Bio-based dispersion coating designed for enhanced functionality, recyclability and economic feasibility

• Scalable biobased coating using lignin and wax nanoparticles for functional textiles. • Coated textiles recyclable via Ioncell® process retaining fiber performance. • MSP of 379 USD/t for an integrated plant and 389 USD/t for a non-integrated plant. • Coating cost of 1.28 UDS per m 2 shows competitiveness against market options • Coating aligns with PFAS-free and wax-based market trends. This study presents a biobased dispersion coating formulated from natural wax and lignin nanoparticles providing hydrophobicity, stain resistance, and antimicrobial functionality for natural fiber textiles. Its durability is demonstrated and has potential for applications like workwear and sportswear to safeguard against fluids, stains, and microbes. A techno-economic assessment for commercial-scale production confirmed the coating’s feasibility and scalability, with a minimum selling price of 379 USD/t for an integrated pulp mill and 389 USD/t for a standalone plant. Despite requiring a higher application volume (3.3 L/m 2 ) than commercial products, the coating remains cost-competitive, with carnauba wax identified as the main cost driver (81 % of variable costs). One-time recycling of coated cotton textiles via the Ioncell® showed properties consistent with the original material, validating the coating’s recyclability potential. Overall, this coating enhances natural fibers performance, is economically competitive, reduces reliance on synthetic materials, and supports the development of high-performance, environmentally friendly textiles.