We are now the pioneer in Vietnam producing raw pineapple fibre on an industrial scale
Ecofa is a materials science company founded in June 2021 in Nghe An, Vietnam, specialising in transforming agricultural waste like pineapple leaves into valuable fibres, yarns, and fabrics for the fashion and sustainable materials industries. With a vision to pioneer the industrial-scale production of these materials using automatic, resource-saving, and environmentally friendly processes, Ecofa is committed to contributing positively to the environment, society, and economy. Speaking to Fibre2Fashion, CEO Dau Van Nam talks about the development and use of pineapple fibre as a sustainable material in the textile industry.
How has the emergence of pineapple fibre as a sustainable material influenced the textile industry in Vietnam and globally?
Pineapple fibre is considered a sustainable material with great potential in the textile industry. Pineapple is a plant with a short growing period, does not require a lot of resources and care, and does not use many chemicals and pesticides during production. This helps minimise the negative impact on the environment compared to other fibres.
The influence of pineapple fibre on the Vietnamese and global textile industry can be described as follows:
Environmental sustainability: Pineapple fibre helps reduce waste and water in the production process, while reducing pressure on other natural raw materials. This could help the textile industry shift towards a more sustainable production model.
Market development: Increased awareness of environmental issues and growing demand for sustainable products can create new business opportunities for textile enterprises using pineapple fibres. Markets with high demands for environmentally friendly products can boost consumption of these products.
Enhance international cooperation: The use of pineapple fibre can create opportunities for international cooperation in the fields of raw materials and production. Sharing technology and experience between countries can promote the global development of the textile industry using pineapple fibres.
It should be, however, noted that there may be challenges, such as higher production costs and dependence on sourcing materials from a specific plant.
What are the environmental benefits of using pineapple fibre compared to traditional textile materials, and how does this align with global sustainability goals?
The use of pineapple fibre over traditional textile materials contributes to global sustainability goals by reducing negative impacts on the environment and encouraging more responsible consumption by industry and consumers, specifically:
Reduced water and chemical consumption: The pineapple fibre production process usually requires less water than other fibres, and does not use chemicals. This helps reduce negative impacts on water resources and the environment.
Short growing time: Pineapple is a plant with a short growing time; it usually only takes about 18-24 months for the pineapple tree to mature and be harvested. This helps reduce pressure on natural raw materials compared to plants with longer growing periods. And in particular, Vietnam has the advantage of abundant raw material areas, creating conditions for continuous production on a large scale.
Reduce greenhouse gases: The appearance of pineapple fibres can help reduce greenhouse gases because the production process emits less thermodynamic emissions than the production process of traditional textile fibres. The production of pineapple fibre from pineapple leaves helps increase income for farmers and change traditional farming habits that cause air pollution.
Enhance sustainability of raw materials: Pineapple has strong renewable ability and does not require many resources. This helps increase the sustainability of raw materials, especially compared to crops that require large planting areas and use a lot of chemicals.
Stimulating sustainable production trends: Using pineapple fibre means supporting sustainable production trends, and meeting the increasing demand for environmentally friendly products from consumers.
Can you describe the process of harvesting and processing pineapple leaves into fibre, and what innovations have been introduced in this area?
The process of harvesting and processing pineapple leaves into fibre involves many basic steps, and there are a number of Ecofa innovations that have been applied to optimise performance and reduce environmental impact. Here are some general descriptions of the process:
Harvesting pineapple leaves:
Selecting pineapple leaves: Pineapple leaves are usually harvested from mature pineapple trees, choosing large leaves with a length of 70-120 cm. Leaves do not dry or break.
Harvesting equipment: Tools such as knives or cutters can be used to carefully harvest pineapple leaves without causing much damage to the plant.
Separate the fibres:
After being harvested, pineapple leaves are gathered at the factory to separate the fibres. It is necessary to ensure that all purchased leaves are processed within 48 hours. Collected leaves are gathered into the warehouse and classified and then put into fibre separation using a semi-automatic machine. At Ecofa, to increase productivity, we have improved and produce pineapple fibre using an automatic line. We are proud to be a pioneer in producing pineapple fibre using automatic lines on an industrial scale.
