Development of high performance low emission brake pad composites using Zingiberaceae derived biofibres

Material systems are an important but less explored area of environmental impact within the mobility sector. Conventional brake pads use synthetic fibres and intensive fillers to operate in addition to causing non-exhaust emissions. This work presents a novel circular material strategy for converting waste Zingiberaceae plant biomass into advanced eco-friendly brake friction composites. Silanized biofibres were used in phenolic resins and compared to conventional brake pad systems. The optimized brake pad system exhibited a stable coefficient of friction ranging from 0.35 to 0.37, fade values between 5.56% and 8.33%, fade recovery exceeding 100%, and more than 50% reduction in wear. The optimized brake pad satisfies the SAE J866 Edge code “FF” friction classification range of 0.35–0.45 under standard operating conditions. Life Cycle Assessment showed a 15% decrease in Global Warming Potential (GWP) and 25% decrease in Cumulative Energy Demand (CED) in addition to significant reduction in water requirement, human toxicity, and particulate emissions. Sensitivity Analysis proved these findings to be reliable.