next step is colour coating. Here the
Synthetic pigments that are made by some organic and inorganic compounds are
used for coating. The pigments used in colour coating are absolutely sustainable
and eco friendly. The pigments are mixed with a binder in a ratio from 1:5 to 1:15,
15 preferably in 1:10 ratio.
Surface treatment
After one coat of spray, the panels are kept for drying for 24 hours for fixation of
colour.
Next step is surface treatment and includes milling and embossing.
20 Milling
After colour coating and drying, the panels are subjected to a Milling process to
increase the softness. It is a drum operation where the panels are revolved in the
drum. Due to this operation the upper surface of the material gets creasing effects
like leather finishes.
25 Embossing
64
It is important to give vegan leather a look of leather. To emboss the upper surface
there are many types of plates in the leather industry. Embossing imparts a raised
pattern and enhances the look of the leather. There are many plates available in the
leather industry. A suitable plate is selected and embossing is done at specific
5 temperature and pressure.
After Embossing, the spray coating step is usually repeated if colours fade during
embossing.
The pigments are mixed with a suitable binder in specific ratio from 1:5 to 1:15
preferably, 1:10 and sprayed on the panel. After colour coating, panels are dried for
10 24 hrs, and then if desired, a second coating is done followed by drying.
Before lacquering the panel, it is mandatory to ensure the colour of the upper
surface has dried properly. So, a minimum 24 hours of drying time is needed.
Lacquering.
.Lacquering is done to give desired finish to the prepared leather.
15 EC, a specific nitrocellulose based lacquer is diluted using water. Additionally, a
feeler that modifies touch and feel of a leather such as plant based or silicon based
coating emulsion having properties like silicon coating is added to impart smooth
touch.
49 % w/w EC lacquer is diluted with 49 % w/w with water and 2 % w/w plant
20 based or silicon based coating emulsion similar properties like silicon coating is
mixed in it to provide lacquer suspension. Lacquer suspension is applied as top coat
on the prepared leather.
Drying is essential after colour spraying, before and after lacquering. When colour
spraying is done multiple times, drying between each spray is essential. Minimum
25 24 hrs. drying time is used after each colour spraying and before and after
Lacquering.
65
During finishing, colours / pigments, binders, preservatives, lacquers, chemicals to
prevent colour leakage and water repellents together not more than 5 % w/w are
added.
The Vegan leather prepared in accordance with the present invention comprises 1
5 – 15 % w/w of backing material, colours / pigments, binders, lacquers, chemicals
to prevent colour leakage and water repellents and 85 – 99 % w/w of coating
composition containing Banana pulp and one or more of additives such as
adhesives, binders, fillers, softeners / plasticizers. Additionally, from 0.001 to 0.1
% w/w preservatives are present when required.
10
Properties of VeganLeather
Vegan leather of the present invention is different from other vegan leathers because
it can be made in fully recyclable form when natural / organic backing material is
used such as cotton fabric and is therefore 100% w/w bio based. Backing material
15 is It passes all the tests (physical and chemical). There are some physical properties
of Vegan Leather produced according to the present invention as follows:
Physical Properties
By using and selecting suitable compositions and suitable backing materials,
20 various vegan leathers of desired properties can be prepared. For example, by
choosing tougher backing material, tearing strength can be enhanced. By choosing
softer material and adding softeners, tensile strength can be enhanced.
Thickness- The thickness of animal leather is between 1.2mm to 1.8mm. But the
thickness of the present Vegan leather can vary between a large range i.e. from
25 0.7mm to 1.4mm.
Tensile Strength- The tensile strength of leather is 8 to 40 N/mm2 whereas the
tensile of the present Vegan leather is 10- 20 N/ mm2
.
66
Tearing Strength - The tearing strength of animal leather is 82.9 N/mm. Various
Vegan leathers prepared in accordance with the present invention exhibit tearing
strength range from 25 – 105 N/mm. Within this range, tensile strength depends on
the nature of backing material. For non-woven backing materials made of cotton,
5 polyester and others, tearing strength is 50-105 N/mm and for soft backing material
such as woven materials made of cotton, polyester and recycled material, the
tearing strength is 30-50N /mm based on the process selected.
Flexing and Elongation - 25 - 35%
Abrasion - The present Vegan leather has water resistance. In dry condition the
10 Vegan leather does not find any coating removal up to 500 revolutions (standard
abrasion testing parameter). Waterproofing can further enhance resistance to
abrasion.
Colour Fastness of Precipitation- The present Vegan leather passes the test of
colour fastness of precipitation which means colour does not fadr during any
15 conditions (wet or dry).
