Corn fiber: A new fiber on horizon

Dr. Reena Aggarwal

(Assistant Professor)

National Institute of Fashion Technology (NIFT)

Plot No- 15 Sector- 4

Mumbai – 410210

022-27747051 / 09769695159

Introduction

Biotechnology has been used in the textile industry for more than 100 years, since amylase
enzymes from malt extract were first used to degrade starch-based sizes for cheap and
effective desizing. In the last 20 years a dramatic rise in biotechnology innovations is leading
to an escalating number of low-cost and effective biotechnology solutions in textiles
processing and the discovery of exciting new fabrics.

To produce those fabrics, yarn and fiber manufacturers

currently are experimenting with a variety of bio-based
products that offer a three-fold market appeal - one is that
the products are derived from a natural renewable
resource, are more earth-friendly than synthetics and are
far less dependent on petroleum-based ingredients.

The product that has emerged as a promising alternative to

synthetic fibers is derived from corn. Corn fiber is made
using fermentation of simple plant sugar to create a range
of textile products and applications.

Although the fiber itself comes from corn starch, which

generates a lactic acid (the basis for a polymer) by
fermentation, it is not “natural” since there is chemical transformation. It is however considered
‘renewable’ since it does not come from a fossil product. The company that makes the corn-
based plastic resins marketed under the NatureWorks PLA and Ingoe™ fiber brand is
NatureWorks LLC, USA. The name Ingoe™ literally means "ingredients from the earth”.
About the fiber:

Corn fiber is a manmade fiber derived entirely from annually renewable resources. These
fibers have the performance advantages often associated with synthetic materials, and
complementing properties of natural products such as cotton and wool.

The process for manufacturing the polymer used to make corn fiber on an industrial scale
centers on the fermentation, distillation and polymerization of a simple plant sugar, maize
dextrose. The sugars are fermented in a process similar to making yogurt. After fermentation
products are transformed into a high-performance polymer called polylactide, which can then
be spun or otherwise processed into corn fiber for use in a wide range of textile applications.

The production and use of corn fiber means less greenhouse gases are added to the
atmosphere. Greenhouse gases are the chief contributor to global climate change.
Compostability and chemical recyclability mean that under the right conditions and with the
right handling, the complete life cycle of production, consumption, disposal and re-use is
neatly closed.

Important attributes of Corn fiber:

The fiber comes entirely from corn, is fully eco-compatible and has exceptional qualitative
features. The properties associated with the corn fiber are:

• Corn is available in both spun and filament forms in a

wide variety of counts from micro denier for the finest
lightest fabrics to high counts for more robust
applications.
• It is derived from naturally occurring plant sugars.
When products come to the end of their useful life, they
can be returned to the earth, unlike petroleum
based products, which can only be disposed of through
thermal recycling, physical recycling or landfill.
• Corn fiber balances strength and resilience with
comfort, softness and drape in textiles. Corn also uses
no chemical additives or surface treatments and amazingly, is naturally flame
retardant.
• It is reported to have outstanding moisture management properties and low odor
retention, giving the wearer optimum comfort and confidence.
• Corn fiber filament is said to have a subtle luster and fluid drape with a natural hand
offering a new material to stimulate creativity.
• Corn fiberfill allows outerwear garment makers to offer a complete story and a more
environmentally friendly alternative to polyester and nylon combinations in padded
garments.
• It reportedly outperforms other synthetics in resistance to UV light, retaining strength
color and properties overtime.
• Easy care, independent wash and dry cleaning tests have shown that the Corn fiber
garment tested can be laundered using standard washing and drying machines.
• Independent testing has confirmed Corn fibers have superior or equal performance
to polyester in key active wear applications.

• Garments in corn fiber reportedly demonstrated good soil release, quick drying and
show excellent after-wash appearance.

