Green Intumescent Systems Using Seed and Seaweed Marine and Agro-Biopolymer Engineered Flame-Retardant Coatings for Textile Applications

Abstract

I\'m looking at how sustainable flame retardant textiles are gaining in importance due to environmental rules and health concerns about old halogen-based retardants. Renewable biopolymers from seeds and seaweed appear to be good alternatives. Seed-derived stuff - phytic acid, soy protein, starch, guar gum - that\'s rich in phosphorus, nitrogen and hydroxyl whilst helping the fabric to dehydrate, puff up and char when it burns. Seaweed polysaccharides - alginate, carrageenan, agar - added film forming ability, thermal shielding and more carbon residue. When you mix these with additives such as nanoclays, metal hydroxides, P-N compounds or bio-crosslinkers, then the outcome is a hybrid which can be used to improve the limiting oxygen index, reduce the peak heat release and reduce the amount of smoke. In this paper, I\'m going to get into the details of the chemistry, the flame retardant mechanisms, how people are hybridizing the systems, the methods used to make textiles out of it and how they are durable on seed and seaweed bases. I\'ll focus on condensed-phase mechanisms, how the additives adhere to the textile fibers, and \"scaling headaches\" that go into trying to make this stuff work in the real world. I\'ll talk about where these can be used - protective gear, transport textiles, home decor and technical fabrics. Even though the science is promising, there are still issues of wash durability, keeping costs down and maintaining mechanical strength. Going forward, I believe future research will need to address multifunctional coatings, nano-enabled biohybrid systems and life cycle assessment verification in order to have these products commercialized. Seed- and seaweed-based biopolymer-based hybrid appears to be a sustainable route for next gen fire safe textiles. Basically, these seed and seaweed biopolymer hybrid flame retailer systems are a solid move toward better fire safe textiles. This review breaks down the following so that we have a base on how to further push sustainable fire safe textile innovation: mechanisms, material combos, processing tech, performance tests and industry use.

Introduction

Seaweed- and seed-derived biopolymers are emerging as sustainable, biodegradable flame retardants for textiles, offering an eco-friendly alternative to conventional halogenated and formaldehyde-based treatments, which generate toxic by-products. These biopolymers act mainly through condensed-phase mechanisms, forming char layers that provide a thermal barrier, reduce heat transfer, limit oxygen access, and slow flame propagation.

Key Points

1. Fire Risk in Textiles

• Common fibers such as cotton, polyester, and viscose are highly flammable due to chemical composition and porosity.

• Burning releases high heat and toxic smoke, posing risks to homes, factories, public transport, and industrial facilities.

• Traditional flame retardants (halogenated compounds, antimony trioxide, formaldehyde) are effective but toxic.

2. Biopolymer-Based Flame Retardants

A. Seed-Derived Biopolymers

• Phytic acid, soy protein, starch, guar gum

• Contain phosphorus, nitrogen, and hydroxyl groups.

• Promote dehydration reactions, intumescent char formation, and thermal barrier properties.

• Phytic acid: high phosphorus content, acts as natural acid source.

• Soy protein: nitrogen-rich, stabilizes char.

• Starch & guar gum: carbon sources, improve film-forming ability on textiles.

B. Seaweed-Derived Polysaccharides

• Alginate, carrageenan, agar, ulva, kelp

• Form stable carbonaceous char, enhancing thermal resistance.

• Alginate-metal complexes produce ceramic-like residues.

• Carrageenan: sulfate groups promote char stabilization.

• Compatible with cellulose-based textiles, applied via eco-friendly aqueous processes.

3. Hybridization & Synergistic Additives

• Combination of biopolymers with:

  1. Phosphorus–nitrogen compounds

  2. Nano-clays (e.g., montmorillonite)

  3. Metal hydroxides (Mg(OH)?, Al(OH)?)

  4. Bio-based crosslinkers

• Results in: increased LOI, reduced smoke density, higher char yield, while maintaining breathability and comfort.

4. Textile Treatment Techniques

5. Flame Retardant Mechanism

• Condensed Phase: Char formation provides thermal barrier, restricts heat and oxygen flow.

• Gas Phase: Non-flammable gases (water vapor, CO?) dilute combustible gases; free radicals are scavenged.

• Intumescent Systems: Phosphorus + nitrogen expand to form protective foamed layers.

• Additives: Metal hydroxides release water endothermically to cool materials.

Evaluation Methods:

• Limiting Oxygen Index (LOI)

• UL-94 vertical/horizontal tests

• Cone calorimetry (HRR, THR, smoke production)

• Thermogravimetric Analysis (TGA)

• Durability & mechanical testing

6. Applications in Textiles

• Protective Clothing: Industrial, firefighter gear

• Home Textiles: Curtains, upholstery, carpets

• Automotive & Aircraft Interiors: Seat covers, fabrics

• Public Infrastructure: Theater drapes, hospital bedding

• Eco-friendly Textiles: Children’s textiles, medical textiles

7. Biopolymer Source & Mechanism Summary

8. Summary

Green intumescent systems based on seed and marine biopolymers provide sustainable, non-toxic flame retardancy, primarily through char formation and condensed-phase protection. These materials are particularly suitable for cotton and other natural fibers, aligning with environmentally friendly textile development while maintaining comfort, breathability, and fabric integrity.

These systems offer a promising path toward eco-conscious protective textiles, home furnishings, and industrial applications, replacing traditional toxic flame retardants.

Conclusion

Seed - and seaweed - based bio-polymers are a revolutionary group of sustainable materials for hybrid flame retardant textile systems. Their renewable origin, low environmental impact and inherent flame retardant functionalities make them attractive alternatives to conventional halogenated systems. Seed derived Compound Phytic acid imbues high phosphorus content essential for intumescent action in soybean Soy protein imbues nitrogen synergism for enhanced char stability. An additional carbon raw material used to promote more extensive char formation is starch and guar gum. Seaweed inflammatory derivatives, like alginate and carrageenan provide great film-forming ability as well as barrier capacity. The additional thermal stability provided by metal-alginate complexes as residues of a ceramic structure. When incorporated into hybrid systems with nano -clays, metal hydroxides or phosphorus - nitrogen compounds, these biopolymers show remarkable enhancements in LOI, lower peak heat release rates, and lower smoke production. Despite these advantages, there have still been challenges. Wash durability and mechanical robustness need to be increased for long term performance. Cost competiveness with synthetics also means optimisation in scalable production processes. Furthermore, full life cycle assessments are required to ensure industrial scale environmental superiority. In the future, future research could place a focus on multifunctional textile systems with antimicrobial, UV-protective and self-cleaning properties. Nano Enabled Reinforcement Green Crosslinking Chemistry Bio Inspired Hierarchical coatings may unlock next generation performance. Future research should focus on the multifunctional nature of textile finishes that benefits the organism from properties such as antimicrobial and UV-protection and self-healing-coating counterbalanced with flame retarding. Advanced nanotechnology and green crosslinking approaches have the potential for further improvement of the durability and performance. Life-face assessment studies are also required to validate the environmental benefits at the commercial level. Overall, the development of hybrid flame retardant systems based on seed and seaweed biopolymers, are a promising, sustainable way towards greener fire safe textile. With further interdisciplinary innovation, it is clear these materials are likely to make a great impact on the future of textile finishing technologies.

References

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Copyright

Copyright © 2026 B. Karthika, Dr. E. Devaki, Monika S., Narmathavarsa V., Srinithi A.. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.