A research team from the University of British Columbia has developed a new method for producing rayon, a widely used fabric, that could reduce chemical solvent use by up to 70%. This innovative approach aims to enhance sustainability within the textile manufacturing industry. The findings were published on December 4, 2025, in the journal Chem Circularity.
Traditionally, the production of synthetic cellulose fibers, like rayon, requires the complete dissolution of cellulose using harsh chemicals. This process poses significant environmental challenges due to the toxicity and energy demands associated with the solvents used. The UBC team, led by associate professor Dr. Feng Jiang and doctoral student Huayu Liu, has shifted this paradigm by utilizing microfibrillated cellulose (MFC), which consists of tiny strands of cellulose that can be produced with minimal chemical processing.
The researchers discovered that by incorporating a small amount of softened, dissolved cellulose into the MFC, they could create a natural binding agent. This innovative technique allows the fibers to connect and twist together, producing a strong, continuous thread suitable for weaving and knitting. Liu stated, “What we found is that we don’t actually need to dissolve cellulose completely to get continuous fibers. By dissolving only a portion of it, we can reduce the amount of solvent needed by as much as 70%—and we can recycle all of it.”
The new method not only minimizes chemical usage but also simplifies the overall production process. It eliminates several steps typically involved in bleaching and chemical treatments that further contribute to environmental degradation. Dr. Jiang emphasized the importance of these findings: “Making man-made cellulose fiber with less chemical input and far lower environmental impact is a meaningful step. Sustainability isn’t only about the final material—it’s about sourcing the raw material responsibly and ensuring the entire process avoids toxic solvents and minimizes pollution.”
As of now, the fibers have been produced at a laboratory scale. The research team is currently exploring opportunities to scale up production and has partnered with Kwantlen Polytechnic University to test the practical applications of their fibers in fabric manufacturing. Dr. Jiang expressed optimism about the potential of this research, stating, “We hope these fibers will eventually be used for sustainable clothing and fabric manufacturing. This research shows that a more circular, lower-carbon pathway for textiles is possible.”
The developments at UBC mark a significant step towards more sustainable practices in the textile industry, aligning with global efforts to reduce environmental impact and promote responsible manufacturing processes.
