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Why Natural Fiber Clothes Wrinkle

Ironing Cotton Shirt Why clothes wrinkle and how to stop clothes from wrinkling have befuddled people from the time when mirrors were invented.  The world of fabrics is littered with many incorrect myths about what causes fabrics to wrinkle and what to do about it. Let’s take a journey together through all the wrinkles of fabric lore to see what we can do about removing wrinkles from clothing.

Why do clothes wrinkle? The two primary causes of wrinkling in fabrics are water moisture and heat. Heat and moisture can remove wrinkles (think ironing and steaming hanging clothes), but they are also the leading causes of that ferociously wrinkled organic cotton shirt. As we’ll see, many other factors can contribute to wrinkled clothing and there is much that you can do to reduce wrinkles that will also reduce the total amount of energy that you will invest in your clothing over their life cycle from when you first go clothing shopping until you are finally ready to send it to the thrift shop, homeless shelter or recyclers.

Which fabrics are more prone to wrinkle? Sometimes it seems as if an organic cotton shirt will sprout contact wrinkles if you just look at it and crinkle your nose while a polyester dress can survive a train wreck and still be ready for a night on the town. Generally, clothes using fabrics made from natural cellulose – cotton, hemp, linen (flax) – are the most prone to wrinkle. Clothes made from regenerated cellulose – bamboo, rayon, Tencel / lyocell, Modal – or from regenerated plant protein – soya, Ingeo – are less likely to wrinkle and wrinkles are easier to remove. Animal fibers – wool, alpaca, cashmere – are generally the least likely to wrinkle. Silk tends to fall in the middle category of wrinkle-ocity.

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But, this doesn’t mean that just because a favorite organic cotton skirt is made from organic cotton or hemp that it is going to have more wrinkles than Shar Pei puppies. The tendency of a garment to attract or repel wrinkle is affected by many qualifications such as: weave – knits are less likely to show wrinkles than woven fabrics; fiber blends – wrinkles will easily fall out of a woven yoga top of 95% organic cotton blended with 5% lycra (spandex); quality of fibers – other factors being equal, high quality long staple organic cotton fibers are less likely to wrinkle than lower quality conventionally grown short cotton fibers; quality of manufacturing – a dress of tightly woven, high thread count cotton finished with tightly sown seams will last longer, look better and often require less ironing than a low quality garment; fabric finishes – this is tricky as chemical fabric finishes can be added during manufacturing or during laundering that will reduce the propensity for wrinkling, more about this later; and laundering – which can make all the difference between having your clothing look like the surface of the moon during a solar eclipse or the smooth, shiny backside of a new baby … well, maybe not the best metaphor but you get the idea.

Why do some fibers wrinkle more than others? The differences are in the structural and chemical natures of the fibers that make the fabrics. Let’s quickly first look at how the chemical nature of fibers affect how they respond to wrinkling.

Polymers are the key to understanding wrinkling. Polymers form the basic structure of many fibers which form fabrics. The cellulose found in cotton, bamboo, hemp and linen flax and the proteins that comprise the new eco-fibers Ingeo and soya are natural polymers. Nylon and PET (PolyEthylene Terephtahalate) are examples of synthetic polymers that have been used in clothing. Polymers help hold fibers together and give stability to fabrics.

The energy in heat, whether the heat comes from hot water during washing, hot air in a clothes dryer or even body heat, weakens the covalent bonds that bind polymers together but different polymers of different fibers have different transition points at which the bonds weaken. The polymers of natural cellulose fibers such as cotton, hemp and flax, which is used to make linen, have a much lower transition level and therefore require less heat energy to break the stable covalent bonds than nylon, polyester or regenerated polymers of bamboo, rayon, Tencel / lyocell, Modal, or Ingeo which means that they wrinkle more easily.

This transition point where a polymer’s covalent bonds become weaker is also known as the “glass transition temperature.” An interesting research paper by J.M. Maxwell at the University Of Melbourne, Australia, found that cotton fibers pass through a glass transition at about 72 degrees F (22C) at a relative humidity of 78% which shows the connectedness between heat and water for fabric wrinkles. Different types of fibers have different glass transition temperatures with natural cellulose fibers such as organic cotton, hemp and linen on the lower end of the spectrum making them more susceptible to wrinkling. Research from other sources suggests that moisture and humidity also lower the glass transition temperature, at least for natural cellulose fibers.

Heat is only half of the wrinkle equation. Heat’s partner in growing or removing wrinkles in clothes is water moisture. Using a scanning probe microscope, Maxwell found that water moisture caused cotton cellulose fibers to swell and soften making it easier for the fibers to move and change shape which are all part of the wrinkling or wrinkle removing processes. These are the chemical processes involved in wrinkles.

Mitsuhiro Fukuda of the Textile Materials Science Laboratory at Hyogo University has researched the “dimensional stability” like wrinkling caused by moisture on hydrophilic and hygroscopic fibers such as cellulose and cellulose derivatives (regenerated cellulose). Fukuda documents that a 1% increase in a fiber’s moisture content causes a decrease of about 10 degrees C in the glass temperature for many polymer fibers. The lower the glass temperature of a fiber then the more likely that the fabric will wrinkle.

The structural factors in natural cellulose fibers involve fiber fibrils which are bunches of cellulose chains all lined up together and twisted together into threads that are woven or knit into clothes. The cellulose fibers are held in place through chemical bonds between hydrogen atoms across cellulose fibers. Both heat and water weaken these hydrogen bonds which help keep the fibers in fabrics together and this can happen during washing, drying, while wearing (your skin releases a lot of heat and moisture even if you aren’t sweating), or even while hanging in a closet during a hot, humid day.

Cotton_microscopic_2 To see how wrinkles develop in your cotton, hemp or linen clothing, look through a microscope at the fabric threads and you will see lots of rough little fibers that stick out from the woven threads and become intertwined with other fibrils from other threads. During laundering or even during wearing on warm, humid days, the heat and moisture help weaken the chemical bonds helping to hold fibers in place and the moisture softens the fibers and allows them to slide around more easily. When the fabric dries and cools, the rough little fibers become intertwined with other fibers in different locations and the chemical bonds reform and give rise to the wrinkles. This is why those natural cellulose fiber fabrics have a greater propensity to wrinkle.

Regenerated cellulose fibers, such as bamboo, Tencel / lyocell, Modal, and rayon, are more immune to wrinkling than natural cellulose fiber clothing for two reasons. First, they tend to have a slightly higher glass transition level. Second, regenerated cellulose fibers are born by being shot from a spinneret head into a chemical bath which gives the fibers a smooth surface without small fibers sticking out to snare and become tangled with other fibers during washing or wear.

Fabric weaves and wrinkling. The type of fibers, the temperature and the moisture absorbed by a fiber all contribute to fabric wrinkling, but wrinkling is also influenced by the type of weave and construction of fabrics. Generally, loosely woven fabrics are more susceptible to wrinkling than tightly woven fabric. A high thread count, tightly woven cotton shirt or bed sheet will tend to wrinkle less than a low thread count, loosely woven cotton shirt or bed sheet. The tight weave tends to hold the threads and therefore the fibers in place without as much freedom to move around and give rise to wrinkles.

Knit Polo Shirt Knit fabrics tend to wrinkle less than woven fabrics because of the inherent elasticity of a knitted fabric compared with a woven fabric.

