The Rise and Fall of Nylon: How a Synthetic Fabric Changed the World
Have you ever wondered what your clothes, carpets, toothbrushes, parachutes, and tires have in common? They are all made of nylon, one of the most widely used synthetic fabrics in the world. This fabric is strong, durable, flexible, and resistant to abrasion, moisture, and mildew. It is also versatile and can be found in many products, from fashion to aerospace. But how is it made, and what are the environmental impacts of its production and use?
Nylon was the first fabric made entirely in a laboratory, and its invention marked the dawn of the age of synthetics. It was developed by the DuPont company in the 1930s, as a cheaper and more durable alternative to silk. Initially it was used for women’s stockings, but soon found many other applications, especially during World War II, when it was used for military products such as parachutes, ropes, and tents. So it became a symbol of innovation, modernity, and convenience, and its popularity continued to grow in the post-war era.
However, nylon also has a dark side. As a synthetic polymer derived from petrochemicals, its production is associated with various environmental problems, such as greenhouse gas emissions, water consumption, chemical pollution, and waste generation. Also it is not biodegradable, which means that it can persist in landfills and oceans for hundreds of years, and release harmful microfibers into the environment. Therefore it is a major contributor to the global plastic crisis, and poses a threat to the health of humans, animals, and ecosystems.
In this blog post, we will explain how nylon is made from raw materials to finished fabric, and what are the environmental impacts of this process. We will also discuss some of the alternatives and solutions that are being developed to make it more sustainable and eco-friendly. We hope that this post will help you understand the hidden costs and inspire you to take action to reduce your consumption and waste.
What is Nylon and How is It Made?
Nylon is a type of plastic derived from crude oil. It belongs to a family of materials called polyamides, which are composed of repeating units of carbon, hydrogen, nitrogen, and oxygen atoms.
To make it, two types of molecules are combined in a chemical reaction called condensation polymerization. One molecule is a diamine, which has two amino groups (NH2) at each end, and the other is a dicarboxylic acid, which has two carboxyl groups (COOH) at each end. The most common form, being nylon 6,6, is made from hexamethylenediamine and adipic acid, which have six carbon atoms each. When these molecules react, they form a long chain of nylon, with water as a by-product.
The nylon chain can then be melted and extruded through a spinneret, which is a device with tiny holes that shapes the molten nylon into thin filaments. The filaments are then stretched, cooled, and wound onto spools. These filaments can be woven or knitted into fabrics, or further processed into other forms, such as bristles, films, or fibers
What are the Environmental Impacts of Nylon Production
It may look sleek and stylish, but it comes at a high environmental cost. The production is a dirty and wasteful process that consumes a lot of resources and pollutes the planet. Let’s take a look at some of the numbers:
- Nylon production emits 5.43 kg of CO2 per kg of fabric, which is more than any other fabric, including cotton, polyester, or wool. That’s like driving a car for 13 miles for every kg of nylon you buy!
- It uses 70 liters of water per kg of fabric, which is less than cotton, but still a lot more than polyester or wool. That’s like flushing a toilet 14 times for every kg you buy!
- The production relies on various chemicals, such as sulfuric acid, nitric acid, and hydrogen peroxide, which can harm the air, water, and soil. That’s like dumping a bucket of toxic waste for every kg you buy!
- Additionally it generates a lot of waste, such as spent acid, sludge, and scrap fibers, which need to be disposed of properly. That’s like throwing away a bag of trash for every kg you buy!
As you can see, the production is a major contributor to global warming, water scarcity, environmental degradation, and human health risks. Nylon is not only bad for the environment, but also for you and me.
Nylon Alternatives and Solutions: Recycled and Bio-based Nylon
Since it is not a very sustainable or eco-friendly fabric, there are some ways to make it better. Here are some of the alternatives and solutions that are being developed or implemented:
Recycled nylon
It is made from waste materials, such as fishing nets, carpets, or plastic bottles. Recycled nylon helps to save resources and prevent pollution, by reducing the need for new petrochemicals, energy, water, and CO2 emissions. It also helps to protect marine life from entanglement or ingestion by waste. It is used for products such as swimwear, activewear, bags, and accessories.
Bio-based nylon
This alternative is made from renewable sources, such as vegetable oils, sugars, or starches. Bio-based nylon helps to lower the environmental impact, by reducing the dependence on fossil fuels, greenhouse gas emissions, and water consumption. It also has the potential to be biodegradable, which means that it can decompose naturally in the environment. It is used for products such as clothing, footwear, and cosmetics .