Softening and cleaning of fibres: Pineapple fibres, after being separated, can be treated by softening and cleaning to remove excess substances like glue to make the fibres softer.
Processed into final product: Pineapple fibre can be used directly in making biological leather, construction materials and in the textile industry or processed into other products such as bags, carpets, or other decorations.
Apply new technology: New technologies such as using enzymes to soften fibres or applying fibre production techniques that do not use high temperatures can be applied to improve fibre quality and reduce environmental impact.
Innovation in the processing of pandan leaves into fibre involves optimising efficiency, reducing waste, and increasing sustainability. Research is continuously driving the development of this technology to ensure that the pineapple fibre production process becomes increasingly efficient and environmentally friendly.
How is the Vietnamese government supporting the development of sustainable materials like pineapple fibre, and what impact has this had on the local economy?
The Vietnamese government has shown interest in developing sustainable materials, including pineapple fibre and other natural materials. Below are some measures and supports that the Vietnamese Government can apply to encourage the development of the pineapple fibre industry and other sustainable materials:
Support and incentive policies: The government can establish financial support policies, tax reductions, or provide grants to encourage businesses operating in the field of pineapple fibre and durable materials.
Research and development: Supporting research and development programmes related to pineapple fibre, from improving the production process to creating the final product, could be a way for the Government to promote innovation in the industry.
Education and training: It can carry out programmes to increase education and training on pineapple fibres and sustainable materials, both in the community and at specialised training schools, to increase awareness and skills of workers in this industry.
The impact of these measures on the local economy may include:
Job creation: Developing a pineapple fibre industry can create many employment opportunities in both harvesting, processing and fibre production, as well as in supporting areas such as research and development.
Promote exports: Pineapple fibres and products from pineapple fibres meet quality and durability requirements, which can increase exports and contribute to income for the national economy.
Environmental sustainability: Switching to sustainable materials like pineapple fibre can help reduce negative impacts on the environment, which can become a long-term benefit for both the economy and communities.
What are the potential applications of pineapple fibre beyond the fashion industry, and how is research and development in this field shaping its future uses?
Applications around the world using pineapple leaf fibre are:
Raw fibre: Used for producing rope, canvas, carpet etc.
Yarn: Used for the production of wicker products and handicrafts.
Finely combed, finely stripped yarn: Used for weaving and garments (soft, good moisture absorption, airy, does not irritate the skin).
Composite materials replace mechanical components and spare parts (cars, airplanes etc.)
Finely combed, stamped and dyed fibres to make wigs for the beauty industry.
For making vegetable leather, and also as a medical protective equipment.
Fibre Reinforcement (Reinforced Fibre) replaces glass fibre.
Ultra-light biological Aerogel material: wastewater treatment and food preservation.
Press raw residue to make soundproofing material for the construction industry and plant pots.
Leaf pulp residue after extracting fibres is used as bio-fertiliser.
What inspired the creation of Ecofa, and how does your personal story intertwine with the company’s mission?
In Vietnam, pineapple is grown quite popularly, distributed from Phu Tho to Kien Giang on an area of about 40,000 hectares, with an output of over 500,000 tons/year; 90 per cent of the area is concentrated in the southern part of the country. Pineapples are mainly grown and harvested for fruit, and their leaves are not given much attention and are often burned. With 40,000 hectares of pineapple, equivalent to 600,000 tons of pineapple leaves burned, 90,000 tons of CO2 gas were emitted directly into the environment. This habit of burning pineapple leaf by-products led to the destruction of the cultivation layer, and the use of more than 40,000 litres of herbicides and pesticides per year.