Blended fabrics and wrinkling. Stretch woven clothes, which are typically 90% to 96% natural fibers such as cotton blended with 10% to 4% spandex / lycra threads, also tend to be more wrinkle-free due to the elastic quality of the spandex / lycra threads. To reduce nasty wrinkles, clothing manufacturers sometimes blend natural fiber fabrics – cotton, hemp, bamboo, rayon, Tencel / lyocell and even silk – with more wrinkle resistant fibers like polyester. There is an ecological case that states that the total lifecycle environmental cost of synthetic clothes made from polyesters can be significantly less than for natural fibers such as organic cotton and hemp. It’s up to eco conscious and health sensitive consumers to decide where their consuming edges really are.

Silk and wrinkling. For such a simple fiber forced out of the lower lip of the silkworm, the processing into fabric and then into clothing is often complex and chemical intensive. Silk clothing manufacturers often use a wide variety of chemical finishes and manufacturer processes to improve the easy care properties of silk including making silk more wrinkle-free. One chemical process for making silk clothing more wrinkle resistant is by bathing silk in “an aqueous solution containing a water-soluble epoxy compound in a catalyst which may be selected from alkali metal or alkali earth metal salts of dicarboxylic acids, tricarboxylic acids, and amino carboxylic acids.”

Warhol_campbells  Another chemical finish for more wrinkle free finish uses glyoxal resin with ethylene urea and a metal-acid catalyst. Machine-washable silks commonly use urethane resins with or without formaldehyde. And, of course, there is nothing on a garment label that gives a clue as to what chemicals that new silk blouse might have been soaked in. To bad clothing isn’t like Campbell Soups that list all their chemical ingredients.

But, silk naturally has a wide variety of wrinkle and care tendencies depending upon what kind of silk it is. Silk crepe de chine, habotai, noil, and charmeuse are generally easy care silk fabrics less prone to wrinkling. Ahimsa silk, also know as Peace Silk because it is made from silkworm cocoons in which the silk worms were not killed, also wrinkles less than other silks.

Wool and wrinkling. Wool does wrinkle and, like other fibers, the propensity to wrinkle depends upon the weave and type of wool. There are basically two categories of woven wool garments: woolens and worsteds. The distinction between the two categories of wool garments depends upon how the wool fibers are prepared which results in different degrees of snugness in the weave. Woolens are more loosely woven and more prone to wrinkling while worsted wools are more tightly woven and more resistant to wrinkles.

Wool will wrinkle like clothes made from cellulose fibers for most of the same reasons – heat and moisture affecting the glass temperature of the fibers and allowing hydrogen bonds in the fiber molecules to disconnect and reconnect to create wrinkles.

Wool is more wrinkle-resistant and recovers more quickly from wrinkles because of the more elastic nature of wool fibers. The elastic filaments and viscoelastic properties in wool fibers help the fiber stretch and then return to its original state when the force which contorts the fabric into a wrinkle is removed. Low Friction between the yarns in wool fabrics also helps wool garments recover quickly from being wrinkled back to their original state. Wool clothes will wrinkle when the wrinkled state is held for a long period of time in a hot and humid environment.

Wrinkle wrap up. All natural fibers – and synthetic fibers also – have a greater or lesser propensity to wrinkle and the twin enablers that encourage wrinkles are heat and moisture. Both heat and moisture help break weak molecular bonds that bind fibers to each other within fabrics. This allows fibers to shift within the fabric and to be reshaped by other forces such as laundering or wearing clothes in hot, humid conditions. When the temperature is lowered and the moisture dried out, the fibers reform new bonds which give the fabric a wrinkled look.

A fiber’s wrinkle destiny is affected by other factors also such as the type of weave, thread count and tightness of weave, and fabric quality.

In the next post, we will examine how you can help your natural fibers resist the urge to wrinkle.

Enjoy.

Michael

Bamboo Sprouting Green Myths

"Advertising is the 'wonder' in Wonder Bread." - Jef I. Richards, Professor of Advertising, University of Texas at Austin

Green Pinocchio Bamboo fabric is becoming the Wonder Bread of sustainable textiles. This isn’t to say that bamboo doesn’t have many exceptional qualities. I’m just saying that the green hype is starting to lead to a loss of credibility. Let’s take a short walk through the bamboo green claims and see what’s real and what’s green spin.

Anti-bacterial & UV Protection. “Bamboo fiber has particular and natural functions of anti-bacteria, bacteriostasis and deodorization” due to a “a unique anti-bacteria and bacteriostasis bio-agent named bamboo kun." The mysterious anti-bacterial component has also been called “bamboo chinone”. This unique claim of bamboo fabric is bolstered by studies performed by the Japan Textile Inspection Association; National Textile Inspection Association in China (NTIA), and the Shanghai Microorganism Research Institute. The theory goes that somehow the bamboo kun is chemically bound closely to the bamboo cellulose fibers and this chemical binding survives the harsh chemicals used to free the bamboo cellulose from the lignin and other components found in bamboo when the bamboo cellulose is regenerated into bamboo fiber.

There are two problems to bamboo’s claim for being a uniquely anti-bacterial fabric. The first is that bamboo fabric’s anti-bacterial claim was recently repudiated by research conducted by Colorado State University chemists Subhash Appidi and Ajoy Sarkar, Ph.D., investigating UV-resistant and anti-bacterial fabrics. They reported at the 235th national meeting of the American Chemical Society that “bamboo fabric did not live up to antimicrobial expectations.” Their research also indicated that bamboo fabric is low in UV-resistance and that most damaging ultraviolet rays pass through bamboo fabric to the skin. The research at the Colorado State University directly contradicts many claims and research performed in China and Japan. We need more independent and transparent research to ferret out why the differences.

The second problem is that claims for being an anti-bacterial fabric are not unique to bamboo fabric. Other regenerated cellulose fabrics also claim to have anti-bacterial properties. According to the Lenzing AG web site, “Bacterial growth was observed in various fibers, and TENCEL®, with its rapid absorption of moisture and high absorption capacity proved most effective in inhibiting growth” and “The result demonstrates that TENCEL® is the most naturally hygienic fiber. TENCEL® prevents the growth of bacteria naturally without the addition of chemical additives.”

Unique Bamboo Properties? Thermal-regulating, Anti-static, Biodegradable, Natural UV Protection, Super Soft. Regenerated cellulose fabrics share many common properties. “Green & biodegradable, breathable and cool, soft had feeling, luxurious shiny appearance” are properties commonly found in regenerated cellulose fabrics such as Tencel® / lyocell, Modal®, Viscose® … and bamboo. And this shouldn’t be any surprise as they all derive from cellulose that has been extracted from plants using similar chemical processing and then excreted through spinnerets to form fibers for textiles and clothing.

Research by Y. Xu, Z. Lu and R. Tang at the Testing and Analysis Center at Suzhou University in China used scanning electron microscopes (SEM), Infrared Spectroscopy (IR), and thermoanalyzers (TA) to analyze the physical structure and properties of bamboo viscose, Tencel® and viscose fibers. Their results, which are reported in the Journal of Thermal Analysis and Calorimetry, Vol. 89 (2007), found that all three fibers belong to the cellulose II category and that, while there are variations in the regenerated cellulose fibers that affect fiber properties, the similarities in structural properties are striking. Among their findings was that Tencel® consists of longer molecules and has a greater degree of crystallinity, while bamboo viscose fiber has a lower degree of crystallinity. Differences in fabrics from regenerated cellulose are a combination of factors – some differences in the cellulose cellular structure between the different sources, differences in the mechanical spinning processes when the fibers are formed and the specific chemicals used, and the finishing processes and the enzymes and chemicals used.

