A team of scientists has developed a novel bioplastic made primarily from wool, offering a sustainable and circular alternative to conventional thermoplastics. This keratin-based material is derived from discarded wool fibres—an abundant, protein-rich by-product of the textile and food industries. The new material stands out for its biodegradability, mouldability, and potential applications in product design, packaging, interior design, and even fashion.

From Protein Waste to Plastic
Keratin is a fibrous protein naturally found in hair, feathers, and wool. Although it contains rich chemical potential, keratin is notoriously difficult to process due to its tightly crosslinked structure. Most previous keratin-based materials have been brittle and limited in performance. This new research, however, introduces a process that transforms keratin into a flexible, durable bioplastic using simple, scalable chemistry.

A Simple, Scalable Method
The process begins by dissolving wool keratin in a solution of urea and sodium metabisulfite, which breaks the protein down into long, unfolded strands. These strands are then blended with plasticisers such as polyethylene glycol (PEG) or soybean oil. The resulting mixture behaves as a thermoplastic, which can be shaped using conventional heat-processing techniques. Depending on the plasticiser used, the material can take on either rigid or flexible characteristics. PEG produces a firm, mouldable bioplastic suitable for creating durable components, while soybean oil yields a softer, more pliable material, ideal for flexible films or coatings.

Tunable Properties for Design Applications
This wool-based plastic demonstrates excellent processing properties and can be shaped via injection moulding, thermoforming, or casting. It also offers good mechanical stability and water resistance. Importantly, it is fully biodegradable and made entirely from renewable resources, aligning with the increasing demand for biobased and circular materials in design. Its tunable flexibility and strength make it especially attractive for designers seeking sustainable alternatives to petroleum-based plastics like ABS or polystyrene.

Researchers also suggest that the keratin plastic can be further enhanced with pigments, fragrances, or antimicrobial agents, opening up additional opportunities for sensorial and functional applications. The material’s natural origin, combined with its versatility and potential for industrial scalability, offers compelling possibilities for a wide range of design disciplines.

A Step Toward Circular Design
According to Dr Giovanni Perotto, one of the lead researchers, the method is both cost-effective and relatively easy to scale. Experts such as polymer scientist Naba Dutta from RMIT University and medical biochemist Olarenwaju Oluba have also endorsed the innovation, highlighting its potential to convert low-value waste into high-value, compostable materials. The approach not only reduces the environmental footprint of plastic use, but also contributes to the valorisation of wool waste, which is often discarded or underutilised.

As the design industry continues to shift toward circularity and sustainability, this keratin-based plastic derived from wool presents a promising material solution. It offers a new way to rethink waste and transform it into something both functional and environmentally responsible.

Source: Chemical & Engineering News
Photo: Giovanni Perotto