Methodology
Fabulose develops a biobased material made from bacterial cellulose and cyanophycin combining a dyed textile backing with tailored functional coatings and advanced surface finishing. The project integrates and scales up lab-proven biotechnological processes. The production chain, from raw materials to textile backings, coatings, and dyes, relies entirely on renewable biomass, ensuring recyclability and zero waste.
Overview of the Value Chain and Fabulose Production Process
Raw Materials
Industrial CO₂ and food industry by-products are transformed into biotech-based feedstocks like bacterial cellulose, cyanophycin, and bacterial pigments. Pigments are integrated directly into the bacterial cellulose feedstock, creating naturally coloured filaments and reducing processing steps.
Textile Backing
Using HighPerCell® technology, bacterial cellulose filaments are spun into woven or knitted backings that offer high tensile strength without toxic tanning agents.
Coating
Functional coating layers made from bacterial cellulose and optionally cyanophycin improve flexibility, durability, and resistance to environmental factors, creating a high-quality, sustainable leather alternative.
Finishing
To refine surface feel and durability, Fabulose applies an embossed topcoat layer of cyanophycin. This finishing step enhances haptics and abrasion resistance, giving the material a premium look and feel.
End Products
The finished Fabulose leather alternative is designed for use in handbags, small leather goods, footwear, upholstery, and automotive interiors, with increasing demands on functional quality across applications.
Recycling
The Fabulose leather alternative is fully recyclable and biodegradable. Bacterial cellulose can be recovered and respun into new fibres, while cyanophycin is reintroduced into fermentation. Any remaining residues can be composted or digested for energy recovery.
Industrial CO₂ and food industry by-products are transformed into biotech-based feedstocks like bacterial cellulose, cyanophycin, and bacterial pigments. Pigments are integrated directly into the bacterial cellulose feedstock, creating naturally coloured filaments and reducing processing steps.
Using HighPerCell® technology, bacterial cellulose filaments are spun into woven or knitted backings that offer high tensile strength without toxic tanning agents.
Functional coating layers made from bacterial cellulose and optionally cyanophycin improve flexibility, durability, and resistance to environmental factors, creating a high-quality, sustainable leather alternative.
To refine surface feel and durability, Fabulose applies an embossed topcoat layer of cyanophycin. This finishing step enhances haptics and abrasion resistance, giving the material a premium look and feel.
The finished Fabulose leather alternative is designed for use in handbags, small leather goods, footwear, upholstery, and automotive interiors, with increasing demands on functional quality across applications.
The Fabulose leather alternative is fully recyclable and biodegradable. Bacterial cellulose can be recovered and respun into new fibres, while cyanophycin is reintroduced into fermentation. Any remaining residues can be composted or digested for energy recovery.
Key innovations of the production process include:
- Using fermentation products to enable fast and cost-effective production of raw materials.
- Grow micro-organisms on waste feedstocks & CO2 to reduce production costs and environmental impact.
- Re-spinning bacterial cellulose to filaments to create recyclable, consistent and high-quality fabrics.
- Enabling production of cyanophycin to create durable coatings & finishing.
- Implementing roll-to-roll production process to simplify future scale-up .
Circularity and Digitalisation
Circular design principles guide every step of the process to ensure maximum material recovery and near-zero waste. Fabulose uses digital tools to optimize materials, processes, and the entire product lifecycle. Virtual models, known as Digital Twins, simulate real production conditions, improve bacterial cellulose fermentation, and monitor material quality. AI-driven analytics further enhance performance, flexibility, and recyclability.
Validation of biobased leather-
like fabrics and end products
All Fabulose materials will undergo industry-standard testing for performance, aesthetics, safety, and environmental impact. Continuous feedback loops, rapid prototyping, and digital tracking through the DPP ensure that every product meets both market expectations and sustainability targets.