Grown on Environmentally Friendly Bamboo Plantations. Bamboo fabric is spun from bamboo pulp manufactured from bamboo grown on bamboo plantations primarily in China. Because bamboo has so many uses and derived products, growing bamboo has become a significant industry in China. The book Rehabilitation of Degraded Forests to Improve Livelihoods of Poor Farmers in South China by Liu Dachang published in 2003 by the Center International Forestry Research researches in depth the environmental and social damage that have been created by poor and over-harvested forests of all kinds, not just bamboo, in China. Chinese government forest policy reforms within the last twenty years have transferred ownership of most forests to private citizens and businesses. The result has been a lack of government regulations for controlling forest land use and many forests were clear-cut to plant money-making mono-cultures such as bamboo plantations.

The adverse environmental impact associated with bamboo plantations replacing natural forests was also documented in a paper by Dr. Jim Bowyer titled “Bamboo Flooring – Environmental Silver Bullet or Faux Savior?”. Because of the severity of the problems, there are now broad initiatives underway in China to rehabilitate degraded forest lands by restoring biodiversity and improving soil and forest conditions. Because bamboo has so many different economics uses such as food products, paper, furniture and housing materials, and textiles, the opportunity and temptation for exploitation of land and resources is great and it is difficult to determine where and under what conditions the bamboo was grown. This is especially a problem for bamboo textiles which are made from regenerated cellulose bamboo pulp because bamboo fiber manufacturers buy their bamboo pulp from suppliers. They don’t manufacture it themselves and there is little transparency in the supply chain.

Here is one example. On their web site, BambroTex proclaims “Bamboo Fibre is a kind of regenerated cellulose fiber, which is produced from raw materials of bamboo pulp by our sole patented technology. Firstly, bamboo pulp is refined from bamboo through a process of hydrolysis-alkalization and multi-phase bleaching. We then process Bamboo pulp into bamboo fiber.” At the same time, Tenbro is declaring “Shanghai Tenbro is the earliest and most specialized bamboo fiber manufacturer in China, and the only patent holder of both material and products of bamboo fiber accredited by State Intellectual Property Bureau.” Both the claims of BambroTex and Tenbro to being the sole patent holders of bamboo fiber are misleading. It seems that Jigao Chemical Fiber Co., Ltd. of China is the actual holder of the patent for manufacturing bamboo fiber in China and the Jigao Chemical Fiber Company produces all the bamboo fiber which Shanghai Tenbro Bamboo Textile Company, China BambroTextile Company, Hebei Jigao Import & Export Company, Jilin Chemical Fiber Import & Export Company, Shanghai Worldbest Company and Minmetals Shanghai Pudong Trading Company export bamboo fiber globally according to the Jigao Chemical Fiber Company.

Things with bamboo fiber are seldom what they seem at first blush. The tens of thousands of tons of bamboo fiber produced by Jigao Chemical Fiber Company for export by its licensed agents such as the Shanghai Tenbro Bamboo Textile Company and the China Bambro Textile Company are manufactured from hundreds of thousands of tons of bamboo plants raised on many thousands of bamboo plantations across China under a wide variety of environmental farming conditions. How can any manufacturer claim that their bamboo fabric is only produced from bamboo grown on environmentally sustainable farms? How do they know where their bamboo was grown and under what conditions? Given the intense emphasis on profits and the lack of transparency in Chinese business and that one company manufacturers the bamboo fibers used in the majority of exported bamboo fabric, claims that only environmentally sustainable bamboo plants are used ring as hollow as a bamboo flute.

The processing of bamboo plants into textile fibers is relatively harmless because caustic soda is the “main chemical used.” Caustic soda, aka sodium hydroxide - NaOH, is one of the ingredients used to reduce bamboo plants to pulpy goo in a process known as hydrolysis alkalization. Caustic soda is a harsh alkaline chemical that must be handled carefully, especially at high levels and under the high temperature and pressure needed for hydrolysis alkalization. As the old saying goes “The poison is in the size of the dose.”

Another toxic chemical in the processing of bamboo rayon is carbon disulfide which has been linked to serious health problems. Breathing low levels of carbon disulfide can cause tiredness, headache and nerve damage. Carbon disulfide has been shown to cause neural disorders in workers at rayon manufacturers.

LITAX fibers In Summary. Bamboo fabric has much to offer but much remains to be done before the growing of bamboo can have significant environmentally positive impacts. Here are some steps to produce a more sustainable bamboo fabric:

  • The Chinese Government must strengthen their forest reform policies.
  • Organic bamboo certifications must be enacted to insure that bamboo plantations are sustainably managed.
  • Bamboo rayon fiber manufacturing must be transformed into a closed-loop process to reduce the escape of harsh and toxic chemicals into waste waters, the air and the textile workers environment.
  • Commercialize natural bamboo bast fiber processing such as that promised by Litrax so that we can get away from chemically regenerated bamboo viscose rayon.
  • And please, make sure that marketing claims match the facts and don’t mislead the consumer.

Enjoy.

-Michael

Regenerated Cellulose Fabrics: Facts Behind the Fibers

Elisa Jimenez ingeo dress  This is the first in a series of posts on regenerated fibers and their fabrics. Many of the sustainably fashionable new fabrics that are giving eco-designers and even conventional runway designers hot eco-flashes are from the family of regenerated fibers – corn fibers such as Ingeo and Sorona, soy fabrics such as SoySilk® from Soy Protein Fiber (SPF – a byproduct of soybean manufacturing), bamboo, rayon, lyocell / Tencel®, Modal®, and Viscose®. 

A Short Overview of Textile Fibers.Fibers are the basic component of fabrics. Fibers from natural or manufactured sources are twisted together to form yarn and threads that are then woven or knit into fabrics and garments. Natural fibers come from plants (such as cotton, hemp, kenaf and flax), or from animals (such as wool, hair and fur), or insects (such as silk).

Manufactured fibers come in two flavors: synthetic fibers and regenerated fibers. Synthetic fibers are cooked up in large vats and are made entirely from chemicals. Some of the most common synthetic fibers are the thermoplastic, petroleum-based synthetic fibers such as polyester and nylon. Synthetic fibers also include the “green” PET fabrics (PolyEthylene Terephthalate) such as EcoSpun from Wellman Inc. which is made from recycled plastic soda bottles. EcoSpun lined coats and jackets are sold by several environmentally credentialed companies such as Sierra Club and Patagonia.

Manufactured regenerated fibers are made from the chemical-induced transformation of natural polymers and basically fall into two categories: protein origin and cellulose origin. Regenerated fibers of protein origin come from plant protein (such as corn, soy, alginate, and peanut), or from animal protein (such as casein from milk). Many of the new, hot eco-friendly fabrics – like Ingeo from corn and soy from soybeans – are manufactured from proteins found in plants.

Regenerated fibers of cellulose origin – bamboo, rayon, lyocell / TENCEL®, Modal® and Viscose® – are made of cellulose from tree wood and inner pith and leaves from bamboo plants using differing fiber manufacturing processes with common roots going back to France in the 1890s to produce a textile that was then called “artificial silk” or “art silk”. The textile industry adopted the term “rayon” in 1924. This family of regenerated cellulose fibers for textiles and fabrics has also been called reconstructed fibers or natural synthetic fibers. This post will be an overview of regenerated cellulose fibers and fabrics.

