Valorization of Waste Feathers in the Production of New Thermal Insulation Materials

Poultry has become the primary source of dietary protein consumed globally and as a result the by-product feathers are an increasingly problematic industrial waste. Developing a circular economy for feathers is, therefore, an important research area that provides an opportunity to make use of the unique combination of properties of this abundant natural material. This paper reports on the thermal properties of novel feather-based thermal insulation materials. Waste feathers were collected, cleaned and processed into fibres, which were then used to form air-laid nonwoven materials. These have a high fibre content and exploit the excellent natural thermal insulation properties of feathers. The performance of the novel materials developed are tested in order to outline the influence of temperature and density on thermal conductivity and dynamic water sorption. Results are compared to a range of commercially available thermal insulation materials for buildings manufactured from denim, hemp, sheep wool, PET and mineral wool. It was found that air laid feather-fibre fabrics have comparable performance to other fibrous materials and have a thermal conductivity of 0.033 W/(m K) for samples with a density of 59 kg/m3. This is due to the low thermal conductivity of feather fibres and the void structure formed by air-laid processing that effectively traps air. These materials additionally offer improved sustainability credentials as they are derived from a readily available waste that is generally considered to be unavoidable. The paper concludes by highlighting the significant technical and commercial barriers that exist to using waste feathers in thermal insulation products and suggests areas for further research that can exploit the unique properties of feathers.