SPE Library

What is Impact of PLA Biopolymer on Corn Supply and Uses? Based on 2001 Harvest of 9.8 billion bushels (NCGA Data): Export 20%; Alcohol 1%; Other 2%; HFCS 6%; Sweeteners 2%; Starch 3%; Ethanol 7%; PLA 0.6%; Feed 59%

Engineering polymers based on condensation thermoplastics like PET, PBT, Polyamides, Polycarbonates and Biopolyesters have to be reprocessed during recycling at very high temperature, where degradation of these polymers are extremely rapid. As the result of this regradation, the possiblities for reprocessing internal process regrind as well as postconsumer - recycle reclaims back into demanding application is very limited. The polymeric chain extender offer a possibility to rebuild molecular weight and melt strengths of these polyester, blends and related product and open a new window of opportunity for recycling.

PALLMANN develops and manufactures size reduction machines and complete systems for the plastics and recycling industries. We have over 100 years in the industry, one of the largest R&D facilities, and a firm commitment to the sustainability movement. PALLMANN continues to offer innovative solutions to the industry, including Size Reduction technology and Agglomeration of Thermoplastics with our Plast- Agglomerator. Our innovating technology is presently applied in such processes as reclamation of carpet waste, packaging products including biodegradable plastic materials such as PLA foam, plastic fibers and non-woven materials, films, etc.

PLA (Polylactide resin) is one of the bio-plastics that has found some product applications and seems to be an extrudable material of growing interest. Any polymer that is made from a renewable resource and that it is a degradable and/or environmentally friendly material seems to gain favor in some markets, especially if it can be processed on existing machinery. This paper will discuss the requirements to efficiently extrude PLA on a single screw extruder with an optimum screw design and processing conditions. Different sizes of extruders will be looked at to give some guidelines as to the required equipment to successfully extrude this material.

Biodegradable and oxodegradable plastics degraded in an in-vessel compost operation along with food waste from San Francisco, California. Biodegradable plastics included, corn starch based biobag, Mirel PHA bag, BioTuf Ecoflex bag, Husky corn starch based trash bag, PLA lids, sugar cane lids, and Kraft paper. Also buried were polyethylene shrink-wrap, UV degradable plastic bag, and oxodegradable plastic bag. The samples were placed in perforated plastic sacks and mixed with food waste at NorCal and Jepson Prairie Organics (JPO) composting operation in Vacaville, California. After 180 days, the materials that completely degraded included PLA lids, Mirel bags, Ecoflex bags, Husky bags, and corn starch trash bags. Small fragments of sugar cane lids and Kraft paper were visible. The sugar cane and Kraft paper fragments were very moist and would disintegrate when picked up. The Kraft paper and sugar cane fragments did not completely biodegrade due to the lack of mechanical agitation while in the plastic sacks. If the materials were placed in the compost soil, higher degradation would occur due to better interaction with the compost soil. The oxo-biodegradable plastic bags, LDPE plastic bags and UV-degradable plastic bag did not experience any degradation and did not fragment into smaller pieces.

Using agricultural crops as material feedstock is becoming more prevalent as scientists search for alternative choices to petroleum based products. Soybeans are one crop within North America that is economical and readily available for use in plastic applications. Recently, we have been evaluating the use of soy as reinforcement and resin in a variety of polymer matrices, including flexible and rigid polyurethanes. Our main focus has been on using functionalized soybean oil in the manufacture and formulation development of flexible, polyurethane foams for seating applications. Soy-based foams reduce the environmental footprint compared with the manufacture of petroleum-based foams. These materials utilize a sustainable material, decrease our dependency on petroleum and reduce carbon dioxide emissions. Ford Motor Company has researched methods to overcome several technical issues such as reducing odor in the foam and maximizing soy content in foam formulations, while meeting rigorous, automotive interior applications. In a partnership between Ford Motor Company and Lear Corporation, we have demonstrated the feasibility of formulating and processing soy-based polyurethane systems that have the key properties required for automotive interior and seating foam applications. Prior to launch of this soy technology, numerous processing trials were completed on headrest, armrest and seating applications. We will review the main steps required in moving the technology from a laboratory research setting to production environment and launch of the soy technology in 2008 Mustang. We will also discuss the technical and commercial challenges and benefits of implementing soy-based foam.

The punched sections of composite substrate/foam/skin (punch outs) have traditionally gone to landfill, typically at a cost of $0.05/lb. to the Tier 1 supplier. Wipag Recycling in Germany has developed a process whereby the substrate material is recovered from the composite structure, separating the resin from the foam and skin. The resin has 99.8% purity and can be subsequently blended back into virgin resin for production at a specified percentage without statistically varying the physical properties of the LFPP IP substrate. The WIPAG laminate separation process has been in commercial operation at American Commodities Inc. (ACI) in Flint, MI for the past 7 years albeit with SMA, PC/ABS and TPO substrates. With regard to recycling LFPP, traditional wisdom dictates that the material properties of the resin will be reduced after each heat history due to glass fiber length attrition, caused from the processing of the material. This study shows that up to 30% of resin reclaimed from the composite substrate can be added to virgin material with a minimal effect on the properties of the final part.