A Bit of Botany and Chemistry. Cellulose has been used to make fabric and clothing for millennium. Cellulose, the structural component of cell walls in green plants, is the most common organic compound on earth. Cotton is 90% cellulose and measurements of bamboo vary from 50% to 60% cellulose. Wood is composed of fibers that are 40% to 50% cellulose, 15% to 25% hemicellulose and fortified with 15% to 30% lignin. The most common organic compound on Earth, cellulose is the structural component of cell walls in all green plants. Like cellulose, hemicellulose is also a polysaccharide but hemicellulose is composed of short, weak sugar chains that can be easily hydrolyzed and decomposed by dilute acids or alkalis in water and by some enzymes. Lignin is the glue which fills the spaces in plant cell walls between the cellulose, hemicellulose and other compounds found in the cell walls. Lignin locks and sequesters atmospheric carbon into green plants and the decomposition of lignin in plants releases the trapped carbon back into the atmosphere. Generally, the higher the lignin content the harder the wood. The essential production processes for chemically manufacturing regenerated cellulose from bamboo and wood are:

  1. Preprocessing of Wood Chips and Bamboo Pith. Imagine just for a moment about what kinds of processes and chemicals it must take to “cook” hard wood chips into a soft, pliable cellulose pulp that can be transformed into a softly, flowing dress.

    To transform hard wood into silky fabric, the cellulose must be separated from the hemicellulose, lignin, and all the other sugars, starches and other compounds found in plant cells and then formed into a cellulose wood pulp. Trees from tree farms are logged, debarked, and hacked into one-inch square wood chips. Strong bases such as sodium hydroxide (caustic soda) and sodium sulfide - called white liquor - are commonly used in a process called the kraft/soda process to digest the wood chips and produce cellulose wood pulp. The resulting waste products containing the chemical wastes, lignins, hemicellulose, and other non-cellulose compounds are called the black liquor. If the color of the wood pulp requires lightening, the wood pulp can be bleached using enzymes such as xylanase enzymes from bacterial isolates or ligninolytic enzymes, or with a hydrogen peroxide solution or sodium hydrosulfate solution, or with a dilute acids such as trifluoroacetic acid, or with elemental chlorine or other chlorinated substances.

    The cellulose wood pulp is dried to produce hard sheets of purified cellulose, also known as “dissolving pulp” or “dissolving cellulose” from selected wood chips or bamboo stalks. The purified cellulose sheets are sometimes bleached with sodium hypochlorite (NaOCl) to remove remaining color. The preprocessing removes most of the lignin, hemicelluloses, free sugars, mineral salts, and starches found in plant cell walls along with cellulose. The resulting purified cellulose sheets contain 87% to 98% long-chain cellulose molecules. Wood chips that are commonly used include spruce, pine, hemlock, beech, and the leaves and inner pith of bamboo. The preprocessing chemicals and amounts used will vary according to the different types of wood.

  2. Processing of Purified Cellulose. The dissolving cellulose pulp sheets are soaked in a caustic alkali solution of 15% to 20% sodium hydroxide, also known as caustic soda, to produce sheets of alkali cellulose. The alkali cellulose sheets are shredded, aged for a few days under closely controlled temperature and humidity, and then bathed in liquid carbon disulfide which transforms the cellulose into cellulose xanthate. Excess carbon disulfide is removed to produce cellulose sodium xanthogenate which is then dissolved in a solution of sodium hydroxide creating a viscous solution.
  3. Regenerating Cellulose into Fibers. The viscose cellulose solution is aged to allow xanthate groups to revert back to cellulosic hydroxyls and free carbon disulfide, filtered to remove undissolved materials, vacuum treated to remove tiny air bubbles which could weaken the fiber strands, and then forced through spinneret heads (similar to a shower head) to create fine streams of viscose threads in a sulfuric acid bath. The sulfuric acid causes the cellulose xanthogenate to coagulate and bond into filaments of pure regenerated cellulose fibers.

  4. Drawing, Bonding, and Cleaning. The newly regenerated fibers are washed in a weak solution of sodium sulfide to remove sulfur impurities and sometimes bleached again to remove discolorations. The fibers are stretched which causes the cellulose chains to reorient along the fiber axis and allows the cellulose chains to also cross-bond as they become parallel to each other. The cellulose fibers are given a final bath to wash away lingering chemicals from the manufacturing process. The fibers are dried, and rolled onto spools for new yarn and threads.

Pulp Manufacturing Environmental Hazards & Health Problems. The preprocessing of wood chips into a cellulose wood pulp for conventional rayon fibers can be environmentally messy. Factories for manufacturing wood pulp are often not located at the same facility which later takes the dissolving cellulose pulp sheets and transforms them into rayon fibers for textile. Because the pulp manufacturing process requires large amounts of water, they are often located near large rivers. The inorganic chemicals are recovered for reuse in other pulping processes.  For more about about the recover process for pulp manufacturing, check this out.  Removing the lignins and other contaminants from wood releases large amounts of organic materials, high biological orxygen demand (BOD), dissolved organic carbon, and a variety of alcohols and heavy metals into the waste waters and into rivers if they are not properly treated.

The early manufacturing of regenerated cellulose into rayon created worker safety hazards from chemical fumes escaping during the processing and environmental hazards from harsh and toxic chemicals escaping in wash waters and waste byproducts. Strengthened environmental protection standards and worker health regulations have lead to improved manufacturing processes but most pulp producing and rayon fiber manufacturing factories are still a long way from being sustainable.

Sodium hydroxide in strong solutions used during the pulping process can be very caustic and can burn skin. Sodium sulfide can react to produce hydrogen sulfide which is a toxic gas. The bleaching process to lighten pulp color is generally the most environmentally problematic, especially if it uses elemental chlorine, chlorine dioxide, or hypochlorous acid in aqueous solution. The use of chlorine in bleaching wood pulp can result in chlorinated byproducts that are toxic and difficult to eliminate with conventional waste treatment. Bleaching processes that use hydrogen peroxide are safer for the environment and for human health.

Toxic chemicals used to manufacture cellulose wood pulp into rayon fibers must also be reclaimed or neutralized from all waste waters and a considerable amount of solid waste byproducts from the non-cellulose components in the wood. Carbon disulfide, lignin and xanthates in the waste solutions are environmental hazards and must be removed from the waste waters. Depending upon the pulping and bleaching processes, contaminants from the pulping process can span a wide range of toxicity from suspended waste solids to carcinogens like dioxins and polychlorinated biphenyls (PCBs).

The great unknown is how willing and capable is each individual fiber manufacturing facility at removing the toxicity of waste products before discharging them into community rivers and streams or dumping them into landfills. It all depends upon the host countries environmental protection laws, worker safety laws and the willingness of local government to enforce any laws that might exist.

Improved Rayon Processing. Technical advancements in rayon processing have lead to improved rayon fabrics such as high wet modulus (HWM) rayon, also known as polynosic rayon and better known by its trade name of MODAL®. Another advanced rayon is lyocel, which is better known by the Lenzing Group trade name for their highly popular TENCEL®. These technical advancements have created a rayon that is not only less prone to stretching when wet but, more importantly, they have also created a closed-loop processing that allows 99.5% of the chemical solvents to be recycled and reused and any remaining emissions and pollutants can be decomposed in waste treatment plants.

