Innovation Takes Root 2008 Conference Report
September 16-18, 2008
Planet Hollywood Resort and Casino, Las Vegas, Nevada, USA
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This first-of-its-kind conference was designed to facilitate and share an exchange of information, expertise, and innovations within the bioplastics industry on specific technical tracks relevant to the entire supply chain. Innovation Take Root included, but was not exclusive to Ingeo biopolymer, and the success of the conference was evidenced by the strong attendance of players from around the world . Representing a diverse set of industries, the attendees shared a common goal – all came from companies looking to reduce their dependence on oil while delivering relevant and performance products that have less impact on the environment and appeal to a discerning eco- aware consumer.
The 236 delegates attending from 149 global companies rated the 2 day conference as very successful, not least because of the wealth of new knowledge that is now in the public arena, set to accelerate the the commercial success of these first-to-market innovators in the field. Organized by NatureWorks as an open forum that included scientists, engineers and manufacturers, the conference showcased 24 companies who contributed presentations throughout the 2 days.
Significant subject areas covered by presentations included improvements in mechanical properties, surface modification, additive innovations and improvements in thermal properties by nucleation packages, blends, and stereocomplex. Valuable technical track presentations from the likes of Arkema, BioFilm, DuPont Corporation, Emmount Technology, Kao Corporation, Rohm & Haas, Samsung-Cheil, Toray, Unitika, as well as NatureWorks LLC, covered a full range of subjects.
Keynote speaker presentations were given from industry leaders Toyota and 3M who explained how they have used innovations as assets to propel their business while Ron Pernick, co-author, The Clean Tech Revolution, presented how his experience with how emerging clean technologies could revolutionize the way in which both established and new companies do business today.
Following the conference, Mark Verbruggen, CEO of NatureWorks LLC commented:
“We are very pleased with the outcome of the Innovation Takes Root Conference this year. As the organizer for this, the first collective exchange of technical innovations for Ingeo, we can confirm the growing significance of biopolymers today, and the impact they can and are having in the commercial world. A measurable critical mass of products are available today, and now not just with the sustainability tag, but ones that are driven by a vision for improving the planet, with lifestyle solutions that are innovative, look good and perform well too, making Ingeo the better material of choice for consumers today.”
A comprehensive review of work presented in each of the following areas is included.
NatureWorks would like to thank all of our keynote presenters, attending companies and delegates for their contribution and keen attention during these two fruitful days. The unique characteristics and appeal of bioplastics in the 21st century are part of an enthusiasm and commitment evident from this first-of-its-kind conference.
NatureWorks LLC and Ingeo: together helping Innovation to Take Root and making businesses work better for all involved.
About NatureWorks LLC
NatureWorks LLC is a company dedicated to meeting the world’s needs today without compromising the earth’s ability to meet the needs of tomorrow. NatureWorks LLC is the first company to offer a family of commercially available low carbon footprint biopolymers derived from 100 percent annually renewable resources with performance and economics that compete with oil-based plastics and fibers. The production of these biopolymers uses less fossil fuel and emits fewer greenhouse gases than conventional polymers. The company applies its proprietary technology to process natural plant sugars to make Ingeo biopolymer, which is then used uniquely to make and market finished products under the same Ingeo brand name.
TECHNICAL PRESENTATION SUMMARY
Ingeo Impact Modification
Arkema’s Dr.Zuzanna Cygen illustrated their Biostrength® additive family, designed for improving Ingeo processing, properties and performance. Biostrength® 150 & 200 modifier grades, intended for use in opaque and transparent systems respectively, are designed specifically to improve polylactide impact strength. Toughening Ingeo improves productivity by reduced scrap and increased line speed, yielding faster cutting and stacking, and eliminating indexing chain puncture, cracks and breakage of sheet during cutting. Toughening of Ingeo also further enables more durable application innovations.
Rohm & Haas has developed a new grade of impact modifier for Ingeo which works at half the loading level of prior grades to improve the strengthen and brittleness normally found in neat polylactide. Bahar Azimipour introduced Rohm and Haas’ new grade, BPM 515 in Las Vegas, noting availability for commercial sampling in Q4, 2008, and illustrating performance enhancements with additive levels as low as 2%. BPM 515 is a significant step forward, while not biobased or compostable. The holy grail for the industry remains an additive that meets these criteria while still providing safe food contact and clarity
Patrick Wernett, Director of Specialty Mineral Inc., compared the impact properties of Ingeo composites incorporating a newly engineered mineral (EMforce® Bio additive) to conventional mineral additives. The EMforce® Bio additive was found to yield a ductile failure mechanism and greatly improve the impact resistance of the composites.
