Innovation Takes Root 2010 Conference Report
April 13-15, 2010
Four Seasons Resort & Club, Dallas, TX, USA
Despite tight corporate travel budgets, more than 300 people from 25 countries attended Innovation Takes Root 2010, the international biopolymers conference hosted by NatureWorks in Dallas, Texas, USA. There were more than 30 exhibitors and booths were filled with interested attendees during breaks in the conference proceedings. During meals and at the conference’s two evening receptions, there was palpable energy in the air as connections were made and attendees discussed the many interrelated aspects of sustainability, biopolymer processing, and marketing products with low environmental impacts.
What follows is a comprehensive review of the conference, panel discussions and presentations.
NatureWorks would like to thank all of our keynote presenters, attending companies and delegates for their contribution and keen attention during these three innovative days. Your attendance at Innovation Takes Root 2010 testifies to the fact that like the delegates at the UN Conference in Copenhagen, you and your organizations are committed to a more sustainable future. You are looking for new solutions to long-term problems.
PRE-CONFERENCE WORKSHOPS
On the day before the formal conference, NatureWorks organized two workshops. One, led by Dr. Ramani Narayan (at left) of MSU, focused on principles and concepts of biobased and biodegradable materials. The second workshop was led by NatureWorks scientists Jim Valentine, Joseph Schroeder & Jed Randall who covered practical tools for characterizing and understanding product performance in biopolymers.
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PLENARY SESSIONS
The opening day keynote address was made by David Haft, Group Vice President Sustainability Productivity, Frito-Lay. Haft showed how 21st century technology and a corporate mandate can transform manufacturing and significantly lower energy consumption and greenhouse gas emissions.
Following Haft, the session focused on government initiatives — the latest in the USDA’s Biopreferred Program, and an industry expert’s perspective on FTC guidelines for avoiding green washing — and non-governmental work being done in the areas of sustainability by the World Wild Life Fund and in the area of carbon foot printing and labeling by The Carbon Trust.
Noted organic dairy producer Stoneyfield Farm followed with a description of Stoneyfield’s mapping of its own carbon footprint, and what factors they are considering as they look at packaging – the major carbon contributor for them after the milk itself. Stoneyfield’s Rolf Carlson wrapped up with a best practices discussion on biopolymers. LOHAS Director Ted Ning closed out the plenary session with a high energy recap of the latest data on the shifting attitudes and opinions of consumers in terms of greener packaging and buying behaviors.
On day 2 during lunchtime presentations, NatureWorks described the work now being done by an ASTM sub committee to develop new Resin Identification Codes that are clear and that broaden out to include such bioresins as Ingeo. Frederic Scheer, Chairman of the SPI Bioplastics Council, described the focus of the new council and invited attendees to consider joining the organization.
NatureWorks President and Chief Executive Officer Marc Verbruggen closed the conference, sharing his perspective with the audience on “keeping the innovation cycle going.” Describing the outlook for Ingeo in the next several years, Verbruggen noted that variable cost parity between Ingeo and incumbent materials is within range, and that the increasing economies of production scale within the supply chain downstream of NatureWorks will help improve efficiencies and cost for all sales channel partners.
As proof points, Verbruggen highlighted the breadth and increasingly mainstream nature of the portfolio of Ingeo-based products now available to consumers; the third party interest and investment is transforming options for after-use treatment of bioplastics into new businesses; and the breadth of consumer communications now evident in the market as a key indicator of awareness and market penetration.
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SUCESSFUL INTEGRATION OF INGEO INTO EXISTING MANUFACTURING FACILITIES
Five leaders in the plastics equipment industry discussed integration of Ingeo into existing manufacturing facilities. All five stressed that processing Ingeo on commercially sized equipment is no longer a dream but now a reality.
- Hayes Stripling (VP of Sales at Welex) stressed that Welex sheet lines already in use for aPET and polystyrene sheet can readily accept running Ingeo sheet for clear and opaque applications with minimal to no modifications.