The manufacturing processes for lyocell and modal differ significantly from those commonly used to manufacture other varieties of rayon. An informed article by Angela Woodward outlines the generic lyocell / TENCEL® processes for closed-loop manufacturing as follows:

  1. Preprocessing of Wood Chips. Select hardwood logs are chipped into small pieces and feed into large metal digester tanks to be cooked at high temperatures under steam in a strong alkali chemical solution which reduces the wood chips to a pulp. The pulp is washed with water to remove the chemicals and then bleached to lighten and create a uniform color. The wood pulp is dried into sheets that are rolled into large spools which are functionally similar to the purified cellulose sheets in the generic rayon process.
  2. Processing of Purified Cellulose. The cellulose sheets are crumbled into small pieces, and cooked again in large, enclosed tanks under high pressure and temperatures in a solution of N-methylmorpholine-N-oxide or some other member of the amine oxide family to dissolve the crumbed cellulose pulp sheets into a liquid solution. The liquid solution is then filtered to remove any undissolved pulp chips.
  3. Regenerating Cellulose into Fibers. The filtered cellulose solution is forced through spinneret heads into a diluted amine oxide solution to cause the cellulose strands to set and align. The cellulose fibers are then washed in a de-mineralized water solution.
  4. Finishing. The filaments are dried and then coated with a lubricant, such as soap or silicone, so that their filaments untangle easily. This is something like applying conditioner to hair after washing. The filaments are carded so they all lay in the same direction, crimped to give the fibers body (again, think of crimping hair), the crimped and carded filaments are cut to a uniform length and baled together. The baled filaments can then be sent to fiber mills where they can be twisted into yarns and woven or knit into fabric. The whole process from processing the purified cellulose sheets to baling the regenerated cellulose fibers is supposed to take only 2 hours.
  5. Recovery of Solvents. The amine oxide is recovered from the processing solutions and reused. The recovery process is supposed to reclaim more than 99% of the amine oxide and any unrecovered amine oxide is decomposed in the waste treatment processing.

The basic manufacturing process for regenerating bamboo leaves and pith into bamboo fibers for clothing is covered in our post “Bamboo: Facts Behind the Fiber”.

The preprocessing of wood chips into pulp for the advanced cellulose fibers of lyocell, Modal and Viscose is essentially the same as for conventional rayon. The processing of the wood cellulose pulp into fiber is more sustainable than the processing used for conventional rayon because the closed-loop process is supposed to capture and reclaim almost all the chemical solvents used in the manufacturing. Also, the solvents such as N-methylmorpholine-N-oxide (NMMO) used to dissolve the bamboo or wood chip cellulose into a viscose solution are from the chemical family of amine oxides which are supposed to be environmentally less harmful.

The important point in understanding the nature of regenerated cellulose fibers is that the underlying process of extracting and purifying the cellulose cells, reducing them to a viscose solution, and then regenerating them into manufactured fibers is essentially the same regardless of whether the source is wood from trees or from bamboo. The differences in fabric properties such as texture, hand, pilling, fibrillation, and dye acceptance generally result from different chemicals and enzymes and their dilution strengths and from processing techniques used during the fiber and finishing.

To be an environmentally and socially ethical fashionista, know how your fabrics are made and then make responsible decisions.

Enjoy.

-Michael

The New Cotton Debate: What is sustainable cotton?

Cottoninclogo While rummaging through the Cotton, Inc. web site (which is a fascinating and well done site), I quickly realized that the Great Cotton Debate is being recast. During the early growth of organic clothing in the late 1990s and early 2000s, organic cotton was recognized as the healthy choice – healthy for the individual, healthy for the environment, and healthy for workers growing and harvesting cotton. Conventional cotton relied upon heavy doses of toxic chemical herbicides and pesticides. We’ve all seen the statistics:

  • Conventionally grown cotton accounts for 25% of all agricultural pesticides used in the U.S.
  • 1/3 of a pound of chemical fertilizers and pesticides is used to grow each pound of cotton harvested which is the amount of cotton needed to manufacture one cotton t-shirt;

Unfortunately, the statistics often cited about chemical pesticide usage for conventionally grown cotton are now incorrect.  They were derived from studies conducted in the 1990s such as the report from Allen Woodburn Associates, Ltd titled “Cotton: The Crop and its Agrochemicals Market” published in 1995. Since then, there has been a change in the playing field … or perhaps we should say in the cotton field.

Cottonincgreen_2 Conventional cotton is being recast as the sustainable savior and organic cotton is being portrayed as the tiny niche bungler, the old and inadequate solution that is as out-dated as last year’s fashions. The organic cotton vs. conventional cotton debate is being reshaped by the conventional cotton industry through a series of Cotton Incorporated sponsored conferences on sustainable cotton and web articles trumpeting conventionally grown as “sustainable cotton”, “an important eco-fiber”, and a fiber that is “making the eco-movement matter” while promoting claims such as:

  • Sustainability is defined “as balance between growing profitability, protecting the environment and promoting social responsibility”;
  • “Technology is the driver behind more eco-friendly agriculture and manufacturing, finding alternative fuel sources and reducing the environmental footprint”;
  • Biotechnology and the resulting genetically modified varieties of cotton are helping drive environmental improvements;
  • Recent advances in cotton manufacturing have helped the “global textile industry be more cost-efficient and environmentally-friendly”;
  • According to their three requirements for sustainability, conventional cotton production has become sustainable and conventional cotton now qualifies as sustainable cotton;
  • Cotton grown by conventional agricultural methods is renewable, biodegradable and environmentally-friendly – all adding to their claims for sustainability;
  • Conventionally grown cotton has become more drought- and heat-tolerant and requires less chemicals and pesticides;
  • Environmentally-concerned consumers are more apt to buy conventionally-grown, sustainable cotton textiles over organic cotton because of the greater selections in styles and designs;
  • Organic cotton will never be a viable option for large retailers such as the British department store chain Marks & Spenser because it “costs upwards of 100 percent more than conventionally grown cotton due to lower yields, a segregated supply chain and reliance on manual labor …”;
  • "Organic" is a limited term that doesn't adequately address spent energy and resources across all phases of cotton growing, ginning, spinning and fabric manufacturing.

Conventionally grown cotton has undergone an amazing PR transformation from being the most heavily poisoned crop on the face of the earth to being proclaimed the new sustainable eco-fiber. There are several factors that have contributed to this astounding morphing:

    1. Improvements in general agricultural practices such as integrated pest management practices, no-till farming (reduced soil erosion and lower carbon emissions from farm tractors) and lateral move irrigation (improved irrigation efficiency resulting in lower water consumption). The integrated pest management practices are teaming up with improvements in pesticides (comprised of insecticides, herbicides and fungicides) that allow for lower application levels and more targeted application. The improved pesticides are not necessarily less toxic or harmful to workers or the environment;
    2. Improvements in textile manufacturing facilities and processes to reduce toxic chemicals lost in waste waters and released into the environment;
    3. And the most important and ubiquitous factor is the rapidly increasing use of GMO cotton seed stock in U.S., Australia, India and China. The International Service for the Acquisition of Agri-biotech Applications (ISAAA) estimates that in 2005 about 28% of the global cotton field acres were planted in transgenic GM cotton, according to “Cotton Outlook to 2010-11” by Drum, Roberts and Smirl. The USDA reports that 87% of the U.S. cotton crop was genetically engineered in 2007.