Main Performances of Corn fiber

Performances Corn Fiber Polyester Fiber Nylon Fiber

Breaking Tenacity (cN/tex) 38 60 45
Specific Density (g/cm3) 1.27 1.38 1.14
Melting Point (℃) 160～175 255 215
LOI(%) 26+ 20～22 20～24
Moisture Regain (%) 0.4～0.6 0.2～0.4 4.1
Refractive Index 1.4 1.57～1.68 1.57
Combustion Heat (KJ/g) 19 25～30 30.9
Elogation Rate(%) 25～35 30～40 30～40
Recovery Rate(Stretch 5%) 93 65 89
Moulds(kg/mm2) 400～600 1200 300
Dyestuff disperse dye disperse dye disperse dye
less smoke heavy smoke
Flammability (self-extinguish off fire (self-extinguish off fire 6 middle smoke
2 minutes) minutes)

Applications of Corn fiber:

Once produced corn fiber has a natural feel that provides true innovation from yarns to
garments. This fibre can replace many various textile materials, it is most fit for clothing, can
be made into yarn, fabric, knitting, nonwoven, staple fiber, multifilament and single filament. It
can be spun into pure yarn, at the same time, it can be spun with cotton, wool, viscose and
other chemical fibers.

The natural source and inherent performance attributes of corn fiber make it ideal for use in a
wide range of fiber applications.

Apparel - Characteristics like strength, resilience, comfort and drape combined with loft,
natural insulating warmth and moisture management make corn fiber the perfect solution for
both outer and inner fabric performance needs. Moreover, because of its easy-care
properties, corn fiber-based fabrics are an easy choice for clothing manufacturers.

Corn fiber is used in many different apparel applications such as contemporary sports and
casual wear t-shirts, fleece and jeans. Functional fashion separates like shirtings, trousers,
duvet jackets, jersey dressing and essential next- to- skin items such as underwear and
hosiery. Corn fiber can also be used in new fiberfill blends for thermal wadding that offers
unique natural insulation properties. The use of corn fiber in clothing fabrics translates into
garments that are both easy care and easy wear.

Home Textiles - The natural versatility of corn fiber allows it to be created as furnishing and
home textile also. Corn fiber is used in different home textile product categories and it is
suitable for bedding fiberfill (such as pillows, duvets and quilts), ticking fabrics, mattresses,
blankets, carpets, draperies, upholstery fiberfill and in office wall paneling.

Nonwovens - Corn fiber is already in use in two non woven applications: wipes and feminine
hygiene products. With its unique end-of-life options, it is well suited for use in cosmetics and
diapers.

Industrial applications - Corn fibres can be used for geotextiles, agrotextiles and specialist
filtration media. Corn in form of biopolymer can also be used, in its plastic form, for packaging.

Reduced Environmental Impact

Corn fiber leads the way toward producing a wide range of materials from renewable
resources, to meet the world's needs today without compromising the earth's ability to meet
the needs of tomorrow. Corn is a clean product; i.e., on reaching the end of its lifetime, it is
completely biodegradable, compostable, burnable (without producing dangerous fumes) and
recyclable.

Corn fiber is an environmentally preferable option to petroleum-based synthetic materials as it

uses natural resource, field corn, instead of petroleum, to make synthetic materials.

Corn fiber in fashion

Corn fiber has already threaded its way into some winning outfits produced by designers from
across the globe. It is currently used in contemporary sportswear, fashion separates, essential
and other knitwear by a number of designers who firmly believe that through the use of corn
fiber in their designs they can raise awareness for the environmental, social and political issues
close to their hearts with the aim of making the consumer aware and inspiring them to act by
taking responsibility for the world we live in and the one that we leave to future generations.
References:

• http://www.cornfibers.com/

• http://www.ecofriend.org/entry/corn-new-fiber-made-from-genetically-engineered-
corn/
• http://www.cloverbrook.com/CornPage.htm
• http://www.legsource.com/consumers/ingeo-fiber-06-05.html
• http://www.natureworksllc.com/news-and-events/press-releases/ingeo-fibers/10-6-05-
ingeo-fiber-backgrounder.aspx
• www.chinayarn.com/xianwei/shqr/product_en.htm