Development of Plant-Based Leather from Naturally Dyed Banana Pseudo-Stem Using a Low-Energy Process

This study explores the natural dyeing of banana pseudo-stem (BSS) fibers as a sustainable material for plant-based leather applications through low-energy processes. Two dye types, lac dye and indigo blue, were applied, and the optimal dyeing parameters were systematically determined. Optimal lac dyeing was achieved using pre-mordanting with a binary mordant system comprising tannic acid and aluminum potassium sulfate (5 g L−1 each), a dye concentration of 10% owf, a pH of 4.23, and a dyeing duration of 6 h. For indigo dyeing, the optimal conditions involved 500 g L−1 wet indigo, 30 g L−1 sodium hydroxide, and 40 g L−1 thiourea dioxide, with a reduction step at 30 °C for 30 min. The dyed samples exhibited good to excellent perspiration fastness in terms of staining, while color change ratings remained low due to the intrinsic sensitivity of natural dyes. Light fastness was rated fair. The dyed BSS was subsequently laminated onto a polypropylene (PP) nonwoven substrate and coated with natural rubber (NR) latex, yielding bursting strengths of 51.8–54.8 psi. Moisture management testing confirmed inherent waterproof properties. Overall, this study presents a resource-efficient approach to transforming agricultural residues into sustainable, plant-based leather alternatives.