Development of masked silica tanning system for sustainable leather production

Amid mounting pressure on the long-term recyclability of chromium in tanned leather and the associated environmental hazards, the quest for an alternative, cleaner tanning system has gained tremendous momentum. In this context, our study explores the remarkable potential of silicates as a versatile platform for skin/hide tanning, circumventing the inherent risks and ecological threats posed by chromium exposure and leaching. We present an alternative approach of using a silica-based tanning system, employing a Taguchi model, to optimize a masked silica (MaSil) tanning product/process for achieving effective collagen stabilization. Our results demonstrate the significant advancements made in hydrothermal denaturation temperature, reaching an impressive 79 °C through precise Taguchi parameters-5% SiO₂, masked with 0.3 mole of citrate salt, and a tanning process fixation pH of 4.5. Notably, the mechanical strength analysis reveals compliance with the stringent upper leather recommendation standards, validating the practicality and quality of MaSil crust leather. Moreover, our research highlights the unprecedented environmental benefits of the first reported application of Taguchi's approach to the MaSil tanning system. The developed tanning system remarkably reduces total dissolved solids (TDS), biological oxygen demand (BOD), chemical oxygen demand (COD), and overall water load by 68.4%, 25.4%, 59.5%, and 33.7%, respectively, heralding a promising era of water and environmental sustainability in the leather sector. This study holds the potential to transform leather production, wherein the envisioned future on the use of the Taguchi model and optimized MaSil tanning system could find a place in shaping a cleaner, greener, and more sustainable leather industry.