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<p>This study explores the development of novel biocomposites utilizing galalith, a versatile protein-based material, and a sustainable waste stream from the equine industry: horse hoof keratin. The primary objective is to investigate the potential of this keratinic filler to enhance the mechanical properties of the protein matrix. The methodology involves the incorporation of micronized horse hoof powder (HHP) at varying concentrations into the galalith during its wet processing phase. The filler in powder form has been introduced in amounts of 4, 8, 11 and 14% on a wet basis: the latter quantity translates to a substantially higher amount i.e., 40% by weight, on the dry material, considering keratin as fully hydrophobic. The idea is to introduce the maximum content of this keratin waste that still ensures compatibility with the matrix material. Initial findings indicate that the inclusion of this bio-derived filler leads to a significant and promising improvement in the composite’s mechanical performance, with Shore D hardness progressively increasing and impact strength reaching values around 2&#xa0;kJ/m² for filler contents up to 8% on a wet basis (≈ 23 wt% on dry mass), whilst the introduction of higher amounts appears more problematic, as confirmed by microscopical observations showing particle pull-out and interfacial discontinuities. Thermal characterization does not indicate significant differences among the various biocomposites, whilst they all have a distinct behaviour from the bare galalith, with an increase of residual mass after TGA of approximately 6–8%. The results of this research highlight the potential for transforming a biological waste product into a valuable reinforcing agent for bioplastics, aligning with principles of the circular economy. The developed composite material could find applications in various fields requiring high-performance sustainable materials, at the same time exploiting some neglected animal waste. Overall, the study demonstrates that horse hoof keratin enables the production of formaldehyde-free galalith composites with substantially enhanced mechanical performance at intermediate filler contents, while allowing the incorporation of unusually high amounts of protein waste, thus confirming the feasibility of a fully protein-based composite within a circular economy framework. </p>

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Production of Formaldehyde-free Galalith with Horseshoe Keratin Filler

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • S. Mattiello,
  • L. Verdecchia,
  • G. Vicentini,
  • M. Merlin,
  • C. Fragassa,
  • C. Santulli

摘要

This study explores the development of novel biocomposites utilizing galalith, a versatile protein-based material, and a sustainable waste stream from the equine industry: horse hoof keratin. The primary objective is to investigate the potential of this keratinic filler to enhance the mechanical properties of the protein matrix. The methodology involves the incorporation of micronized horse hoof powder (HHP) at varying concentrations into the galalith during its wet processing phase. The filler in powder form has been introduced in amounts of 4, 8, 11 and 14% on a wet basis: the latter quantity translates to a substantially higher amount i.e., 40% by weight, on the dry material, considering keratin as fully hydrophobic. The idea is to introduce the maximum content of this keratin waste that still ensures compatibility with the matrix material. Initial findings indicate that the inclusion of this bio-derived filler leads to a significant and promising improvement in the composite’s mechanical performance, with Shore D hardness progressively increasing and impact strength reaching values around 2 kJ/m² for filler contents up to 8% on a wet basis (≈ 23 wt% on dry mass), whilst the introduction of higher amounts appears more problematic, as confirmed by microscopical observations showing particle pull-out and interfacial discontinuities. Thermal characterization does not indicate significant differences among the various biocomposites, whilst they all have a distinct behaviour from the bare galalith, with an increase of residual mass after TGA of approximately 6–8%. The results of this research highlight the potential for transforming a biological waste product into a valuable reinforcing agent for bioplastics, aligning with principles of the circular economy. The developed composite material could find applications in various fields requiring high-performance sustainable materials, at the same time exploiting some neglected animal waste. Overall, the study demonstrates that horse hoof keratin enables the production of formaldehyde-free galalith composites with substantially enhanced mechanical performance at intermediate filler contents, while allowing the incorporation of unusually high amounts of protein waste, thus confirming the feasibility of a fully protein-based composite within a circular economy framework.