- Bill Goldfarb (President of Universal Dynamics) talked about learning curve at his firm. He described how experience has helped in the modification of existing designs to better handle crystallizing and drying of Ingeo. He also discussed how several installations are already in place using silos to store bulk Ingeo.
- Dave Fogarty (President of Plastics Engineering Associates) discussed the development of screw and cooling mandrel technology for processing Ingeo sheet foam and how it has moved from 30% of polystyrene rates to over 60% of polystyrene rates and soon will be even higher. He stressed that even as process rates are catching up the quality of the final product is equivalent to polystyrene foam trays.
- Karl Zimmerman (Sales Director at Brueckner) talked about the company’s more then 10 years involvement in the development of the biaxially oriented film. Karl discussed the organization’s expertise in understanding the differences between OPP, OPET, OPS and the conversion to OPLA production. He mentioned that Taghleef is the latest conversion they are assisting. (Taghleef recently introduced a new line of films based on Ingeo).
- Alberto Ramirez (VP Sales at Pallmann) talked about film and foam scrap reclaiming equipment and the effectiveness of a densification unit like the Pallmann agglomerator. The unit effectively densifies the scrap without the need to pre dry the low-bulk density material before processing..
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NEW INGEO-BASED PRODUCT DEVELOPMENTS
Bioplastics in Sony Products
Hiroyuki Mori, Senior Eco-products Producer, Material Laboratories, Sony Corporation, Japan
Hiroyuki Mori, Senior Eco-products Producer, spoke about Sony’s use of Ingeo biopolymer in products, initiated with the 2002 introduction of a biopolymer or biomass Walkman® plastic casing. Hiroyuki Mori noted the public already thinks positively of biopolymers, and designers can and should create new attractive products from them. Sony’s global environmental plan “Road to Zero,” states a vision of achieving a zero environmental footprint throughout the life cycle of products and business activities by 2050. Targets include increasing the amount of recycled or renewable materials and a 5% reduction in the utilization ratio of virgin oil-based plastics by 2015 (relative to 2008). A broad number of new Sony products made with biopolymers were visually displayed. A number of these innovative uses required the development of new product technology, led by Sony or by suppliers.
Marketing Green Food Serviceware: Opportunities & Challenges
Dave McIntosh, Senior Engineer, Fabri-Kal Corporation, Kalamazoo, MI USA
David R. McIntosh, Senior Engineer of Fabri-Kal Corporation, opened with a success story; relaying the investment made first to learn how to process Ingeo biopolymer, optimize equipment, move that knowledge to two additional plants, and finally to install and operate one of the highest throughput Ingeo lines in the world. The remainder of David’s talk addressed the challenge of understanding and successfully communicating to business customers and consumers the value of products made with renewable materials. As Fabri-Kal manufactures products using many different plastics, they are relying on LCA/LCI comparisons calculated per case of product for a more objective means to present portfolio options to customers.
Commercialized Products using Ingeo Resin and On-Pack Messaging
Roman Forowycz, Group President / Chief Marketing Officer, Clear Lam Packaging, Elk Grove Village, IL USA
Roman Forowycz, Chief Marketing Officer of Clear Lam Packaging Incorporated, spoke about the firm’s experiences developing rigid and flexible Ingeo biopolymer based packaging, and communicating the value of renewable packaging to consumers using on-pack messaging. A number of the new Clear Lam packaging innovations incorporate materials in addition to Ingeo to expand food packaging applications by providing barrier and other property enhancements. The on-pack messaging draws attention to the renewable resource content. Clear Lam presented survey market research showing that although the idea of packaging made from plant based plastics is very new, already 47% of those surveyed expressed a preference for renewable plant based plastic to packaging made from recycled content. The more environmentally conscious the consumers believed himself or herself to be, the more they preferred renewable plant based packaging. Consumers considering themselves not at all environmentally conscious expressed a strong preference for recycled content packaging rather than packaging made with renewable materials.