Daniel Ganz, Sukano’s Business development manager, wrapped up a comprehensive review of Sukano’s functional masterbatches by introducing Sukano’s new impact modifier with new test data, as well as introducing their new antistatic and UV content protection masterbatch.
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Modifiation of Ingeo Heat Characteristics
A key attribute of Ingeo is its transparency when thermoformed. Dupont’s Julius Uradnisheck highlighted how a combination of their Biomax modifiers with optimization of thermoforming conditions can improve the mechanical stability of Ingeo at elevated temperatures while still maintaining transparency. DuPont BioMax 300 Thermal is a new heat improvement additive that relies on the cPET process to achieve improved results. BioMax 300 modification of Ingeo™ allows use of a Hot Mold (cPET process) which provides PLA articles with low haze and fast cycle times.
Kao Corporation’s Kenichi Miyamoto highlighted his company’s modification of Ingeo resin based on their technology of polymer nano-modification. This involves the control of softening, control of polylactide nano-crystallization, and modification with another component.The physical properties of the resultant Ingeo blend can be adjusted to match PP or ABS performance & characteristics. Also, product moldability is similar as the level of PP or ABS resin due to its very quick crystallization.
PolyOne’s Roger Avakian outlined the technical approach PolyOne has taken to improve the heat distortion temperature of Ingeo, highlighting their current ability to modify PLA's heat distortion temperature from it’s normal ~50 C, into the range of ~80C to ~100C . Avakian wrapped up by introducing PolyOne’s future plans and bio-derived content of targeted formulations.
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Modification of Ingeo Processing Behavior
Arkema’s Cygen described how their Biostrength® 700 Melt Strength Additive for Ingeo increases melt strength by 25% at low loadings, while actually doubling it at higher loadings. Biostrength 700 has the further advantage of being transparent in the product, even at these high loadings. Data provided illustrated how Biostrength 700 can be used to compensate for the loss of melt strength encountered with the addition of Ingeo regrind, offering significant improvements at 75% regrind, for example, with 2% Biostrength 700.
Adjusting the metal release characteristics of Ingeo offers the potential for increased line speeds and lower scrap rates in calendaring, as well as for improved mold release or injection molding. Here, Arkema illustrated how the use of their new Biostrength® 900 Melt Strength Additive will significantly improve Ingeo metal release. As an example, data demonstrated how 3-5% Biostrength 900 enabled the processing of neat Ingeo on two roll mill at 160°C without impacting clarity
Noting how historically, esters-based modifiers have been manufactured from petroleum-based raw materials, Hallstar’s Kimberly Stefanisin highlighted how his company has responded to the booming interest in renewable raw materials such as Ingeo with the commercialization of esters from plant-derived, sustainable resources that are fully compatible with Ingeo biopolymer
When compounded with Ingeo, these renewable esters offer improved flow characteristics, reduced brittleness, improved processing and enhanced physical properties. Stefanisin noted that these renewable esters are now past the experimental design phase and are commercially available. In addition to the renewable based performance enhancement that these offer, they are also non-volatile and extraction resistant.
Daniel Ganz, Sukano’s Business development manager described their development of a wide range of functional masterbatches designed to tune and optimize the properties of Ingeo for numerous applications. With anti-block and slip masterbatches, excellent slip performance, low adhesion and fast, easy de-stacking can be obtained for food packaging. Sukano’s nucleating agents facilitate controlled crystallization and improved thermal properties, while their portfolio of optical masterbatches for visual enhancement includes organic and inorganic pigments, soluble colorants and white and black pigments incorporated into easy-to-process, transparent or opaque concentrates for Ingeo.
