Conference Speakers

Sanjay Patel, Ph.D.

Consultant, Fibroline SA

BIOGRAPHY

Sanjay Patel, Ph.D. is a retired senior technology executive with over 35 years of experience in developing and commercializing sustainable new products and processes across a wide range of high-performance applications. He holds a Ph.D. in Polymers from the University of Akron in Ohio. Dr. Patel is respected for his dynamic, hands-on leadership of multinational teams, driven by vision, energy, and enthusiasm that inspire results. Recognized for his broad technical expertise, extensive professional network, and innovative use of resources, he established CheMASTERY Consulting LLC in 2021–22. Through this firm, he provides international consulting services focused on material development, structure–property optimization for specific product end uses, and advanced coating solutions.

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Disruptive Dry Powder Impregnation Solutions for Flax Fiber Intermediate Products

Fibroline’s dry powder impregnation technology represents a breakthrough in the manufacturing of technical textiles and composites. Particularly well-suited to natural fibers, this innovative process enables highly homogeneous impregnation and functionalization of a wide range of base material constructions, using various types of additives, resin chemistries, and loadings. The technology has led to the development of multiple flax fiber-based intermediate products for composite applications in the automotive, marine, and sports industries. It replaces high-energy, solvent- and water-based processes such as dip coating. Depending on the application, the process allows both low binder loadings (<5%) for bonded flax fibers and high resin content (~50% wt) for semi-pregs in sheet or tape form.

These products clearly demonstrate the technology’s ability to address current sustainability challenges while maintaining high mechanical performance. As a dry process, it eliminates the need for liquids (solvents or water), thereby avoiding the release of volatile organic compounds (VOCs), wastewater generation, and significantly reducing energy consumption. Comparative life cycle assessments (LCA) have highlighted the substantial environmental benefits of dry powder impregnation.