High Heat Ingeo Advancements From Spartech
Tim Dawsey, PhD.,Sr. Director of Technology & Todd Niemuth, Business Development Manager, Spartech, Clayton, MO USA
Todd Niemuth, Business Development Manager, and Tim Dawsey, Senior Director of Technology, of Spartech Corporation have long been involved in the successful launch of impact modified cut sheet products for Ingeo-based gift cards and other card products. At Innovation Takes Root 2010, Spartech introduced two new Ingeo products.
- Rejuven8®EX17 is a white, opaque sheet or roll stock product that has good impact properties and heat resistance without secondary processing similar to PET and PETG. This product is intended for both cards and printed cut sheet products or for thermoformed products.
- In the near future, Spartech will offer an additional new grade suitable for cards and any printed cut sheet product. This grade, Rejuven8 EX42, will also be white, opaque cut sheet, with good impact properties, but with more enhanced heat resistance to around 200°F (93.3° C), without the need for secondary processing.
ECO2PUNCH Ingeo PLA Carpet: From Idea to COP15
Dirk De Saedeleir, Director Product Development, Sommer Needlepunch, France
Dirk De Saedelier, Director Product Development of DS-Sommer, a company he and other family members own and manage began by talking about Ingeo-based event carpet. The production and recycling of this carpet is gaining wide attention and use in Europe. For example, the carpet was used at the United Nations Conference on Climate. Initial prototypes for the carpet were 100% Ingeo biopolymer, and were able to meet the highest fire classification (EN 13501-1 classification Bfl/s1) without use of additives. This carpet under the Eco2punch carpet name is able to be recycled by Galactic and then reformulated back into carpet and other products. A video (at right) of the recycling process was showed on the following day. Dirk closed his presentation with a description of non-wovens for use in weed control and for use in horticultural applications. Interestingly, an important feature for these applications is that the Ingeo non-woven is UV stable, without need for additives, which contributes to the longevity of serviceable life.
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BLENDING APPROACHES TO TAILORING INGEO PERFORMANCE
Blends of PLA and Polyhydroxybutyrate (PHBV)
Dr. James Lunt, VP Sales and Marketing, Tianan Biologics Co. Ltd., Ningbo, China
Tianan currently has PHBV production capacity of about 2000 MT/yr. PHBV is a biodegradable, 100% renewable biopolymer made directly by the fermentation of glucose in Ralstonia eutropha bacteria. Compared to PLA, PHBV exhibits excellent heat resistance and low water vapor transmission rates (WVTR), but poor thermal melt stability. Two PHBV/PLA (30/70) and PHBV/ BASF EcoFlex formulations were described showing improved property profiles over the individual biopolymers. Injection molded office and bathroom accessory prototypes were pictured. Lunt concluded with a look into the future where high performance, biodegradable biopolymers and non-biodegradable, bio-derived conventional polymers will be used both separately and in combination for a broad variety of durable plastics applications.
High Performance Biopolymers via Compounding
Steve Maki, VP Technology, RTP Company, Winona, MN USA
Limitations in impact strength, heat resistance and tensile strength preclude PLA from many high performance engineered durable applications. Maki described a number of compounded biopolymer formulations (32-80% biocontent) as offsets to HIPS, PC/ABS, 30% glass fiber reinforced polypropylene or polyamide composites using PLA alloys or reinforced PLA to achieve notched Izod impact strength ranging from 2-16 ft lb/notch, up to 320 deg F HDT and 1.6 MM psi flexural modulus. In addition, Maki indicated that RTP is currently working on several other specialized applications requiring antistatic, custom color, flame retardant, wear resistant, or electrically conductive end-use performance.
Terraloy™ Masterbatches and Compounds for PLA Modification
Greg Anderson, Technical Manager--Bioplastics, Teknor Apex Company, Providence, RI USA
Anderson described thermoplastic starch (TPS) technology for the modification of PLA biopolymers. TPS can be made by compounding a variety of granulated starches, water and glycerol. TPS/PLA blends can be compounded via patented Teknor Apex technology for improved impact strength, melt strength, and metal (mold) release behavior without detriment to biocontent or compostability. Plasticizer level is an effective means of modifying performance with maximum elongation and notched Izod impact strength found at about 36% glycerol, e.g., 200% and 4 ft lbs/in notch, respectively. MB 90000 (non-starch based) series provides improved melt strength or impact strength while maintaining excellent clarity. M20000 (starch based) series provides two levels of further strength improvement, but result in opaque products.