Ecofa is a story of young people’s love for their hometown’s pineapple fields. Established in 2021 in Nghe An, Vietnam, we are trying to turn agricultural by-products into new high-value materials for the fashion, textile, construction materials, and bio-leather industries, promoting local economic development, contributing to reducing waste, minimising the risks of environmental pollution, and creating livelihoods for farmers.
Can you elaborate on the challenges and breakthroughs in developing the technology to transform pineapple leaves into high-value fibre?
Although pineapple fibre brings many benefits, it also faces certain challenges and limitations. One of the main challenges is the use of labour in production. The entire process, from harvesting the leaves to spinning the fibres by hand, requires skilled artisans and a significant amount of time and effort. This may limit the ability to expand pineapple fibre production. Another limitation is the availability of pineapple leaves because it takes several years for the pineapple plant to mature for fibre extraction. This means that the supply of these leaves may be unstable, affecting the production of pineapple fibre on a larger scale. Additionally, the extraction process itself can be time-consuming and uneconomical.
Despite these challenges, Ecofa offers a solution to separate pineapple leaf fibre and pineapple fibre from raw state to basic state on an industrial scale using automatic machinery systems. Our circular, renewable technology provides systemic solutions to transform agricultural waste into valuable fibres, cottonised fibres, yarns and fabrics for the fashion and sustainable materials industries, paving the way for a more sustainable and accessible production process.
How does Ecofa’s approach to sustainability set it apart from other companies in the sustainable fashion industry?
Ecofa’s approach to sustainability sets it apart from other companies in the sustainable fashion industry in the following ways:
Raw material source: Pineapple fibre is considered a renewable and sustainable raw material source and is currently a hot-trend in the textile industry.
Environmental protection from the production process: Highly efficient production processes that do not use chemicals, reduce waste, save energy, and apply environmentally friendly processes make Ecofa stand out compared to other competitors in the same field.
Commitment to the local community: Pineapple fibre production creates jobs, increase income, create livelihoods for farmers, and develops the local economy to create human values.
Quality: Products certified and tested by third parties are also an advantage of Ecofa. Certifications from the textile research institute and certification of raw material areas have clear and transparent traceability so that consumers can easily find them.
Could you discuss the impact of Ecofa’s operations on the local communities and the environment in Vietnam?
After three years of formation and development, we are now the pioneer in Vietnam producing raw pineapple fibre on an industrial scale using a fully automatic machinery line, minimising the use of toxic substances and chemicals, while reducing the use of water in the production process. We build and position ourselves as a central factor connecting farms, raw material areas, pineapple factories, companies producing organic fertilisers and animal feed to build a circular economy network towards regenerative, waste-free agriculture. With sustainability as a top priority, we are considered a project with far-reaching economic, environmental and social impacts. Currently, we have built and linked 100 hectare of main raw material area to convert to a safe model according to Global GAP (Good Agricultural Practices) standards with centralised production factories and 10,000 hectares of buffer zones according to the ‘home is a factory’ model, which directly and indirectly create jobs for workers. At five farms, there are 40 workers and nearly 500 local farmers, solving employment problems and increasing income for them.
What are the key factors that have contributed to the success of Ecofa in the Vietnamese and global markets?
There are three key factors contributing to Ecofa’s success in the Vietnamese and global markets.
High quality product and service: Ecofa’s products are highly appreciated by partners and customers for their quality, design, size, colour etc.
Professional customer care: Demonstrated by the rate of customers returning to use the product and becoming strategic partners of Ecofa.
Focus on sustainability: With a closed production process that does not discharge waste and especially does not use toxic chemicals, Ecofa always focuses on sustainability and environmental protection.
How do you envision the future of sustainable fashion, and what role do you see Ecofa playing in it?
Sustainable fashion is becoming an increasingly important trend in the fashion industry. Consumers are increasingly aware of the negative impact of the fast fashion industry on the environment and society, so the demand for sustainable fashion products is increasing. Here are some points where sustainable fashion can develop in the future and how Ecofa can contribute:
Sustainable materials and manufacturing processes: The trend towards using recycled, organic materials, and sustainable manufacturing processes will continue to be strong. Ecofa plays an important role in developing and promoting the use of waste-free and environmentally safe closed-loop production methods and materials.
