Comparative Evaluation of the Physical and Mechanical Properties of Commercial Vegan Leather Alternatives and Calfskin

The conventional leather processing industry poses severe environmental hazards due to the extensive use of hazardous chemicals and synthetic tanning agents. Driven by the principles of the circular bioeconomy, there is an urgent need to engineer high-performance PUR-coated composites with plant-based fillers. This study presents a comprehensive comparative evaluation of commercially available plant- and fruit-derived leather alternatives—specifically utilizing apple, olive, and cactus-based materials—versus traditional synthetic alternatives and animal-based calfskin. To systematically evaluate their technical viability as sustainable flexible composites, their physical, mechanical, and thermophysiological comfort properties were examined. Furthermore, Fourier-transform infrared spectroscopy (FT-IR) and scanning electron microscopy (SEM) were deployed to elucidate the molecular interactions and microstructural surface morphologies of the composite matrices. Experimental results indicate that plant -based alternatives offer diverse performance profiles; for instance, cactus-based polymeric sheets excel in distension and color stability, while apple-derived layers demonstrate remarkable surface resilience. However, traditional calfskin remains the most robust fibrous network due to its superior tear resistance and tensile strength. This study establishes critical engineering baselines for the functional selection and design of alternative PUR-coated composites with plant-based fillers, presenting viable green solutions to mitigate the environmental footprints of flexible materials.