Compounded Solutions for Injection Molding of Semi-durable Goods with High Bio Content, High Impact Strength and Good Heat Resistance
Jed Randall, Research Scientist, NatureWorks LLC, Minnetonka, MN USA
Randall’s presentation describes in great detail the formulation and processing conditions for two heat resistant, Ingeo formulations (HHIM and Ingeo 3801X) which were recently developed for injection molded semi-durable applications. Both formulations contain a combination of ca.10% talc, 10% plasticizer/crystallizing accelerant (dioctyl adipate) and 1.0% Takemoto aromatic sulfonate nucleating agent relative to the Ingeo polymer. Heat resistance is gained by the in-situ crystallization of the PLA component. The Ingeo 3801X formulation also contains about 10% Arkema Biostrength 150 proprietary impact modifier. Injection molding processing conditions are critical to achieving a balance of both heat resistance and impact toughness. (Notched Izod impact strength was found to be inversely proportional to mold temperature.) Neither of these two products is compostable nor approved for food contact. To support the durability of Ingeo products, the effect of aging on molecular weight stability for several different Ingeo products under elevated temperature and humidity were presented along with molecular weight data recently obtained for retained samples stored for 8 to 17 years under ambient office conditions. Estimated useful product life for unmodified grades were >10 years for amorphous high % D Ingeo polymers and >20 years for crystallized low % D Ingeo fibers. Recommendations for DSC and accelerated aging test protocols were also presented.
Blending with Ingeo Biopolymers for Enhanced Properties
Roger Avakian, VP Scientific Development, PolyONE, Inc., Avon Lake, OH USA
Avakian presented information on the new reSound™ Biopolymer line which contains a minimum 30 wt% Ingeo, PHB, PHBV, etc. for applications requiring improved sustainability and higher engineered performance. PolyONE was able to improve key HDT to 120 deg C and notched Izod impact strength up to 14 ft lbs/in notch without requiring any special PLA grade. Performance was shown to be independent of D-lactic acid content as evidenced by equivalent performance for blends made with Ingeo resin grades, e.g., 4032D, 4042D, 4060D. The reSound™1100 series is targeted at polypropylene and ABS resins, while the reSound™1200 series emulates PC/ABS blends having higher performance characteristics. Target markets for reSound™ biopolymers include automotive interiors, electronic enclosures and high heat packaging. Comprehensive additional data was presented supporting the durability of these formulations under conditions of high humidity and elevated temperature while not supporting fungal growth and QUV and Xenon accelerated UV exposure.
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ADDITIVES APPROACHES TO TAILORING INGEO PERFORMANCE
Promoting UV Flexo Ink Adhesion for PLA Film
Rory Wolf, VP of Business Development, Enercon Industries Corporation, Menomonee Falls, WI USA
Wolf’s presentation focused on strategies used to increase adhesion of UV Flexo inks to PLA surfaces. UV Flexo inks are considered a more sustainable printing technology with 100% solids ink systems containing monomers, oligomers and photo-initiators for high graphic brilliance. Optimization of UV flexo ink anchoring to PLA surface requires surface modification by corona, flame or atmospheric plasma for roughening and functionalizing effects. Corona treatment of PLA surfaces was found to provide the best adhesion for the polyester acrylate biologomer and fatty acid modified polyester formulations studied.
