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Hof, June 30, 2025 – In the research project “RuhBio,” scientists from Hof University of Applied Sciences are working together with industry partners to develop innovative nonwoven materials for rail transport. The goal is ambitious: to replace conventional noise protection elements currently used in trains with a sustainable, bio-based alternative. The project team is supported by the companies Cellofoam GmbH, ROWA F. Rothmund GmbH & Co. KG, and the Thuringian Institute for Textile and Plastics Research (TITK). The research began in early 2023 and is scheduled for completion by the end of this year.
“Up to now, soundproofing components in rail transport have mostly been made of conventional foams or polyester fleeces. While functionally proven, these materials are neither bio-based nor biodegradable,” explains Robin Heinrich, research associate at the Institute for Circular Economy of Bio:Polymers (ibp) at Hof University of Applied Sciences. In order to meet growing environmental awareness and sustainability goals in the transportation sector, the project team relies on polylactide, or PLA – a bioplastic made from renewable resources such as corn starch. PLA is already used in numerous applications, including packaging and medical products. However, in those fields, the focus is typically on biodegradability rather than long-term durability.
New Demands on a Familiar Material
Different standards apply to materials used in rail transport. They must remain stable for decades and withstand extreme environmental conditions. Temperatures ranging from minus 40 to plus 100 degrees Celsius and high humidity are not uncommon. Therefore, the "RuhBio" project pursues two main development goals: significantly increasing the temperature resistance of the PLA material and reliably preventing hydrolytic degradation, i.e., breakdown caused by moisture.
High-Tech from Two Components
The solution lies in a newly developed fiber structure: a so-called bicomponent fiber with a core-sheath structure combines the desired properties. The core consists of a partially crystalline PLA type with talc content, giving the material the necessary heat resistance and mechanical stability. The sheath is made of amorphous PLA with a wax component. This combination makes the nonwoven material resistant to moisture while enabling thermal bonding.
Caffeine to Prevent Material Degradation
A particularly innovative approach is the addition of caffeine as a biogenic residual material. Extracted from coffee grounds, it helps further inhibit hydrolytic degradation. To assess the long-term quality of the material, a special hydrolysis test was developed. Samples of the new material are stored in water at 50°C for up to ten weeks. Before and after storage, as well as after a drying phase, they are weighed, microscopically examined, and tested for their mechanical properties.
From the Lab to the Train
The developed material blends were first processed on a laboratory scale. Following successful optimization, larger quantities of fibers were produced and processed into nonwovens by project partner ROWA. Cellofoam GmbH then handles cutting and laminating, producing ready-to-install noise protection elements for real-world use.
A Contribution to the Mobility of Tomorrow
With the “RuhBio” project, Hof University of Applied Sciences demonstrates in impressive fashion how applied research, ecological responsibility, and technological innovation can go hand in hand. The result is a forward-looking material that meets the high standards of rail transport while setting new benchmarks in sustainability. Thus, the project contributes not only to technological advancement, but also to environmentally friendly mobility for the future.
The project is funded by the German Federal Ministry for Economic Affairs and Climate Action as part of the Central Innovation Programme for SMEs (ZIM).
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