Environmental and social protection: Ecofa pays great attention to building strategies for environmental and social protection. We participate in social activities, environmental protection and community support to increase our positive influence on those around us.
Transparent traceability: Ecofa builds transparent traceability in the supply chain, helping consumers track the origin and production process of fashion products.
Changing Consumption Trends: Currently, the fast fashion trend is causing serious negative impacts on the environment. To address that situation, Ecofa has come up with a solution to provide high quality and affordable fashion products that have a long-term value.
Can you share insights into the research and development process at Ecofa and how you collaborate with academic institutions and government bodies?
Investment in Research and Development (R&D): At Ecofa, we have invested a large portion of our resources in research activities to develop new products, improve production processes, or reduce environmental impact. Currently, Ecofa has an R&D department with two leading experts in science and textiles in Hanoi.
Ecofa is collaborating with Hanoi University of Science and Technology and the Textile Research Institute.
Ecofa complies with standards and regulations on sustainability, environment and product impacts.
Ecofa participates in the research and development community through participating in conferences, industry events, or collaborating with other businesses.
How does Ecofa plan to maintain its competitive edge in the rapidly evolving field of sustainable materials and fashion?
To maintain a competitive advantage in the field of sustainable materials and fashion, Ecofa plans as below:
Continuous research and innovation: Invest in research and innovation in production processes, developing new materials, and innovative fashion products.
Quality and sustainability: Maintain and improve product quality and commitment to sustainable standards.
Cooperation and strategic partnerships: Strengthen the supply chain and increase influence in the industry.
Educate and create community: Create a community of people who care about and support sustainable products.
Marketing and PR strategy: Share Ecofa’s story and commitment to attract attention and support from customers.
Event and industry appearances: Participate in events, exhibitions, and forums about sustainable fashion and materials.
What are the long-term goals of Ecofa, and how do you plan to achieve them?
With the current level of environmental pollution of the textile and garment industry ranked second in the world, Ecofa sets the goal of researching and producing textile materials from silk fibres of pandan leaves, through an environmentally friendly process. These fabrics can replace other materials that are heavily polluting the environment during the production process.
Specifically, the plan to research and produce environmentally friendly fabrics from pandan leaves is as follows:
Fibre from pandan leaves
Fabric from pineapple fibre
Bio-skin
Organic fertilisers from pandan leaves
Ecofa will continue and develop patterns and colours that can be printed with natural dyes on the above-mentioned fabrics to add diversity to products, in line with the consumer needs of the fashion industry. In addition, Ecofa will explore and research other natural materials that can be made into environmentally friendly textile materials.
Lastly, what message do you have for young entrepreneurs and businesses looking to make a positive impact on the society and the environment?
To young entrepreneurs and businesses wishing to create a positive impact on society and the environment, I would like to share some encouraging messages:
Find opportunities in challenges: Facing social and environmental challenges is not only an opportunity for business development but also a way to create social value. Look for problems that need solving and see them as opportunities to shape the future.
Innovation and creativity: Channel your innovation and creativity into developing products and services that have a positive impact. New and sustainable solutions not only create value for your business but also contribute to solving global challenges.
Create community and collaboration: Be a partner with other businesses, non-profits, and communities to build an environment that supports and stimulates innovation. Collaboration between parties can create more comprehensive and robust solutions.
Accept and promote cultural change: Building a corporate culture oriented towards sustainability and creating a positive impact is important. Encourage employees and partners to join your mission and understand its importance.
Continuously learn and improve: The business environment changes rapidly, and to maintain stability and positivity, continuously capture new information, learn from others, and continuously improve your business processes.
Confidence and perseverance: Believe in your mission and persevere in the face of challenges. The path of a positive business may not always be smooth, but patience and self-confidence will help you overcome all difficulties.
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