Oligomeric Epoxy-Functional Chain-Extenders as Enablers for PLA Processing, Enhanced Properties, and Novel Blends
Dr. Alex Sokolowski, Business Development Manager, BASF, Wyandotte, MI USA
Dr. Sokolowski focused on the applications of Joncryl®-ADR family of multifunctional chain extenders. The primary reactive functionality present in these oligomeric chain extenders is the epoxy groups, which react preferentially with carboxylic acid end-groups of PLA to generate esters of increased weight-average molecular weight and viscosity. Several grades of Joncryl-ADR are available with different glass transition temperature, molecular weight, and epoxy concentration. The melt strength of PLA can be increased to that of polystyrene upon adding <1 wt% Joncryl-ADR, while low Joncryl-ADR loadings have also been found to provide regular shape and steady and continuous blown PLA film at increased line speeds, while maintaining film clarity. A further application of Joncryl-ADR is in the compatibilization of immiscible and compostable polymer blends, such as polyhydroxyalkanoates and BASF Ecoflex®. The low loadings of Joncryl-ADR required to bring about improved rheological and mechanical properties of PLA does not negatively impact the compostability of PLA per ASTM D6400. Sokolowski recommended zinc stearate as a catalyst for PLA + Joncryl-ADR reactions, and noted that aging of PLA pellets was better after reacting with their epoxy.
Investigation of Nucleating Agents for PLA Resin
Michiya Hiei, Technical Sales Manager of Polymer Additives Division, Takemoto Oil & Fat Co., Ltd, Japan
Hiei focused on efforts within Takemoto targeted to the identification of nucleants that can increase the semi-durables market penetration of PLA. The technical objective for Takemoto was to reduce cycle time in injection molding process, and thus a nucleant was sought where the onset of crystallization occurred at the highest possible temperature. Several aromatic sulfonate nucleants, of unspecified structure, were screened using different Ingeo resins. At 1 wt% loading in Ingeo 3251D resin, Takemoto’s LAK-301 nucleant was found to reduce injection molding cycle time to <30 seconds at a peak crystallization temperature of 115.2 °C. Hiei noted that a patent pending for LAK-301 nucleant in Japan, USA, Europe, Asia and Australia.
Acrylic Modification: Enabling PLA to Advance into Challenging Applications
Dr. Zuzanna Cygan, Research Scientist in Arkema’s Sustainability Additives Division, Arkema, King of Prussia, PA USA
Dr. Cygan focused on the applications of Arkema Biostrength® acrylic additives for improving the impact strength, melt strength, and compatibilization of PLA. Biostrength 280 (introduced at ITR 2010) impact modifier at 4 wt% loading provides high impact and low haze, while Biostrength 150 was developed to provide high impact for opaque applications, durables and blends. Biostrength 700 is a transparent melt strength additive for PLA that improves processability, while meeting FDA standards for food contact certification. It has also been found in improve PLA compatbilization with polyolefins. Biostrength 900 additive was developed to improve PLA metal release without impacting clarity. Dr. Cygan noted as a commercial example, the PLEXIGLAS® RNew family, which are PLA/PMMA blends.
SUKANO® BIOPOLYMERS-PLA a la carte
Daniel Ganz, Business Development Manager, Sukano Products Ltd., Switzerland
Mr.Ganz provided a thorough review of commercially available Sukano additives and masterbatches for film extrusion applications made from PLA. New BIOLOY biobased polymer alloys are ready to use compounded alloys made from an array of compostable biopolymers, and designed for injection molding applications. These BIOLOY products contain impact modifiers and processing aids to make them suitable for easy processing and contain fillers to obtain the desired mechanical properties. Ganz provided the characteristics and performance of the BIOLOY.
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ADVANCES IN INGEO FIBERS & NONWOVENS
Development of the Next Generation of Renewable Nonwovens for Agricultural and Disposable Hygiene Applications
Dr. Larry C. Wadsworth, Chief Technical Officer, U.S. Pacific Nonwovens Industry Ltd., Hong Kong
Dr. Wadsworth laid the groundwork for the recent U.S. Pacific Nonwovens announcement during his presentation at the Innovation Takes Root. Wadsworth presented the results of USDA-funded research on biodegradable mulches for crops produced under protective covers, which included an assessment of next-generation nonwovens including Ingeo. He concluded with new results based on work done at Biax-Fiberfilm and U.S. Pacific in China on the blending of Ingeo with PHA’s to produce melt-blown wet wipes fabric not only with improved shelf-life in the package, but also with enhanced biodegradation in river water, mud, and compost.