Moisture content- The present Vegan leather material has moisture content up to
3 % w/w and therefore there are no chances of peeling or the coating removal like
other vegan leathers. Additionally hydrophilic bacteria cannot affect the panel.
Water Vapour Permeability (WVP)- The present Vegan leather material has low
water vapour permeability of up to 0.5 mg/cm2
/h, preferably up to 0.2 mg/cm2
20 /h.
Water Vapour Absorption (WVA)- The present Vegan leather material has water
vapour absorption of up to 2 mg/cm2
.
Chemical Properties
Usually during manufacturing of leather, many toxic / hazardous substances are
25 added especially in processes like tanning and dyeing etc. Some of them are
carcinogenic also. Leather produced may contain some traces of hazardous / toxic
67
substances and therefore should be tested for such substances. Commonly such
substances include metals like lead, chromium and cadmium. Various hazardous /
toxic amines can be employed. Various toxic phthalates can be found in traces.
The present Vegan leather has passed all the chemical tests conducted for absence
5 of hazardous / toxic substances and no such compounds are found in the Vegan
Leather produced in accordance with the present invention. Hence Vegan Leather
of the present invention is Phthalate free, lead free, chrome free, cadmium free.
These are toxic heavy metals found in animal leather due to the tanning process.
The Vegan leather is also free of various banned amines, organotin compounds,
10 Polycyclic Aromatic Hydrocarbons (PAHs), Alkylphenols and Alkylphenol
Ethoxylates, Short Chain Chlorinated Paraffins, pentachloro phenol.
The pH of the present Vegan leather is 7.5 + 0.2 i.e. almost equal to neutral pH.
Fungal and Bacterial Resistance
Preservatives have been sprayed or added in the process of making. So, there is no
15 chance of bacterial or fungal growth or bacterial existence in the present Vegan
leather material.
Composition Specifications
Although there are various finishes, different backings, different outer coverings,
different dyes, different machinery operations possible for the present vegan
20 leather. The core process of banana based leather material is consistent.
Backing options
A suitable backing material is selected from recycled plastic bottles, polyester,
rayon, nylon, velvet, cotton fabric from a locally grown cotton, vegan fabrics made
from banana, bamboo, jute, linen etc..
25 Overall material composition split
68
The thickness of the backing material in the overall panel is up to 40 % w/w,
preferably up to 30 % w/w, more preferably from 5 – 30 % w/w and most
preferably from 10 – 30 % w/w and the rest of the coated material is from 60 – 95
% w/w.
5 In terms of weight, backing material is up to 20 % w/w, preferably up to 10 % w/w
and more preferably up to 5 % w/w. Most preferably, coating composition make
from 85 – 99 % w/w of the Vegan Leather; and colours / pigments, binders,
preservatives, lacquers, chemicals to prevent colour leakage and water repellents
together up to 5 % w/w, preferably, from 0.5 - 5 % w/w of final finished leather
10 produced . Vegan leather prepared using compositions of the present invention has
employed various natural and synthetic compounds to make the material most
effective, usable and suitable for manufacturing various products.
Coating compositions /Leather mixtures
Coating compositions / leather mixtures contain Banana pulp having banana fibres
15 and natural additives like rubber, gums, saps and additional small quantities of
substances like PVA, resins, polyurethane, waxes, fillers, starch powder (like
Tapioca, corn, potato, rice etc), cork, PEG, Glycerol, IPA, PVC etc is used. It is
important to make the leather fungus free, so trace amounts of antifungals,
bactericides are used in the manufacturing process.
20 Finishing compositions
There are various finishes available i.e. in the upper coatings 2-4% w/w different
Binders like Protein binder, acrylic binder, PU binder, thermoplastic Binder, nonthermo plastic binders, Butadiene Binder etc; different types of lacquers like
Nitrocellulose lacquer, PU lacquer, Acrylic Lacquer; water based silicone emulsion
25 are used.
69
There are various options in the surface treatment and suitable machines are
employed during various process steps eg. Milling, Molisa, Hydraulic pressing,
Roller coating, splitting, spraying, trowelling etc.
The images of various Vegan leather produced using coating compositions are
5 provided under figures.
Advantageously, the plant-based method of the present invention has at least the
following benefits on the environment and livestock.
This plant based leather has wide spread uses across fashion (bags, shoes, belts,
wallets), furniture (sofas), and automotive (seats) being the major areas. It is an
10 alternative to a more polluting alternative and also doesn’t harm any animals.
The benefits of this plant-based method are significant CO2 emission savings, the
number of livestock saved and the weight in crop waste that was upcycled. Other
advantages include waste- water pollution avoided, and resource reduction. Apart
from these environmental impacts, measuring additional income for farmers
15 becomes an added advantage of this manufacturing process.
