Ingeo biopolymer as a sustainable solution for the packaging Industry by Plastics & Rubber Asia

Ingeo Biopolymer: A Sustainable Solution for Packaging Industries Junaidi Zen Principal Application Engineer NatureWorks LLC Green Packaging Conference November 21, 2013

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Agenda 1. 2. 3. 4.

NatureWorks Introduction The Biopolymers Landscape - An Overview Applications & Market Developments Why Ingeo?

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What we offer •

• • • •

World’s leading bio-polymer player − 150,000 ton plant in Blair, NE − Engineering ongoing for a 2nd plant in S.E.Asia − Significant manufacturing know-how and an extensive IP position

Jointly owned by Cargill and PTTGC Proprietary portfolio of Ingeo biopolymers & intermediates

Ingeo - competitive on a cost and performance basis with traditional plastics (PS, PET)

Superior environmental characteristics − Lower carbon footprint , low fossil energy − Additional end-of-life options

•

Established global market channels − Over 100,000 ton in annual sales volume − Commercial partnerships with global brands 3

NatureWorks LLC Ingeo Biopolymer Plant Blair, Nebraska USA

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Global commercial footprint with sales to over 25 countries worldwide NatureWorksâ&#x20AC;&#x2122; global footprint

Netherlands Minnetonka, MN UK Blair, NE

Savage, MN

Ireland

Naperville, IL Doylestown, PA USA

Belgium

Germany South Korea

Italy

Cary, NC Marietta, GA

Israel

Mexico

Shanghai Hong Kong

Japan Taiwan (Taipei)

Thailand

Vietnam Bangkok Singapore

Colombia Brazil

Australia Chile

South Africa

New Zealand

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What We Do . . . CO2 CO2

Additives (Modifiers)

CO2

Adhesives

Intermediates

Coatings Printing Toners

The Conversion Chain

Specialty Lactates

Carbon dioxide and water

Resins

Surfactants

Plant Sugars

Plants

Manufacture 6

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Ingeo Ingredients from the Earth (geo = greek for earth) performance plastic & fibers from plants â&#x20AC;&#x201C; not oil

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What Ingeo stands for • It assures our partners, brands, retailers and ultimately the consumer that the product made from Ingeo Feedstocks

Environmnental Credentials

Ingeo has numerous 3rd party certifications, including those around: • where it comes from, • environmental performance, and • “where it goes” Compostability

Agenda 1. 2. 3. 4.

NatureWorks Introduction The Biopolymers Landscape - An Overview Applications & Market Developments Why Ingeo?

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What if … All a reality •

5 billion products bio-packaged, end 2011

•

Commits to begin conversion of its product to 100 % biobased packaging

•

Shifts to biobased plastic for Health & Beauty lineup

•

America’s favorite condiment repackaged in bio

•

Automotive supply chain partnership for bioplastics

•

Complete replacement of Polystyrene packaging

•

Global Sports Brand and Automaker team with others to accelerate 100% bioPET

The Biopolymer Landscape

What Are Biopolymers ?

Renewable Feedstock

Renewable, NOT compostable

Renewable AND compostable

• Bio-PE- Braskem • Bio-PET – (partially bio) • Nylon 11

• Ingeo • PHA • Thermoplastics Starchs

Non-Compostable

•Biopolymers are NOT based on Petrochemical “degradable additives” based •Biopolymerse do NOT use NOT compostable “oxo-degradable” additives • Conventional Plastics (Not Considered (e.g. PE, PP, PS, PET, •Biopolymers are NOT Bioplastics) PC, PVC,and etc) designedABS, to fragment ‘disappear’

Compostable

Petrochemical based AND compostable • PBS, PBAS, PBAT, PBAST, PCL, etc. Non-renewable (fossil) Feedstock 11

And What Biopolymers Are Not… • • •

Biopolymers Are NOT Based on “degradable additives” Biopolymerse do NOT use “oxo-degradable” additives Biopolymers are NOT designed to fragment and ‘disappear’

Numerous National & GPnow PLASTICS ACCEPTS NAD local lawsuits, DECISION IN ‘GREEN’ CASE resulting in rulings against those who use “degradable additives” • Greenwashing • False advertising

Numerous Industry Opinions & Concerns Against Degradable Additives The National Association for PET Container Resources

Dec 3, 2008

APR Position Statement on Degradable Additives use in Bottles & Films

BPI’s Position on “Degradable” Polystyrene Food Containers 13

Environmental

Value drivers Biopolymers (NatureWorks)

(consumer, retail, brand owners) • Lower carbon footprint, less energy usage • Better end-of-life options (litter, landfill, incineration) • Target: lower environmental footprint of plastics

Economic

Strategic

(plastics value chain) • • •

Oil vs. plants feedstock cost (stability) Carbon or waste taxation Target: create viable alternate product portfolio (plastics)

(governments) • •

•

Renewable feedstock vs. oil Reduce dependence on foreign oil Target: cellulosic bio-refinery concept (gas + plastics)

Agenda 1. 2. 3. 4.

NatureWorks Introduction The Biopolymers Landscape - An Overview Applications & Market Developments Why Ingeo?

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Whatâ&#x20AC;&#x2122;s Resulted in the Global Market Rigids

Food Serviceware

Nonwovens / Fibers

Durables

Films

Lactides

Bus. Dev.