All three of these factors apply to other major conventionally grown crops such as corn and soybeans. But the self-proclaimed advances toward sustainability and environmental friendship in conventionally grown cotton are largely founded upon the conversion of conventional cotton to GMO cotton fields. We have reviewed the GMO cotton issues in our post Perspectives on GM Cotton.

Claims for conventional GMO cotton sustainability are based upon the generic three-cornered definition of sustainability: growing profitability, environmental protection, and social responsibility. Let’s look at these three self-proclaimed sustainability factors.

Growing profitability – the promise.  Cotton yields – and therefore farmers’ income and profitability – are threatened by three major forces: insects, weeds, and weather. Bio-engineering companies, such as U.S. biotech giant Monsanto, have invested heavily in developing Bt cotton seeds, which have been genetically modified to contain a slice from the insecticidal gene Bacillius thuringiensis (Bt) to make it resistant to insect pests such as the bollworm. The theory being that when insect pests eat and digest the Bt cotton plant the Bacillius thurengiensis bacteria spliced into the genetically modified Bt cotton will cause a lethal paralysis in the digestive tract of the devouring insect.

Competition in weed-infested fields can reduce cotton yields by 50% or more. The biotechnology solution has been to genetically modify cotton to become resistant to herbicides so that weed killers can be liberally applied to cotton fields to kill the weeds without doing in the cotton. Monsanto developed herbicide-tolerant (HT) cotton plants that would be tolerant to Monsanto’s widely used Roundup herbicide. Roundup contains the active ingredient glyphosate, the most commonly used herbicide in the U.S. and widely used globally. The isopropylamine salt in glyphosate kills actively growing plants by inhibiting an enzyme involved in the synthesis of selected amino acids needed for plants to grow. Monsanto has genetically engineered genes into cotton seeds that allow the growing GMO cotton to be resistant to the Roundup that is applied to fields of cotton. The Roundup kills growing weeds but doesn’t affect the “Roundup Ready” GMO cotton.

While improvements in agricultural practices are helpful, a report by the Foreign Agricultural Service of the USDA reveals that many conventional cotton farmers in Brazil believe that the key to increased yields and therefore increased profitability is in large-scale plantings of GMO cotton. This promise has been sold to cotton farmers and producers across the globe. In Brazil where GMO cotton was recently legalized, cotton farmers converting to GMO Bt cotton seed and Roundup-ready cotton varieties are lead to expect cost savings of 15-30% due to reductions in manual labor costs and herbicide usage needed to control weeds.

Burkina Faso, the largest cotton producing country in Africa, has been conducting studies supported by the U.S. biotech giant Monsanto on GMO cotton since 2003 and plan to begin large scale commercial cotton growing in 2009. GMO cotton has already been introduced into South Africa and Egypt. Government leaders in Burkina Faso believe that they must use GMO cotton to achieve higher production efficiencies that will allow their poor cotton farmers to compete more effectively with developed countries such as the U.S. where cotton is subsidized by the U.S. government. This is the promise.

Growing profitability – the results.  The economic benefits to cotton farmers of GMO cotton have been hotly debated.  India passed legislation in 2002 opening the door for GMO cotton into India’s quickly blooming cotton agriculture. In 2007 an estimated 19% of the global cotton production came from India with per acre cotton yields and total number of acres in planted in GM cotton steadily increasing. Most cotton in India iis grown on small farms. A survey funded by Monsanto reported that Indian GMO Bt cotton farmers in 2004 harvested 58% more cotton per acre with net profits 163% greater than non-GMO conventionally grown cotton. Other biotech-industry funded studies proclaimed similar results in South Africa and the U.S.

A comprehensive study by Friends of the Earth International titled “Who Benefits from GM Crops?” attempts to examine the complex issues surrounding genetically modified crops and sort out cause and effect, fact and fiction, hype and actuality. Their primary findings were that the positive results from the studies most often cited by Monsanto funded studies were largely due to favorable weather and rain during the study period and improvements in irrigation. The Friends of the Earth study reported that GMO cotton farmers’ costs actually increased over time rather than decreased because GM seeds are more expensive than conventional cotton seeds and farmers actually used more expensive herbicides than they did previously while still requiring significant levels of insecticide spraying.

An extensive and independent survey, “Economic Impact of Genetically Modified Cotton in India” by Bennett, Ismael, Kambhampati and Morse of the University of Reading in the UK, compared Bt and non-Bt cotton production in the Indian state of Maharashtra across 7,751 cotton plots in 2002 and 1,580 cotton plots in 2003. The results indicated:

1. Bt cotton yields were at least 45% higher than for non-Bt cotton;

2. The amount and costs of insecticides needed to control aphids and other sap sucking insects pests were the same for Bt and non-Bt cotton fields;

3. The amount and costs of insecticides needed to control bollworms were 70% to 80% lower for Bt cotton fields than for non-Bt cotton fields;

4. The costs for conventional non-BT cotton seeds are only one third the price of Bt cotton seeds for planting and farmers are prohibited by the large chemical seeds companies such as Monsanto from saving seeds from their harvest for planning next year. Every year, cotton farmers must buy new, expensive Bt seeds from the GM seed companies;

5. The costs of seeds plus the cost of insecticides is slightly higher for Bt cotton crops compared with non-Bt cotton crops. Higher yields for Bt cotton enable Bt cotton to be more profitable.

While the Bennett, et al. study is comprehensive with a well designed methodology and lacking any apparent bias, it is also significant in what isn’t in the study. The study did not compare Bt cotton costs with organically grown cotton nor did it consider the costs of conventional non-Bt cotton when the farmers use their own seed harvested from their previous crop. The study also did not address environmental costs or field worker health costs from herbicide and insecticide toxic chemical sprays. Issues of GMO safety and long-term considerations were also not part of the study. The study examined only economic effects of Bt cotton and did not examine issues of herbicide-tolerant (HT) generically modified cotton. Herbicide-tolerant cotton has been genetically modified to resist weed sprays, specifically Monsanto’s costly Roundup weed killer. Herbicide-tolerant (HT) cotton plants allow farmers to liberally use Monsanto’s popular Roundup weed spray to kill weeds sprouting up in cotton fields. Strains of weeds are developing which are resistant to Roundup. Also, the study only looks are results for the first two years of commercial planting of Bt cotton in one state in India. A longer, multi-year study is necessary to evaluate longer term effects.

As a note concerning insecticide usage on Bt cotton, three different categories of insects plague cotton – chewing caterpillars and cutworms which eat leaves and stems of the cotton plant; insects such as bollworms and boll weevils which attack and feed on the fluffy white cotton bolls; and sucking aphids and mites which pierce the cotton plant leaves and stems to suck the sap from the plant. The types and severity of cotton insect pests varies from local to global regions. Bt cotton with its genetically implanted soil bacterium gene is resistant to bollworms, a major cotton pest in the U.S., but not to the other insects which feast upon cotton plants and cotton bolls. Depending upon the region, Bt cotton must still be sprayed with insecticides to control for the other categories of insects.  The resistance of Bt cotton to bollworms is not total, however, and Bt cotton still requires spraying with insecticides but at a much lower level of application to control for bollworms.