In the environment, carbon emission reduction - Leather is very emission heavy and
requires a lot of energy for tanning. Chromium, H2S and other hazardous,
carcinogenic animal leather chemicals will be reduced as these are not used in the
present invention.
20 Further, waste reduction is achieved including crop waste from banana stems. Air
pollution reduction is achieved by this invention, for example, crop waste that is
used is typically burned or degrades on fields.
The present invention also helps in water resource management. The plant-based
leather produced in the present invention uses 90% w/w less water than animal
25 leather.
70
Further, the present inventive method is also impactful to avoid animal cruelty. The
leather industry is responsible for cruelty to animals (cows, crocodiles, snakes,
sheep, goat, buffalo) many of them killed only for their skin, whereas this method
completely avoids this.
5 For farmers also, there is an additional income from sale of banana stem waste in
their fields. Also, they have less banana stem waste to deal with and do not need to
burn the crop waste, resulting in less pollution.
For the customers, they can get natural, sustainable, vegan, environmentally
friendly and cruelty free products.
10 While certain embodiments have been described, these embodiments have been
presented by way of example only, and are not intended to limit the scope of the
present disclosure. Indeed, the novel methods, devices, and systems described
herein may be embodied in a variety of other forms. Furthermore, various
omissions, substitutions, and changes in the form of the methods, devices, and
15 systems described herein may be made without departing from the spirit of the
present disclosure.
It is easily perceived that the research could indeed produce material akin to leather.
20
71
Claims
We claim
5 1. A composition for preparing a Vegan Leather comprising banana pulp made
from banana pseudostems and at least one adhesive or binder.
2. The composition as claimed in claim 1 for spraying, coating, or applying on
a backing material to produce Vegan Leather.
3. The composition as claimed in claim 1 comprising two or more adhesives,
10 two or more binders or at least one adhesive and one binder.
4. The composition as claimed in claim 1 further comprising other additives
selected from the group comprising filler, softener / plasticizer, preservative.
5. The composition of claim 1 wherein banana pulp is produced by processing
banana crop waste containing banana pseudostems and banana pseudostem fibres.
15 6. The composition as claimed in claim 1 wherein Banana pulp is from 40 –
70 % w/w.
7. The composition as claimed in claim 1 wherein at least one adhesive and /
or binder from 5 – 50 % w/w.
8. The composition as claimed in claim 4 wherein filler is from 5 – 35 % w/w.
20 9. The composition as claimed in claim 4 wherein softener is from 1 – 15 %
w/w.
10. The composition as claimed in claim 4 wherein preservative is from 0.01 –
0.1 % w/w.
11. The composition as claimed in claim 1 wherein adhesive is selected from
25 neoprene, natural rubber, ethylene vinyl acetate, polyvinyl acetate, gum arabic
solution, gum rosin solution, guar gum, jackfruit glue, agar agar solution, banyan
sap, arrowroot flour or glue, corn-starch adhesive or a combination of adhesives.
72
12. The composition of claim 1 wherein binder is selected from poly lactic acid,
maleic anhydride, polyvinyl chloride, polyurethane, bio polyurethane, acrylic
binder, resin binder and starch.
13. The composition as claimed in claim 1 wherein softener / plasticizer is
5 selected from polyethylene glycol, polypropylene glycol, glycerol, isopropyl
alcohol, citric acid, fruit waxes, paraffin waxes, vegetable or fruit oils comprising
Corn oil, Sunflower oil, palm oil and epoxidized vegetable oils.
14. The composition as claimed in claim 4 wherein filler is selected from i)
Starch from tapioca, rice, corn, potato, ii) rice husk, iii) cork filler, iv) polymer filler
10 comprising one or more of Magnopal IPF, Magnopal BP, Magnopal Pure-A, v) one
or more waxes, vi) one or more agri-waste filler, vii) wheat straw, viii) vegetable
oil; ix) talcum powder.
15. Vegan Leather comprising backing material coated with composition
comprising banana pulp and at least one adhesive or binder.
15 16. The Vegan Leather as claimed in claim 15 further comprising one or more
of filler, softener / plasticizer, preservative in the composition coated on the backing
material.
17. The Vegan Leather as claimed in claim 15 wherein composition comprising
banana pulp and at least one adhesive or binder is sprayed, coated, or applied on the
20 backing material as one or two or multiple coatings.
18. The Vegan Leather as claimed in claim 15 further comprising one or more
of dyes, pigments, binders, lacquers, preservatives, and water resistant / water
repellent coatings.