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APPLICATIONS & TECHNOLOGIES
Films
Biofilm S.A.’s Alexandra Quiceno reviewed their work in improving intrinsic Ingeo barrier performance. Biofilm have achieved clear barrier for several food packaging applications, and Quiceno reviewed substrate properties, process compatibility, and downstream processes requirements
The physical vapor deposition of aluminum onto substrates such as paper, PET films, OPP films, polyamide films and nonwoven polymers has long been well developed. Emmount Technology’s Eldridge Mount reviewed his work in breaking new ground with the application of this technology to Ingeo biopolymer substrates. Although the development of the metalized barrier properties of Ingeo films is still at very early stage, production tests conducted at a commercial metalizer have already provided a good overall metalized film with excellent metal adhesion and optical uniformity.
Toray’s Masahiro Kimura described how their nano-structure controlled film technology can improve basic properties of Ingeo film and open a potential of advanced PLA film.
Brückner’s Karl Zimmermann described their stretching technology for present and future biaxially oriented Ingeo film applications, line layouts for processing Ingeo, product applications and samples, and stressed the advantages of green films in comparison to incumbent film types.
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Fibers & Nonwovens
NatureWorks’ Rick Benson outlined test method development and results for measuring crystal growth rate for thermoforming applications as well as the development of modeling techniques useful for understanding and mapping the chemistry to polymer physical properties for trans-esterified stereo-complex. This modeling was used to successfully produce several types of stereocomplex fibers, and NatureWorks’ Robert Green described process & product work done with continuous filament, false twist texturing and flat fiber or hard yarns, staple fibers, and bulk continuous filament carpet yarns.
Ralf Taubner of the Sächsisches Textilforschungs institut e.V. (STFI), described the potential for innovative process engineering solutions and product development resulting from their recent developments in spunbond Ingeo nonwovens. Taubner described the spinning behaviour and production parameters of Ingeo spunbond fabrics. Fiber speeds between 2000 and 6000 m/min were realised in order to determine the threshold regarding minimum attainable filament deniers. Fiber strength up to 25 cN/tex were achieved.
Taubner highlighted that Ingeo showed excellent spinning ability and strong textile-physical fiber parameters. Nonwoven bonding was accomplished by calandering, spunlacing and needle-punching while best mechanical properties were achieved by spunlacing. This research work has been recently continued with further Ingeo fiber grades and first results show promise with the development of very low gram weights for key hygiene market applications.
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Blends, Injection Molding
Chang-Do Jung from Samsung-Cheil described the evolution and technology of the Ingeo/polycarbonate technology behind Samsung’s environmentally friendly handset introduced in June. Jung presented specifics on optimized heat resistance, and impact strength by using Ingeo engineered plastic blends.
In the resins area, Michiuyki Nakase described how technology development by Toray’s core technologies such as “Nanoalloy” can contribute to extend the Ingeo property set. Yoshiharu Okumura presented Toray’s novel work in improving abrasion and hydrolysis properties. With a long history of Ingeo-based development, and now over 500 patents and applications around polylactide, Toray’s investment and commitment in this arena is obvious
Unitika’s Dr Kazue Ueda described their modification of Ingeo to increase heat resistance using crystallization for injection molding and foaming. In the case of foaming, increasing the melt tension is also important. Udea discussed the technical factors key to their achievements, the resultant physical properties of their PLA resins and where they are seeing applications development today.
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Strong Automotive Interests
Dr. Masatoshi Matsuda of the Toyota Motor Corporation laid out Toyota’s ambitious vision of establishing technology for 20 weight % usage of ecoplastics and recycled plastics by 2015.
Matsuda highlighted Toyota’s investment and progress to date in polylactide, starting in 2003 with the commercial production of the spare wheel cover for the Toyota Raum and floor mats for both the Toyota Raum & Prius. Following 2005, with Toyota showcasing at the Tokyo Motor Show & Aiche exhibition, their developmental focus extended to seat back board and mesh with PLA/Kenaf blends, door trim fabrics in PLA hemp blends, and instrument panels.
Matsuda discussed the challenges for PLA in competing with PP in automotive applications. In product, the low HDT, impact strength, and hydrolytic stability, and in process, the relatively higher molding cycle times, and wrapped up on a positive note, stressing how Toyota is engaging with it’s suppliers to comprehensively address these in order to meet it’s long term vision. For Heat resistance this involves using fillers, controlling MW, and optical purity, moldability, nucleating agent, plasticizer useage, and stereocomplex. For impact resistance, the addition of elastomers, and for long term durability (hydrolytic stability), the use of end-capping and residue reduction.