Another evolving concern affecting long-term profitability of GM cotton is that Nature is adaptive and over time bollworms and other insects will develop insect strains that are resistant to the toxins in Bt cotton. An extensive study by Gould, et al. of the Department of Entomology at North Carolina State University, published in the Proceedings of the National Academy of Science reported that within a few years varieties of bollworms were being naturally selected that have a resistance to the Bt toxins. With farmers exercising careful pest management techniques, the period of naturally selective resistance could be delayed for a few more years but insects developing Bt resistant strains are inevitable. The more effective pest management techniques involved planting 4% of their cotton crop in non-Bt refuge zones to harbor susceptible insects and slow down the evolution of pests resistant to the Bt gene.

Protecting the environment – the promise. The second pillar of the conventionally grown cotton industry’s claim to sustainability is in their assertion to protecting environmental quality. The premise of the promise for improved environmental stewardship by the conventional cotton industry is in attempting to transform their image from being a toxic chemical polluter to sustainability by reducing and improving their environmental impact in the cotton field and in the manufacturing factory.

In the cotton field, growers are encouraged to implement soil conservation techniques such as no-till farming and improved irrigation to reduce soil erosion and integrated pest management techniques to better control insect pest. Most of these farming techniques are also practiced by organic cotton farmers. Cotton farmers in the U.S. and globally are being heavily pressured to plant GM cotton seeds from the large chemical biotech companies such as Monsanto. The promise is that Bt cotton will require lower levels of costly and environmentally harmful insecticides.

Protecting the environment – the results.  A short history of the genealogy of pesticide families will help to understand the issues of sustainability swirling around cotton. Pesticides refer collectively to chemical herbicides used against herbs or plants considered weed pests, insecticides used against insect pests, and fungicides used against fungi which can grow on cotton plants reducing their vitality and yield. Pesticides are a cornerstone of conventional cotton agriculture which credits pesticides with reducing cotton pests and increasing cotton yields, but the damage to the health of the environment, wildlife, field workers, and nearby communities has been considerable and well documented. In a report “Problems with Conventional Cotton Production” the Pesticide Action Network of North America (PANNA) warns that “these pesticides can poison farm workers, drift into neighboring communities, contaminate ground and surface water and kill beneficial insects and soil micro-organisms.”

Because of environmental protection regulations in the U.S. and countries around the world, new classes of chemical pesticides are continually being developed which are applied at lower rates of active ingredients per acre of cotton grown. These newer classes of chemical pesticides still contain toxic and hazardous chemicals but the environmental and health impacts have been reduced. A meaningful interpretation of any global reductions in pesticide usage over time is difficult because of vast differences in geographies, climates, agricultural practices, cultures, the changing active ingredients in pesticides, and the ever-changing nature of threats from local pest. A study title “Global Impact of Biotech Crops: Socio-Economic and Environmental Effects in the First Ten Years of Commercial Use” by Brookes and Barfoot of PG Economics Ltd (a private consultancy largely funded by the biotech industry) estimated that GM insect-resistant cotton has reduced insecticide usage by 19.4% with a corresponding Environmental Impact Quotient (EIQ) reduction of 24.3% during the period of 1996 to 2005. The Environmental Impact Quotient (EIQ) was developed by Kovach, Petzoldt, Degni and Tette of the Integrated Pest Management Program at Cornell University. The EIQ provides a standardized method for calculating the environmental impact for various agricultural pesticides and pest management systems.

A study title “Do GM Crops Mean Less Pesticide Use?” by Charles Benbrook of the Northwest Science and Environmental Policy Center analyzed official U.S. Department of Agriculture (USDA) data on GM crops grown in the U.S. from 1995 through 2000 and concluded that “Bt cotton has reduced insecticide use in several states.” Benbrook points out the difficulties in identifying cause-effect relationships in multi-year multi-state cotton insecticide use trends. Bollworm-budworm complex insecticide usage in some states went down and in other states went up. The data suggests that Bt cotton was a significant factor in declines in some states but not in others. In some states with high Bt cotton adoption, insecticide usage actually increased, and some low-adoption Bt cotton states saw a marked reduction in bollworm-budworm insecticide treatments.

Benbrook states that the data overall indicates that GM cotton reduces insecticide applications but that bio-engineering is only one factor and that sustainable pest management requires a total system approach. An important consideration in a sustainable pest management system is in ways to reduce the concentration and use of pesticides – applied externally in sprays and also bio-engineered into the genes of cotton plants – to delay the rise of pesticide resistance in insects and weeds.

Besides environmental protection regulations from governments, another motivating factor for chemical pesticide manufacturers to develop new classes of pesticides is because natural selection begins to develop strains of insects and weeds resistant to the popular pesticides du jour. Resistance to specific pesticides is governed by many factors but typically tends to develop within four to ten years depending upon the degree to which the pesticide is used. Generally, the more a pesticide is used in an area, the more quickly resistant strains of insects will begin developing. A central focus of integrated pest management systems is to delay the rise of pesticide resistant insects and weeds.

The study by Brookes and Barfoot also suggests that GM cotton reduces the level of green house gas (GHG) emissions by requiring fewer pesticide sprayings by crop dusting spray airplanes or tractors and soil tillage that use fuel guzzling farm tractors with their supporting fleet of trucks to deliver pesticides and operators to the fields. They also report that “no-till and reduced-till farming systems that utilize less plowing increase the amount of organic carbon (in the form of crop residue) that is stored or sequestered in the soil. This carbon sequestration reduces carbon dioxide emissions to the environment.” Of course, no-till farming practices are not unique to GM crops and havelong been a component of organic farming.

Conventional cotton (including GM cotton) plants are sprayed with a variety of harvest-aid chemicals to help improve cotton harvesting yields, preserve high fiber quality before cotton bolls can become ruined by late-season insect damage, and to improve cotton harvest efficiencies. Conventional cotton harvest-aid chemicals include chemical defoliants which cause the cotton plants to shed their foliage allowing the cotton bolls to be more effectively machine harvested. Chemical defoliants are composed of reactive organic compounds and volatiles which lead to increased air pollution and have an adverse environmental impact. The organic cotton and the conventional cotton industries are researching environmentally healthy defoliation methods such as thermal defoliation which “eliminates water and air pollution caused by harvest-aid chemicals, reduces the need for insecticides, protects the crop from insect sugar deposits and is independent of the weather.”  A hot blast of typically propane-fired air in what is essentially a moving furnace wilts tender leaves on cotton plants and also kills insects, parasites and possibly some plant diseases.

Depending upon weather, time-of-year, and cotton plant condition, the conventional cotton industry uses a variety of harvest-aid chemicals to prepare cotton for harvesting. The University of California Integrated Pest Management Program has categorized and detailed the wide range of harvest-aid chemicals that are sprayed on cotton fields to:

  1. Defoliate cotton plants by using chemicals that disrupt plant growth hormones causing leaves to die and drop so that automated machines can pick the cotton bolls more easily;
  2. More quickly strip leaves from plants by using chemical desiccants which are more severe than defoliants and cause leaf dehydration and death within a couple days. Desiccants are often applied as a follow-up after application of defoliants;
  3. Encourage late blooming cotton bolls to open earlier so that cotton harvesters can make only one pass over cotton fields. It has also been found that these chemicals can also reduce vegetative re-growth;
  4. Inhibit new growth on cotton plants nearing harvest or to help enhance the effects of defoliants

Many of the harvest-aid chemicals are listed in the Pesticide Action Network as being possible carcinogens, ground water contaminants, cholinesterase inhibitors, and moderately to highly toxic. Harvest-aid chemicals are included in computations of conventional cotton pesticide usage.