These are some of the ways to make nylon more sustainable and eco-friendly, but they are not perfect. Recycled nylon still requires energy and chemicals to process, and it is not biodegradable. Bio-based nylon is still expensive and scarce, and it may compete with food crops for land and water. Therefore, the best way to reduce the environmental impact is to consume less, reuse more, and recycle properly.
Polyester Comparison: How Polyester Differs from Nylon in Terms of Properties, Performance, and Environmental Impact
Polyester and nylon are both synthetic fabrics that are widely used in the fashion industry. They have some similarities, such as strength, durability, flexibility, and resistance. However, they also have some differences, such as:
- Polyester is made from ethylene glycol and terephthalic acid, while nylon is made from hexamethylenediamine and adipic acid. These are different types of petrochemicals that have different impacts on the environment.
- It is more hydrophobic than nylon, which means that it repels water and dries faster, but it also absorbs more oil and stains. This affects the washing and cleaning of the fabrics, and their interaction with the skin and other substances.
- Polyester is more resistant to UV rays and sunlight than nylon, which means that it fades less and lasts longer, but it also generates more static electricity and pilling. This affects the appearance and comfort of the fabrics, and their potential to attract dust and lint.
- The melting point of polyester is a higher than nylon, which means that it can withstand higher temperatures and ironing, but it also releases more harmful gases when burned. This affects the safety and disposal of the fabrics, and their contribution to air pollution and greenhouse gas emissions.
According to a study by the Textile Exchange, polyester production emits about 5.43 kg of CO2 per kg of fabric, which is the same as nylon. Polyester production also consumes about 60 liters of water per kg of fabric, which is less than nylon. However, polyester production also uses various chemicals, such as antimony, cobalt, and manganese, which can pollute the air, water, and soil. Moreover, polyester production generates a lot of waste, such as plastic pellets, sludge, and scrap fibers, which need to be disposed of properly.
Polyester is also not biodegradable, and it releases microplastics into the environment. According to a 2020 study at UC Santa Barbara, approximately 176,500 metric tons of synthetic microfibers, such as polyester and nylon, are released each year. These microfibers can harm the health of humans, animals, and ecosystems, by entering the food chain, the water supply, and the air.
Therefore, polyester is not a very sustainable or eco-friendly fabric, and it has similar or worse environmental impacts than nylon. Some of the ways to make polyester more sustainable and eco-friendly are to use recycled polyester, bio-based polyester.
Conclusion: How to Reduce Your Nylon Footprint and Make More Eco-Friendly Choices
Finally it is a synthetic fabric that has many advantages, such as strength, durability, flexibility, and resistance. However, it also has many disadvantages, such as high environmental impact, low biodegradability, and microfiber pollution. The production and use contribute to global warming, water scarcity, environmental degradation, and human health risks. Therefore, we need to be more aware of the hidden costs and take action to reduce our footprint and make more eco-friendly choices.
Some of the ways to make this fabric more sustainable and eco-friendly are to use recycled nylon, bio-based nylon. These alternatives and solutions can help to save resources, prevent pollution, and support the health and well-being of people and the planet. However, they are not perfect, and they may have some limitations and challenges. Therefore, the best way to reduce the environmental impact is to consume less, reuse more, and recycle properly.
How to Learn More About Nylon: FAQ
What is nylon and how is it made?
Nylon is a type of synthetic fabric made from petroleum-based chemicals. It belongs to a family of polymers called polyamides, which have repeating units of atoms linked by amide bonds. The fabric can be molded into everyday products or drawn into fibers for making fabrics.
Nylon is made by a process called polymerization, which involves combining small molecules called monomers into long chains called polymers. The most common monomers used to make it, are adipic acid and hexamethylene diamine, which form nylon 6,6. Other types can be made by using different monomers or adding other substances to modify the properties of the polymer.
What are the properties and uses of nylon?
Nylon has many desirable properties, such as high strength, durability, elasticity, abrasion resistance, water resistance, and low moisture absorption. On the other hand it also has some drawbacks, such as low breathability, tendency to pill, and susceptibility to damage by heat, sunlight, and acids.
This fabric is widely used in various applications, such as clothing, sportswear, lingerie, stockings, carpets, upholstery, parachutes, ropes, tents, and fishing nets. It is also used to make other synthetic materials, such as Kevlar and Nomex, which have special properties such as bulletproofing and fire resistance.
Who invented nylon and when?
