Banana waste finds new life as textiles and paper in Brazil’s emerging bioeconomy

BRASÍLIA, April 20, 2026 — The tonnes of banana trunks left behind after harvest are increasingly being transformed into raw materials for clothing, paper and packaging, as advances in mechanical extraction and controlled drying accelerate industrial development in the sector.

What was once agricultural waste may soon end up in everyday items — from T-shirts and notebooks to supermarket packaging — as factories refine methods to convert banana pseudostems into standardised industrial inputs for textiles, paper and bio-based composites.

Studies on circularity in banana farming indicate that only a small portion of the plant is consumed as food, with the remainder left as biomass. In some systems, this residue can reach approximately 220 tonnes per hectare, highlighting why industry interest in the underutilised material is growing rapidly.

Researchers estimate that banana pseudostems generate tens of millions of tonnes of waste annually in major producing countries such as Brazil. Yet these stems contain strong cellulosic fibres, with tensile strength surpassing traditional natural fibres such as jute and sisal, making them attractive for yarn production and composite reinforcement.

From craft to industrial scale

While banana fibre has long been used in small-scale artisanal projects, the sector is now transitioning towards industrial production. Companies are beginning to establish structured supply chains, complete with quality standards, traceability and safety protocols similar to those used for other natural fibres.

In Brazil, this shift has been underscored by initiatives highlighted by the Federation of Industries of Santa Catarina (FIESC), particularly at the SENAI Institute of Textile Technology, Apparel and Design. These projects are focused on developing banana fibre fabrics suitable for large-scale manufacturing.

One such initiative, Banana Têxtil, reached the finals of the BRICS Solutions Awards, demonstrating the viability of banana fibre for industrial weaving beyond niche craft markets.

Inside a banana fibre processing plant

Processing typically begins near banana farms, as fresh pseudostems are heavy and water-laden, making long-distance transport impractical. Upon arrival at processing facilities, the stems are sorted based on size, moisture content and condition — key factors that influence fibre quality.

The core stage is mechanical extraction, known as decortication, where rollers and blades separate fibrous material from softer pulp. This method is considered the most viable for industrial-scale production, as it avoids the use of harsh chemicals while producing fibres suitable for spinning.

Laboratory studies show that mechanically extracted banana fibres can achieve tensile strengths of around 570 megapascals — higher than many commonly used plant fibres in textiles and composites.

Following extraction, fibres undergo intensive washing to remove impurities, reduce odour and improve texture. However, this stage presents environmental challenges, particularly due to high water consumption. Advanced facilities are therefore investing in water recycling systems and wastewater treatment to mitigate environmental impacts.

Drying, quality control and applications

After cleaning, fibres must be dried under controlled conditions to prevent mould and maintain consistent quality. Many factories combine ventilated air drying with temperature-controlled ovens, as research indicates that drying conditions significantly affect fibre properties.

The fibres are then processed using equipment similar to that used for other plant-based materials, preparing them for spinning, nonwoven production or use in composite materials.

Quality control focuses on fibre length, moisture levels, impurity content and mechanical strength. For downstream industries, consistency is essential to ensure reliable performance in manufacturing.

Although much of the current focus is on textiles — including blends with cotton for clothing and home furnishings — the applications extend further. Trials in paper and packaging are progressing from laboratory stages to pilot production.

A recent open-access study found that thermomechanically extracted banana fibre, combined with gum arabic, can be used to produce fruit packaging boards. These performed as well as, or better than, recycled paper pulp trays in several mechanical tests, though they showed higher water absorption.

Maximising the whole plant

Beyond fibre extraction, the remaining pulp and sap can be repurposed into compost, fertilisers, biogas and other by-products. Experiments using banana pseudostem as a base for organic liquid fertiliser, enhanced with microbial inputs, suggest it can help reduce reliance on synthetic fertilisers.

For processing plants, achieving both environmental and economic sustainability depends on utilising as much of the biomass as possible. Failure to do so can result in disposal costs and environmental concerns, including odour and runoff.

A growing opportunity with challenges ahead

While banana fibre is unlikely to replace synthetic materials entirely, experts say it offers a promising pathway to reduce reliance on fossil-based inputs in textiles, paper and packaging.

However, challenges remain, particularly in logistics, farmer training and wastewater management.

Nonetheless, the concept is straightforward: rather than discarding or burning banana trunks after harvest, they can be converted into valuable products that may ultimately return to the soil, supporting a more circular and sustainable agricultural system.

The findings were published in the journal Packaging Technology and Science.

https://thecooperator.news/regional-banana-researchers-amazed-by-ugandas-progress/

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