It transitioned from a petroleum-derived plastic named polypropylene to a more sustainable feedstock. It developed its own process and machinery to produce the plant-derived biopolymers.
With the aim to reduce the amount of waste or change the type of waste so it could be handled differently at the end of life, Roswell transitioned the from a petroleum-derived polypropylene (PP) to a more sustainable feedstock. It developed its own process and machinery to produce the plant-derived biopolymers.
The result is Ecofuse, a biodegradable material which reduces waste and cuts CO2
emissions related to its life cycle by almost two-thirds compared to plastics on the market.
Ecofuse is a meltblown biopolymer which is spun-woven using high velocity hot air to draw down the polymers into microfibers through a single process. The feedstock is derived from corn, sugar cane and sugar beets sourced from North American and international suppliers.
Biopolymer nonwovens, branded under Ecofuse, are expected to reduce total greenhouse gas (GHG) emissions by 3,750 MT CO2
per year, growing to over 10,000 MT CO2
by year 2030 as increased adoption is achieved. Ecofuse technology is expected to initially reduce 1,500 MT CO2 in the Energy Sector with proprietary water filtration bags that are used in industrial water processing, 1,500 MT CO2
in the food and beverage industry by replacing synthetic polypropylene-based materials, 400 MT CO2
in the HVAC filtration industry and 350 MT CO2
in the Healthcare industry.
Ecofuse materials are being used by Roswell Textile's strategic partners and clients to decrease the carbon footprint of their products (generally speaking, the raw materials used to manufacture Ecofuse have a 70% smaller carbon footprint than the conventional synthetic polymer materials made in the United States). The Ecofuse materials are already commercial in medical filtration (510(k) approved face masks, respirators, etc.), water filtration (industrial water processing filters) and residential filtration applications (first HVAC filters made with plant-based materials) with additional commercialization processes underway for the use of Ecofuse materials in hygiene, food and beverage packaging as well as in construction materials. Ecofuse materials, once fully adopted and commercial, will be displacing conventional synthetic PP plastics in medical gowns, drapes, wraps, bed sheets, pillows, dressings, wipes, coffee filtration, teabags, absorbent pads, insulation bags, packaging, home wrap, plastic wrap/packaging, HVAC filters, ventilators, fluid filtration, geotextiles, grain bags, silage wraps, seeding bags, and car filters.
Roswell Textiles, Calgary/Canada, was formed in 2020 to answer a call from the federal government to supply meltblown filtration media for Canadian personal protective equipment (PPE) manufacturers during the Covid-19 pandemic. To start the business, it received funding to develop the first commercially available, made-in-Canada meltblown nonwovens.