It was invented by a team of chemists at the DuPont Corporation in the United States in the late 1930s. The leader of the team was Wallace Carothers, who is considered the father of synthetic polymers. Nylon was first introduced to the public at the 1939 World’s Fair in New York, and it soon became a popular and versatile material.
How to care for, dye, print, and sew nylon?
Nylon is easy to care for, as it can be machine washed and dried at low temperatures. However, some precautions should be taken to avoid damaging the fabric, such as using mild detergents, avoiding bleach and fabric softeners, and ironing at low settings. It should also be stored away from direct sunlight and heat sources, as they can cause fading and deterioration.
By using acid dyes it can be dyed, which are water-soluble dyes that bond with the fabric through acid-base reactions. Acid dyes can produce bright and vibrant colors, but they require high temperatures and acidic conditions to work. Some steps to dye nylon with acid dyes are:
- Prepare the fabric by washing and rinsing it thoroughly.
- Prepare the dye bath by dissolving the dye and some vinegar or citric acid in hot water.
- Submerge the fabric in the dye bath and stir gently.
- Heat the dye bath to a simmer and maintain it for about an hour.
- Remove the fabric from the dye bath and rinse it well with cold water.
- Dry the fabric as usual.
It can also be printed on by using various techniques, such as screen printing, digital printing, heat transfer printing, and dye sublimation printing. Screen printing involves using a mesh screen and a stencil to apply ink to the fabric. Digital printing involves using a computer and a printer to print designs directly onto the fabric. Heat transfer printing involves using a heat press and a transfer paper to transfer designs onto the fabric. Dye sublimation printing involves using a printer and a special paper to print designs that are then transferred to the fabric by heat and pressure.
Nylon can be sewn by using a sewing machine or by hand, but some tips and tricks can help to achieve better results, such as:
- Use a sharp needle and a polyester or nylon thread to avoid snagging and breaking the fabric.
- Use a zigzag stitch or a stretch stitch to allow the fabric to stretch without breaking the seams.
- Use a presser foot and a feed dog to prevent the fabric from slipping and puckering.
- Use a low temperature and a pressing cloth to iron the fabric and avoid melting or scorching it.
How to recycle nylon and what are the challenges and opportunities?
It can be recycled by various methods, such as mechanical recycling, chemical recycling, and depolymerization. Mechanical recycling involves shredding and melting the fabric into pellets, which can be used to make new products. Chemical recycling involves breaking down the fabric into its monomers, which can be reused to make new polymers. Depolymerization involves using enzymes or bacteria to degrade the fabric into its basic components, which can be used as feedstock for other industries.
Recycling nylon has several benefits, such as reducing the consumption of fossil fuels, water, and energy, lowering the greenhouse gas emissions and waste generation, and extending the lifespan of the material. Recycling also creates new opportunities for innovation and circularity in the textile industry, such as developing new products, technologies, and business models.
However, recycling also faces some challenges, such as the lack of collection and sorting systems, the low quality and quantity of recycled nylon, the high cost and complexity of recycling processes, and the limited market demand and consumer awareness. Recycling also requires collaboration and coordination among various stakeholders, such as manufacturers, retailers, consumers, recyclers, and policymakers.
How does nylon impact the environment and society?
Nylon has a significant impact on the environment and society, both positive and negative. On the positive side, it has some desirable properties, such as high strength, durability, elasticity, abrasion resistance, water resistance, and low moisture absorption. It also has some useful applications, such as clothing, sportswear, lingerie, stockings, carpets, upholstery, parachutes, ropes, tents, and fishing nets. Other synthetic materials, such as Kevlar and Nomex, which have special properties such as bulletproofing and fire resistance.
On the negative side, nylon has some detrimental effects on the environment and society, such as:
- Consuming large amounts of fossil fuels, water, and energy, which deplete natural resources and contribute to climate change
- Emitting greenhouse gases, such as nitrous oxide, which is 310 times more potent than carbon dioxide, and creating acid rain and smog.
- Releasing microplastics into the environment, which can harm aquatic life and human health. Microplastics are small pieces of plastic that are less than 5 mm in length, and they can be released during production, washing, wearing, and disposal. Microplastics can also absorb toxic chemicals and transfer them to the food chain.
- Generating waste and pollution, which can contaminate soil, water, and air. Nylon is not biodegradable, and it can take up to 40 years to decompose. It also accounts for about 10% of ocean debris, especially from fishing gear. Also it can contain hazardous substances, such as dyes, additives, and coatings, which can leach into the environment.