Does GM and conventionally grown cotton improve the environment? The studies indicate that it hurts the environment less than it did a decade ago but to what degree is difficult to quantify. The Institute of Science in Society published a press release in 2007 “Picking Cotton Carefully” which declared that “conventional and GM cotton accounts for 16 percent of global chemical pesticide use, more than any other single crop.” Considering the rising degree to which rivers, streams and ground water systems are testing positive for toxic chemicals used in cotton pesticides, it is very difficult to justify how conventional cotton agriculture could be considered sustainable. Improved farming techniques – many of which have also been incorporated in organic agriculture – have also reduced farming’s environmental impact. And then there is the unknown impact of biotechnology and genetic modification on the environment and the health and safety of people.

Promoting Social Responsibility – the promise. The textile and garment industries have long been plagued by unethical labor practices from child labor in fields and factories and sweatshop factories to unfair and exploitive purchasing of clothing and textiles produced by native and indigenous peoples. Change will only occur when consumers, manufacturers, retailers and governments demand fair and healthy labor practices.

Another aspect of social responsibility is in maintaining community welfare and health by respecting the environment and not polluting the air, water and land that communities depend upon, and also by insuring the health of the community members who work the fields and factories.

Promoting Social Responsibility – the results. When these abuses are exposed in the media, the garment industry in general and specifically the large retailers buying from sweatshop-tainted manufacturers are displayed in a very bad light. In an attempt to convince consumers and shareholders that they are really good global citizens, most large clothing manufacturers and retailers have adopted Corporate Social Responsibility (CSR) statements to explain how they will monitor for and avoid abusive labor practices among their suppliers and manufacturers … while still maintaining high investor returns. Our post “The Fog of CSR” has gone into these issues.

The result has been that clothing manufacturers and large chain retailers have become much for sensitive and responsive to charges of sweatshops and child labor. Many have teamed with independent and ethical organizations to help monitor and reduce abuses and there have been improvements. Large retailers, such as Wal-Mart in the U.S. and Marks & Spencer in the U.K., are encouraging farmers in developing countries to adopt restrictions in child-labor and reduce pesticide usage. Large corporations are beginning to realize that greening their product lines and reducing their corporate environmental footprint is good business and helps to reduce their costs and improve operating efficiencies.

Fairtradelogo_copy Fair trade is another concern of the ethical shopper (see our post “Ethical Shopping and Fair Trade”). Independent non-profit organizations such as the Fairtrade Foundation offer fair trade certification so shoppers can have confidence that marginalized producers and workers in developing countries received a fair and sustainable wage for their products and labors.

Ms_fairtrade_tshirt Marks & Spencer offers a number of Fairtrade certified cotton clothes.

Almost all organic clothing standards such as Control Union’s Global Organic Textile Standard (GOTS) identify minimum social criteria that a textile must meet as part of the overall requirements to achieve organic textile certification. These include freely chosen employment, collective bargaining, safe and healthy working conditions, no child labor, a fair wage, reasonable working hours, and a non-discriminatory and non-abusive work environment. Note that these ethical social standards apply to textile manufacturing and processing and not to the fields that grow the natural fibers.

Better_cotton_initiative_logo The Better Cotton Initiative was founded to take it to the field and “promote measurable improvements in the key environmental and social impacts of cotton cultivation worldwide to make it more sustainable (economically, environmentally, and socially).” Social responsibility must also include safeguarding the community welfare from toxic pesticides that threaten community water supplies and the health of workers and families that live near sprayed crop lands. Reducing and eliminating pesticides on crops is an important component of a social responsibility agenda.

So how does conventional cotton shape up to the social responsibility factor in their sustainability equation? Improving but still a long way to go. Textile manufacturers and retailers seem to be trying to improve working conditions in manufacturing and garment factories but they face an inherent conflict of interest between the increased costs necessary to improve social responsibility and the need to improve profits by lowering costs. Consumer pressure will be key in the future.

Considering community welfare, as long as toxic pesticides are sprayed on cotton fields there will be community health problems which detract from any claims of sustainability.

Final score on conventional cotton sustainability. With improved soil and pest management agricultural practices and some improvements in reducing the chemical toxicity of pesticides, conventionally grown cotton has improved but still hasn’t achieved any common definition of sustainability addressing trade, good environmental stewardship, and social responsibility.

A thorough and comprehensive study in 2006 by Kooistra, Termorshuizen and Pyburn of Wageningen University titled “The Sustainability of Cotton” reported that cotton is grown globally on about 2.4% of the world’s farm lands but consumes an estimated 11% of the agricultural chemical pesticides. Cotton plants are more sensitive to insects than most other crops and tend to be more heavily sprayed. Many developing countries which grow cotton do not monitor or poorly regulate pesticide use and many of their pesticides are stronger and more toxic than pesticides approved for use in the U.S.

Kooistra et al. report that “worldwide 15% of cotton yield loss is due to insect damage”. Integrated Pest Management programs can contribute to significant reductions and perhaps elimination of hazardous chemical pesticides. Pressure will also increase on cotton farmers to fight the insect and weed threats by planting GM cotton.

Conventionally grown cotton is still one of the most chemically sprayed crops in the U.S.  In May 2006, the U.S. Department of Agriculture released a report “Agricultural Chemical Usage 2005 Field Crops Summary” for the major U.S. crops. For all U.S. corn crops, 2.124 pounds of pesticides were used per acre; for all oats, 0.166 pounds pesticides per acre; for all soybeans, 1.23 pounds of pesticides per acre; for cotton (upland), 4.486 pounds of pesticides per acre of cotton. An acre of conventionally grown cotton requires more than twice the dosage of chemical pesticides as corn, the next highest consumer of chemical pesticides. It’s interesting to note that in 2005, almost 80% of the U.S. cotton crop was from genetically engineered cotton seeds. In 2007, the USDA estimated that 87% of the U.S. cotton crop was genetically modified. In some locals, herbicide-resistant GM cotton actually increased herbicide usage. Where previously, cotton farmers used spot spraying to attack localized outbreaks of weeds, they now sprayed the entire field because there wasn’t the concern about affecting the cotton plants with the herbicide and it was more cost-effective.

Using the USDA statistics from 2005, we calculate that 0.0947 oz of pesticides is used to grow one pound of conventionally grown U.S. cotton. When 2005 synthetic fertilizer usage (nitrogen, phosphate, potash and sulfur) is included in the calculation then the combined synthetic fertilizer and pesticide usage is 2.85 ounces per pound of conventionally grown cotton, and is considerably less than the 5 ounces reported in the late 1990s.  This is in keeping with the 0.08637 ounces calculated by Coral Rose of Eco-Innovations and published in her Sustainable Action Leadership blog and the pesticide usage per pound of cotton reported in the Cotton Incorporated site.

Conventionally grown cotton will need to improve its environmental impact through improved pest management and will need to reduce and eventually eliminate hazardous chemical pesticide usage before it can approach sustainability. Hazardous chemical pesticide usage is not sustainable.

And then there is also the little issue of bio-engineered, genetically modified cotton. The Global Organic Textiles Standard prohibits “genetically modified organisms (GMO’s) and their derivatives (including enzymes derived from genetically modified micro-organisms).” The SKAL International Standards for Sustainable Textile Production states that all agricultural fibers have to “originate from an organic production method that is recognized by Control Union Certifications” and all organic production methods exclude genetically modified plants.

When you hear claims of "sustainable" always look upon the cotton kimono to see what it really means.

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