Advances in the field of polyolefin resins in the area of PP copolymers, PE homopolymers, and PP & PE blends have allowed for the creation of new and improved polyolefin bead foams. These polyolefin bead foams are capable of improved performance due to the advancements that have been made in the area of polyolefin resin catalyst systems and additives. The benefits of polyolefin bead foams allow for lower densities to be used where higher density extruded foams are currently being utilized. There is a move in the automotive industry to promote the use of sustainable products. Sustainability considerations in automotive design must include a variety of factors. These include: • Weight reduction • Commonization of materials • Use of more environmentally friendly materials • Ease of disassembly at vehicle’s End-Of-Life • Consideration of RoHS requirements • Compliance to OEM, Federal and Industry regulations • Recyclability of materials and current recycling stream • Component design and performance requirements • Vehicle and occupant safety While evaluating all of these considerations when designing for sustainability, it is necessary to understand the allowances for performance and cost trade-offs as they relate to meeting the needs of both the OEM and end user (or customer). This paper will explore the industry trends, particularly those published by the OEM’s as they relate to designing for sustainability and recyclability. This paper will compare some of the newer industry recycling guidelines, as well as vehicle End-Of-Life dismantling requirements. This paper will also explain the intention of the newer vehicle component part guidelines for sustainable development as they relate to automotive component design and ease of disassembly and recyclability. Case studies will be presented to evaluate component part design and the move toward the use of more commonly recycled and recyclable products. Industry trends will also be reviewed as they apply to market demand for more environmentally friendly materials. The pros and cons of using some of the new biobased materials will also be compared and contrasted.

Being sustainable means that a product or service meets both today’s needs and results in minimized burden to our children and their children and to the environment for the future. This paper will present a proven alternative to environmental issues such as heavy metals used chrome plating for application to plastic components in the global automotive, light truck, and heavy truck industry. It will highlight how this technology, Fluorex® bright film, further contributes to a “greener” environment by eliminating environmental hazards and residual footprints from substances such as heavy metals by using film based solutions contributing to the development of lighter and potentially “greener” light weight vehicles. This translates in both better fuel economy in vehicles using this technology and reductions in emissions from the manufacturing processes. Other environmental benefits for other coating opportunities using Flourex® Paintfilm will be evaluated based on this technology that specifically involve more opportunities to minimize the environmental impact and improve recyclability while contributing to a more aesthetically pleasing environment by enhancing the appearance of vehicles worldwide. This is a solution for manufacturers to provide the appealing and marketable look of chrome or other pleasing surface characteristics on plastic components while being environmental compliant and responsible. This is a sustainable solution for coloring and coating – Fluorex® bright film and Fluorex® paintfilm – a “green” alternative to painting metal and plastic products that enhances the environmental benefits of plastics is both possible and here today.

The years 2006 and 2007 saw popular culture embrace issues such as global warming, alternative energy production, biofuels, hybrid transportation, and carbon credits. Clean Technology became the fastest growing investment sector and produced some of the most-watched initial public offerings of the recent past. While this new 'fame' has led to an increase in new companies and initiatives, investment dollars, state and federal legislation, and media coverage, it has also led to concerns that the marketplace is a bubble without strong fundamentals to drive the marketplace. Certain investment funds have set up new funds designed to purchase failed and distressed cleantechnology companies. What is the current status of the clean-technology marketplace? What fundamentals exist for the companies that are succeeding and those that fail? Where are the investment dollars and how can companies take advantage of the current marketplace? While some may question aspects of the clean technology revolution, it is without question that a fundamental shift in our consciousness and our culture are occurring -- that has led to unique opportunities and challenges for tomorrow's leaders in clean-technology markets.

Advanced Blending Technologies has developed a software program that creates low cost optimized blends from wide-/off-spec and/or recycled Polyethylene streams of material, by providing blend formulations based on up to seven selectable material properties. The resulting blends are prioritized by least cost and eliminate the need for costly “Trial and Error” experimenting with blends. Combined with rapid testing of incoming material streams, the OptiMISER® system has successfully been used to convert 100% virgin material processors to 100% recycled usage, at substantial bottom line savings. The OptiMISER system provides the materials engineering needed to maintain production efficiency and insure product quality. Using recycled or wide-/off-spec PE usually results in decreased manufacturing efficiencies, increased scrap and worse; decreased end product quality. This paper discusses a systematic approach which allows the use of up to 100% recycled and/or wide-/off-spec materials while maintaining or even increasing manufacturing efficiencies, reducing process scrap, insuring a consistent end quality product, and significantly reducing overall finished product costs.

Single use plastic bags are used by the billion in supermarkets, fast food outlets and retail stores because of their excellent fitness for use, resource efficiency and cheap price. They come in many varied shapes, sizes and materials. Because of their light-weight nature they are only a tiny fraction of the tonnage of plastic used in the packaging industry, yet they make a major contribution to litter, thanks to their large surface area and lack of biodegradability. In 2006 the Australian Government Department of Environment and Heritage initiated and funded, courtesy of the Natural Heritage Trust, a study to investigate the effect of bag design on litterability. This paper draws on report materials from the study that are the intellectual property of the Commonwealth. The paper presents a review of previous studies on plastic bags, a review of international plastic bag regulations, as well as the results of an assessment of the environmental impact of bag design using a streamlined life cycle assessment and the litterability of bag design using equipment including wind tunnels. The paper concludes with recommendations for bag design to maintain resource efficiency while reducing litterability.

To be both green and profitable, many plastic manufacturing processes need to reprocess scrap into useful, saleable products. By its very nature the regrind derived from scrap is usually heterogeneous particularly by way of its melt properties. The proper use of peroxide masterbatches can transform regrind, and also post consumer waste, into a useful raw material stream where not only the melt properties are homogenous, but other desirable properties are developed, resulting in high quality products. This paper shows the chemistry behind peroxide‐induced modifications of polypropylene and polyethylene, the increased melt flow rate by using peroxides in reaction extrusion, the advantages of using the peroxide additive in concentrate form, and a method for increasing the properties of commingled polypropylene and polyethylene.