Ellen Lee from the Ford Motor Company’s Biomaterials Research Group highlighted how Ford CEO Alan Mulally’s commitment to offer their customers affordable, environmentally friendly technologies in their vehicles translates down into their fundamental work to improve the performance of Ingeo resin in injection molding via crystallinity modification.
Starting from a comprehensive review of automotive requirements, from temperature, to moisture, to scuff, dent, and ding resistance in exterior parts, UV weathering characteristics, and for underhood applications, corrosion and cyclic fatigue resistance, Lee highlighted where Ford sees potential for Ingeo in automotive applications in the shorter term. In textiles, this includes, carpet, floor mats, and upholstery; in interior parts, in injection molded applications such as trim, knobs, buttons, and non-appearance parts; and finally, in Ford’s own manufacturing processes, in packaging and protective wrap
In Lee’s current work, the overall crystallization rate and final crystallinity of Ingeo were controlled by the addition of physical nucleating agents and optimization of injection molding processing conditions. Ford has comprehensively compared the effect of a range of nucleating agents, including talc, nanoclay, purified cellulose, soy flour, and thylene bis-stearamide (EBS) . Use of optimum nucleating agents and conditions showed dramatic increases in crystallization rate and final crystalline content. Isothermal crystallization half-times were found to decrease nearly 65-fold by the addition of only 2% talc. Process changes also had a significant effect on the final crystallinity of molded neat Ingeo, which was shown to increase from 5% to 42%. The combination of nucleating agents and process optimization not only resulted in an increase in final injection molded crystallinity level, but also allowed for a decreased processing time.
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Processing Equipment For Ingeo
A respected set of equipment and technology providers from agglomerators, to single & twin screw extrusion experts gathered to highlight the ability of their systems to process Ingeo, comparing and contrasting processing performance, efficiencies, and energy usage to name a few. Collectively, presentations from Brueckner, Pallmann, Xaloy, Leistritz, Universal Dynamics represented an “Ingeo Processing- 101”, on improvements, handling , and advantages of processing Ingeo resin.
The use of twin screw extruders is a common practice to process Ingeo resins, and Charlie Martin of Leistritz explained how their High Speed Energy Input (HSEI) applications include compounding, reactive processing, devolatilization, and foaming. The HSEI’s final product can be pellets for subsequent forming processes, or for the direct extrusion of a fiber/film/sheet or profile. Recent design enhancements to the Leistritz HSEI twin screw extruder offer improved heat transfer capabilities, higher torque and more free volume. Martin presented a comparison of their traditional HSEI twin screw extruder to the enhanced design, along with examples of standard and atypical twin screw extrusion systems for various Ingeo resin process applications.
Alberto Ramirez of Pallmann Industries described their system for addressing the waste produced during the production and processing of Ingeo – waste which can be effectively recycled through a material-gentle agglomeration and continuous process. The Ingeo waste is turned into a high quality, free flowing, and high bulk density granules which can be reused for production as valuable raw material. The heart of this continuous process consists of an agglomeration step where through frictional heat only, and mechanical pressure, the material is evenly sintered, within fractions of a second, through the holes of a die.The adjustable frictional heat and the mechanical pressure allows for the sintering to be performed below the melting point of Ingeo, thus minimizing any thermal degradation of the product. The resulting high quality granules at the end of the process can be collected in super sacks or silos to be reintroduced directly into production.
Willam Goldfarb of Universal Dynamics, Inc presented a review of energy-savings benefits and special material handling requirements of Ingeo. Ingeo biopolymer requires significantly cooler crystallizer and drying system temperatures than PET resulting in significant energy-savings - as little as one quarter the energy to dry vs PET.
Tim Womer of Xaloy, Inc., described how, since the early 1990s Ingeo resins have made enormous improvements in their process ability. In the early days, when the resin was being manufactured at pilot plant capacities and the monomer levels were very high, processing Ingeo was often difficult. Today, natural additives are being used to improve the process ability of these bioplastic resins. Xaloy has tested several new lubricant additive packages to determine which package produced the best performance and process improvements. The process data, such as throughput rate, head pressure stability, melt temperature, and drive power consumption were collected and used to quantify the process ability of the various additive packages. All of this data was then compared to the internal pressure data that was collected to analyze what was happening during the feeding, melting, and pumping of the Ingeo resin.
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