Researchers at the University of British Columbia (UBC) have unveiled a groundbreaking method for producing rayon, a widely used fabric, that could reduce solvent usage by up to 70%. This innovative approach promises to enhance sustainability in textile manufacturing while minimizing the environmental impact associated with traditional processes.
The study, led by UBC Forestry associate professor Dr. Feng Jiang and doctoral student Huayu Liu, was published in the journal Chem Circularity on December 4, 2025. The team’s findings reveal a technique for spinning continuous cellulose fibers without relying on the harsh, toxic solvents commonly used in commercial fiber production.
Innovative Production Process
Historically, creating synthetic cellulose fibers like rayon has involved fully dissolving cellulose with large quantities of strong chemicals. This process not only consumes extensive resources but also generates hazardous waste. In contrast, UBC’s researchers utilized microfibrillated cellulose (MFC), which consists of tiny, hair-like strands of cellulose produced through mechanical grinding with minimal chemical intervention.
To overcome the challenge of MFC’s flow properties, the researchers introduced a small amount of softened, dissolved cellulose, which acts as a natural “glue.” This innovative binding method allows the tiny fibers to connect and twist together, resulting in a strong, continuous thread suitable for weaving, similar to conventional textile fibers.
Huayu Liu expressed excitement about the findings, stating, “What we found is that we don’t actually need to dissolve cellulose completely to get continuous fibers. By dissolving only a portion of it, we can reduce the amount of solvent needed by as much as 70%—and we can recycle all of it.”
Environmental Benefits and Future Prospects
This new method not only reduces the quantity of chemicals used but also eliminates several steps typically associated with bleaching or harsh chemical treatments. This enhances the overall cleanliness and sustainability of the production process. Dr. Jiang emphasized the broader implications of the research: “Making man-made cellulose fiber with less chemical input and far lower environmental impact is a meaningful step. Sustainability isn’t only about the final material—it’s about sourcing the raw material responsibly and ensuring the entire process avoids toxic solvents and minimizes pollution.”
Currently, the fibers have been successfully produced at a laboratory scale. The research team is now seeking to scale up production, collaborating with Professor Stephanie Phillips at Kwantlen Polytechnic University‘s fashion design school to explore knitting and weaving prototypes as larger quantities become available.
Dr. Jiang expressed optimism about the future applications of this research, stating, “We hope these fibers will eventually be used for sustainable clothing and fabric manufacturing. This research shows that a more circular, lower-carbon pathway for textiles is possible.”
As the fashion industry increasingly embraces sustainability, innovations like this could play a crucial role in reshaping textile production for a more environmentally conscious future.
