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Recycling
Various topics related to sustainability in plastics, including bio-related, environmental issues, green, recycling, renewal, re-use and sustainability.
NatureWorks® Polylactide Biopolymer: A Sustainable Polymer for the 21st Century
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%
Polymeric Chain Extenders and Biopolymers
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.
Recycling of packaging products including biodegradable plastic materials such as PLA foam, plastic fibers and non-woven materials
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.
Can I Run PLA on My Existing Extruders? A Practical Application Guide
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.
Degradation of Biodegradable, UV-degradable and Oxodegradable Plastics with In-vessel Food Waste Composting Environment
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.
Development and Implementation of Soy-Based Foam in Automotive Applications
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.
Recycling of Long Glass Fiber Reinforced, Padded Instrument Panels
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.
Automotive Interior Material Recycling and Design Optimization for Sustainability and End of Life Requirements
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.
Sustainable Automotive Component Manufacturing Solutions
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.
Trends & Challenges for Start-Up & Emerging Companies in the Clean-Technology Marketplace
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.
Using Recycled Polyethylene: Avoiding the Pitfalls
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.
The Litterability of Plastic Bags: Key Design Criteria
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.
The Use of Peroxide Masterbatches in the Processing of Regrind and Post Consumer Waste
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.
Applications & Markets for Renewable Resource Based Sheet Molding Compound
Unsaturated polyester resins based on renewable resource raw materials (soy and corn) have been commercially available since the late 1990s. These resins have successfully been formulated into sheet molding compound and are compression molded into parts used by the John Deere Corporation to manufacture farm machinery. This paper will discuss the economics and environmental effects of using renewable resource based composites describe the current applications where the technology is being used and consider the future of bio based technology in the composites industry.
Development & Thermo-Physical Properties of Bio-Based Polymer / Clay Nanocomposites
Bio-based resin systems obtained as blends of functionalized vegetable oils and petroleum based resins have been found to increase toughness of petroleum based resins and improve their environmental friendliness. Nevertheless this improvement in toughness generally compromises the stiffness of the resin system. Nano-scale layered silicate (nano-clay) polymer nanocomposites exhibit enhanced mechanical and physical properties at relatively low weight fractions of inclusions. The reported study shows that proper stiffness – toughness balance along with enhancement in many other physical properties can be obtained by incorporating nano-scale layered silicates in bio-blended polymers. Polymer nanocomposites with varying clay contents and varying bio-blend (epoxidized soya bean oil) in unsaturated polyester resins were manufactured. Tensile properties and moisture absorption properties were studied. Fracture surface morphologies and characterization of nanocomposites were performed using electron microscopy. The resulting bio-blended polymer nanocomposites exhibit promising results for use in structural applications.
Effect of Additives on the Structure and Properties of Wheat Straw-Polypropylene Composites
Natural fibers from agricultural activities have been emerged as alternative fillers in the thermoplastic industry. Crops such as wheat straw are renewable and low cost materials that combined with thermoplastics such as polypropylene provide engineering products with unique characteristics. Due to the wide range of thermoplastics and potential agricultural fillers the influence of additives in the systems is one of the points yet to be determined for different combinations of matrix and filler. In this study composites containing 30 wt-% of wheat straw (WS) fibers and polypropylene (PP) were prepared in a batch mixer. The individual effects of two coupling agents and a lubricant in the composites were investigated. Scanning electron microscopy (SEM) was used to examine the morphology of wheat straw particles and composites. The water absorption behavior and mechanical properties were assessed for those composites prepared. Results showed a strong interaction between filler and matrix in compositions containing coupling agent; differences were observed in the performance of the two coupling agents tested. Furthermore the lubricant used contributed to the water absorption of the composites.
Renewable Bio-Composites for Automotive Applications
PowerPoint Presentation at ACCE 2007.
Evaluating Extrusion Compression Molding for Imparting Better Surface Finish in Long Fiber Thermoplastics Using In-Mold Film Technology
Automotive applications of compression molded products with a thermoplastic matrix have been growing rapidly within the last few years as demonstrated by increased use in applications including front-ends bumper beams dashboards and under body shields. Long fiber thermoplastics (LFTs) have received much attention due to their processability by conventional technologies. However applications of LFT materials have been limited in external body parts that require a good surface finish. Painting LFT parts is rare and requires considerable equipment investment. Further painting is often associated with environmental concerns such as Volatile Organic Compounds (VOCs) and high energy consumption. This paper innovates the process of extrusion compression molding for long fiber thermoplastic parts by placing a film (with a thermoplastic olefin backing) in-mold that melt bonds to the LFT material. This results in a compression molded LFT part that has the nice surface finish required for exterior applications. In order to evaluate the process variables potentially contributing to the surface quality are identified and analyzed. A Design of Experiments is carried out to investigate thoroughly yet
economically the effect of four process variables. Gloss chip resistance and adhesion of film to substrate are tested according to ASTM standards. These test results are used to evaluate the effect of the processing variables considered and to establish optimum operating parameters.
Hybrid Bio-Based Composites from Nano-Reinforced Bio-Petro Polymer Blends & Natural Fibers
Natural fiber composites or biocomposites have recently gained much attention due to their low cost environmental friendliness and their potential to compete with glass-fiber composites. However the use of all-natural resins is limited due to performance concern and hence the blending bio-resins in petroleum resins has gained importance due to their improved toughness and environmental friendliness. Nevertheless addition of bio-resins generally compromises stiffness barrier and thermal properties. The enhancement of polymer stiffness and barrier properties with small concentrations of layered silicates is well established. With this context the paper presents the development and thermo-physical characterization of a hybrid composite material with increased environmental friendliness that can retain stiffness without sacrificing toughness barrier and thermal properties. Hybrid biocomposites were made from bio-based resins (blends of unsaturated polyester and epoxidized soya bean oil) reinforced with organo-nanoclays and natural fibers (unprocessed industrial hemp). Results show that an optimum material design that maximizes the synergy of the constituents is possible and provide an initial benchmark in identifying such balance.
Investigation of Sheet Molding Compound Fabricated from Soy-Based & Petroleum-Based Resins
Plaques fabricated from sheet molding compound (SMC) with soy-based resins in both glass fiber-reinforced and carbon fiber-reinforced versions are compared with the equivalent SMC with petroleum-based resins. Since soy-based resins are less sensitive to the price of petroleum than petroleum-based resins these materials represent potential cost savings to the automotive industry if the price of petroleum continues to increase as well as providing opportunities to decrease overall carbon dioxide emissions. Soy beans are also a renewable resource. Material thermal properties including dynamic mechanical analysis (DMA) and coefficient of linear thermal expansion (CLTE) are evaluated as are mechanical properties including tensile and compressive characterizations. The effect of humidity aging was evaluated by moisture absorption as well as residual tensile and compressive properties. For as-received properties the glass-reinforced version of the soy-based material is found to be similar in performance to the petroleum-based material. However the carbon-reinforced soy resin material has lower mechanical properties than the petroleum-based SMC probably due to a lack of fiber-matrix adhesion. In humidity aging the petroleum based materials absorbed less moisture than the soy-based although the relative property loss caused by humidity aging was similar for the petroleum-based and the soy-based materials.
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