BioWeb™ - The Renewable Option
Ray Volpe, Technology Director, Ahlstrom, Finland
Ray Volpe, technology director for Ahlstrom Advanced Nonwovens business area, also shared new details of Ahlstrom’s Ingeo-based BioWeb spun-bond nonwoven product line. Noting that BioWeb is now available in a range of basic weights, Volpe attracted strong interest when he compared BioWeb and polypropylene webs. With tensile strength, dye ability, and surface energy equivalent to, or better than PP, BioWeb offers improved cuttability, stain release, and flammability/heat/smoke characteristics, while lowering web elongations. With the 2009 announcement of its new Chirnside UK spun-bond line, Ahlstrom made it clear that its immediate intent is to target beverage infusion applications such as tea bags. In Dallas, however, Volpe also emphasized that Ahlstrom’s interest in BioWeb renewable nonwovens is broad, covering a wide variety of end-use applications including topsheet/backsheet for diapers, plant-root protection, and soft furnishings.
Meltblown Ingeo Nonwovens for the Filtration Industry
Dr. Gajanan S. Bhat, Professor Materials Science & Engineering, The University of Tennessee, Knoxville, TN USA
Rounding out the Ingeo nonwovens discussion, Dr. Gajanan Bhat of the University of Tennessee – Knoxville’s Nonwovens Research Lab reviewed Ingeo melt-blown nonwovens for filtration applications. Bhat included a detailed review of Ingeo melt-blowing process parameters, process variables, and response factors for nonwovens, property characterizations that are important to the filtration industry. With research that underpinned Wadsworth’s earlier points, Bhat showed that Ingeo can be melt-blown to produce fine fiber webs with good mechanical and performance properties.
Advances in the Surface Modification of PLA Fibers
Chris Hagler, R&D Manager, Goulston Technologies, Inc., Monroe, NC USA
Goulston Technologies’, Chris Hagler described the company’s latest advances in Ingeo fiber surface modification for fibers and nonwovens, emphasizing Goulston’s core strength in tailoring the finish chemistry to meet the specific application demand. Goulston now has a formal relationship with Polyvel, which has been a long-time provider of additives for a wide variety of Ingeo packaging applications.
The Power of PLA in Specialty Fibers
Dr. Jeff Dugan, Co-Founder, Fiber Innovation Technology, Inc., Johnson City, TN USA
Fiber Innovation Technology co-founder, Dr. Jeff Dugan, described his organization’s long relationship with NatureWorks since it became the first Ingeo fibers master licensee partner in 2003. Fiber Innovation Technology has extensive experience with and knowledge of Ingeo fibers and processing, and Dugan shared the latest innovations and ongoing work on producing Ingeo (PLA/PLA) binder fibers with significantly improved bond strength.
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CRADLE-TO-CRADLE
A highly interactive panel session, moderated by the Sustainable Biomaterials Collaborative’s Brenda Platt, looked at recovery from two angles — both composting, and reformulating post consumer and post industrial Ingeo back into lactic acid. Galactic and BioCor, two companies operating in Europe and North American respectively, discussed their businesses based on the model of lactic acid recovery from a variety of post consumer and post industrial polylactide residual sources.
Frito-Lay gave an overview of its extensive composting research for the compostable Sun Chip snack bag, while Canadian manufacturer Dyne-a-Pak introduced the successful development and market introduction of its compostable Ingeo-based alternative to polystyrene foam food packaging. California State Chico’s Dr. Joe Greene discussed the holistic approach the school has taken to analyzing claims and performance of biobased packaging and food serviceware.
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THE BUSINESS CASE FOR GREEN
This panel discussion was moderated by noted sustainability expert Joel Makower, who gave the April 15th keynote address. Panelists representing: All Nippon Airways, Elements Naturals, Frito-Lay, International Paper, and Target Corporation shared their personal experience across a wide breadth of markets, products and geographies, discussing what they have done, how they have authentically positioned the product, and what they have heard back from their consumers.
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