The poultry industry produces a considerable amount of waste. In Europe alone, around three million tonnes of feathers are produced every year, which are either incinerated or processed into low-quality animal feed. But feathers can do more: whether as a raw material for the production of adhesives, as a component of fuel cells or as an insulating material for cold chain logistics, the feather-light natural product can be used in a variety of applications.
Feathers are made of keratin, a chemically resistant and physically solid protein that is also of interest to scientists. Researchers at the Fraunhofer Institute for Interfacial Engineering and Biotechnology (IGB), for example, have developed a process in a joint project with global adhesives market leader Henkel that extracts the bio-based raw material keratin from feathers and then uses it to produce a new product. as a starting material for the production of various adhesives can be used for various applications. Chicken feathers can even make electricity greener: Researchers at ETH Zurich and the Singapore University of Technology (NTU) have succeeded in converting the protein keratin from feathers into extremely fine fibres known as amyloid fibrils. These are then used in the centrepiece of a fuel cell, a semi-permeable membrane, where they replace toxic chemicals.
Thanks to their microscopically small, hollow fibre structure feathers are among the lightest natural fibres of all and are excellent heat insulators. The founders of the west London-based start-up Aeropowder were therefore certain that there must be a better use for surplus feathers than disposal and developed a sustainable insulating material. PluumoPlus is the world's first sustainable insulation material made from feathers. The patent-pending insulating material utilises the natural insulating properties of feathers and is intended to replace expanded polystyrene as a thermal packaging material. Possible areas of application initially include the storage and transport of temperature-sensitive goods, such as therapeutics and medicines. According to the manufacturer, the sustainable material is able to maintain an internal temperature of 2 to 8 °C for 72 hours, even if the outside temperature averages 30 °C during this period.
Lightweight natural fibres insulate well
Before the insulation material is manufactured, the springs are first cleaned and treated in accordance with international hygiene standards. Then they can be wrapped with a starch-based outer film and finally processed into PluumoPlus liners. Aeropowder collaborated on product development with Indorama Ventures Fibers Germany GmbH, which Binding fibres made from two different biopolymers developed for the new product. The collaboration has made it possible to produce a fully biodegradable insulating material. In practice, the use of two PluumoPlus liners in a delivery box and another thinner liner enclosing the payload creates a robust thermal barrier that protects the temperature-sensitive contents.
Financing secured for the market launch
The start-up has currently Investment of 150,000 pounds from the British Design Fund and now wants to use the cash injection for the market launch of PluumoPlus. Damon Bonser, CEO of the British Design Fund: „Aeropowder fulfils all the criteria for us. They are a creative and ambitious team developing an innovative product range that has the potential to have a positive impact globally. Innovations like these that support the transition to sustainable materials are very important.“ The British Design Fund is a British early-stage investor in the manufacturing sector and supports ambitious start-ups on their growth path.
„The investment from the British Design Fund will be instrumental in enabling us to manufacture our first batches of PluumoPlus and deliver them to customers in the pharmaceutical and logistics sectors who are already waiting. Over the next twelve months, we will then focus on expanding production capacity for PluumoPlus and further spring-based product development.“
Dr Ryan Robinson, biologist and Aeropowder co-founder