19. The Vegan Leather as claimed in claim 15 wherein backing material is
25 selected from recycled plastic bottles fabric, polyester, nylon, velvet, cotton fabric,
and natural fabrics made from organic cotton, banana fibre, bamboo, jute, linen,
rayon.
20. The Vegan Leather as claimed in claim 15 comprising from 40 – 70 %
banana fibres / banana pulp.
73
21. The Vegan Leather as claimed in claim 15 comprising from 50 – 65 %
banana fibres / banana pulp.
22. The Vegan Leather as claimed in claim 18 wherein lacquer is selected from
nitrocellulose lacquer, polyurethane lacquer, acrylic lacquer, and water-based
5 silicone emulsion.
23. The Vegan Leather as claimed in claim 15 wherein backing material
comprises up to 20 %, preferably up to 10 % and more preferably up to 5 %.
24. The Vegan Leather as claimed in claim 18 comprising from 1 – 15 % of
backing material, colours / pigments, binders, lacquers, chemicals to prevent colour
10 leakage and water repellents and 85 – 99 % of coating composition containing
Banana pulp and at least one adhesive / binder and optionally one or more of other
additives such as fillers and softeners / plasticizers and from 0.001 to 0.1 % w/w of
preservatives.
25. Vegan Leather as claimed in claim 15 having three or more; preferably four
15 or more, more preferably five or more, and most preferably seven or more of the
following properties / characteristics
i) banana pulp content from 50 - 65 % w/w;
ii) thickness from 0.7mm to 1.4mm.
iii) tensile strength from 10 - 20 N/ mm2
.;
20 iv) flexing and elongation 25 - 35%
v) tearing strength from 30 – 80 N/mm;
vi) no abrasion or coating removal in dry condition up to 500 revolution;
vii) moisture content not more than 3 %;
viii) water vapour permeability up to 0.5 mg/cm2
/h;
ix) water vapour absorption up to up to 2 mg/cm2
25 .
x) phthalate free, lead free, chrome free, cadmium free, zinc free Vegan
Leather.
26. A process of preparing compositions which are coated / sprayed on backing
material to produce Vegan Leather wherein the process comprises
74
v) Preparing banana pulp from banana pseudostems;
vi) Mixing banana pulp and adhesive / binder in a blender;
vii) Optionally adding any additional adhesive and / or binder; or adding
filler and / or softener and blending further;
5 viii) Mixing dyes / pigments / synthetic colour with a binder and adding the
mixture to above blend while mixing.
ix) Coating, spraying, applying the above mixture to a backing material
x) Mechanized treatment of top layer with pressure and heat in the form of
embossing, plating to form leather patterns
10 xi) Applying one or more final layers of coating with preservatives, water
resistant chemicals, dyes, binders, and lacquers.
27. The process of preparing compositions as claimed in claim 26 wherein
banana pulp is prepared by comprising
vii) Preparing or obtaining banana psuedostems in the form of stem cuttings
15 and stem fibre after fruit has been harvested;
viii) Subjecting banana fibre and stem cuttings to alkali treatment;
ix) Boiling banana fibre and stem cuttings in a suitable equipment or
digester causing them to form banana pulp;
x) Washing and straining pulp to wash out left over alkali;
20 xi) Grinding pulp and washing ground pulp;
xii) Optionally bleaching the pulp and washing pulp to wash out bleaching
agent.
28. The process of preparing compositions as claimed in claim 27 wherein
banana pulp is subjected to bleaching using water and one or more of bleaching
25 agents selected from calcium hypochlorite, sodium hypochlorite, liquid bleach,
hydrogen peroxide, sodium percarbonate, sodium perborate and washing the pulp
after bleaching.
29. A process of preparing Vegan Leather comprising
viii) Selecting and cutting backing material in suitable dimensions;
30 ix) Preparing pulp from banana pseudo-stem or pseudo-fibre.
75
x) Preparing coating compositions;
xi) Applying or spraying coating compositions on the backing material of
suitable sizes to obtain panels;
xii) Trowelling panels or spreading even the coated composition on panels;
5 xiii) Drying panels under controlled temperature;
xiv) Plating dried panels;
xv) Subjecting plated panels to colour spraying, drying and surface
treatments comprising one or more of, milling, embossing, and
lacquering.
10 Or
xiii) Providing mechanized treatment of top layer with pressure and heat in
the form of embossing, plating to form leather patterns
xiv) Applying one or more final layers of coating with preservatives, water
resistant chemicals, dyes, binders, and lacquers.
15 30. The process of preparing Vegan Leather as claimed in claim 29 comprising
adding i) chemicals to prevent colour leakage and / or ii) water repellents during
surface treatment.