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Ingeo™ Grades • • • • •

2003D – Food service ware and rigid packaging 3251D, 3001D, 3052D, - Injection molding – Varying in MFI 4043D, 4032D, 4060D - Films/Graphic Arts – Polymers vary in melting point 6000 Series - Fibers 7001D, 7032D – Bottles (ISBM) –

•

Polymers vary in melting point

8052D - Foam

Amorphous vs. Crystalline Ingeo™

Amorphous Ingeo • Transparent in appearance • Glass transition is approx. 55C (130F) • Regrind will be amorphous. – Susceptible to feeding problems during processing. – Screw sticking/screw wrap

• Requires lower drying temperatures – 50C (120 F).

Crystalline Ingeo • A majority of our grades are supplied from our plant crystalline. • Pellets are opaque in appearance. • Crystallinity improves extrusion performance. – Due to higher melting point (around 165C/330F) – Eliminates screw sticking/screw wrap

Ingeo Needs To Be Dried • Standard desiccant driers work well. CAN INGEO BE OVER DRIED ??

Drying Ingeo resins Drying Curve 3000

2500 Amorphous 40 C

Amorphous 50 C

Crystalline 50 C

Crystalline 80 C

Moisture Level (ppm)

2000

1500

1000

<400 ppm from our plant

500

0 0

Time (hrs)

Drying Curve of Ingeo pellets at various temperatures. Air flow volume rate was 0.25 cfm/lb of pellets. The air dew point was – 40 C. 22

Viscosity Stability of Ingeo in the Presence of Water at Various Temperatures Viscosity Stability of Ingeo with 850 ppm of Water (constant shear rate of 10 sec-1)

Viscosity Stability of Ingeo with < 100 ppm Water (constant shear rate of 10 sec-1) 100000

100000

180 C

-4%

-4.5%

-5%

210 C

-5%

10000

-4.5

-5%

-5.5%

10000

- 11%

- 21%

-15%

-20%

- 17%

- 35%

- 23%

- 43%

- 29%

- 49%

1000

-7%

- 27%

- 10%

240 C

Viscosity (Pa-sec)

Viscosity (pa-sec)

180 C

210 C

- 37%

- 43%

-24% 100 0

1000 0

300

600

900

1200

1500

300

600

900

1200

1500

1800

Time (seconds)

1800

Time (seconds)

30 minutes 23

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Moisture Pickup of Ingeo Biopolymers Water Pickup of Crystalline Ingeo Pellets 5000

50% RH 80% RH

4500

4000

In one hour moisture is too high

Water Content (ppm)

3500

3000

2500

2000

1500

1000

500

0 0.1

100

Time (hrs)

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Moisture effects on Processing Ingeo extrusion

→

Lower viscosity

Melt strength

→

Water like extrudate (sag)

Melt pressure

→

Low pressure at die

Crystallinity

→

Higher rate of crystallinity

Casting

→

Poor web stability

Molding

→

Increased brittleness and potential flash

Injection Molding Process and Applications 3251D 3001D 3052D

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Ingeo Innovations in Durables

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General Property Comparison Ingeo GPPS

PET

Tensile Strength, Mpa

53.1

45.5

58.6

35.9

Elongation at Break,%

4.1

1.4

5.5

350

Tensile Modulus, Gpa

3.45

3.03

3.45

1.31

Izod Impact, J/m

21.4

26.7

48.1

Tg, C

102

-20

Melting Point, C

170

None

270

165

Density, g/cc

1.25

1.05

1.35

0.9

* properties measured on 3.2 mm thick injection molded tensile bars 28

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Process Conditions • • • • • • • • • • •

Melt Temp Feed Throat Feed Temperature (crystalline pellets) Feed Temperature (amorphous pellets) Compression Section Metering Section Nozzle Mold Screw Speed Back Pressure Mold Shrinkage

390 F (200C) 70 F (20 C) 330 F (165 C) 300 F (150 C) 380 F (195 C) 400 F (205 C) 400 F (205 C) 75 F (25 C) 100-175 rpm 50-100 psi 0.004 in/in

Note: These are only starting points 29

Sheet Extrusion and Thermoforming 2003D

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Ingeo Innovations in Food Serviceware

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Ingeo Innovations in Rigids

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Extrusion Set Up • General purpose screws work well. • Completely clean hoppers, filters, convey lines. – This is easily over looked and the major cause or poor quality sheet

• Purge high melt polymers (PET) with PS, PP, or PETG. (follow guide) • Polymer must be dried. • Regrind up to 40% can be used. – Higher levels require recrystallizing the flake or screw cooling 33

Sheet Extrusion Optimizing • • • • • •

Three roll stack with high PLI, 600-800 (similar to PET) Sheet cannot contact middle roll prior to top roll. (very important) Run very small or no bank in nips. Adjust roll temps to just below polymer sticking. Die as close as possible to roll. Reverse profile for larger extruders.

Slitting • Rotary shear works the best. • Razors may work on thin sheet, highly modified sheet, or heated sheet. 35

Thermoforming

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Ingeo Thermoformed Parts Performance Features  Excellent clarity and printability = PET  High modulus for downgauging > PET, HIPS  Good practical toughness increased by orientation  Sealable -- heat, RF  Food contact compliance  Excellent resistance to food fats/oils  Annually renewable resource based 37

Ingeo Thermoforming 

Edge pre-heaters required



Deep draws with good definition (sheet ~200°F or ~93°C) Oven commonly set ~ 75-100°F (~24-38°C) below PET



Competitive cycle times with sufficient mold cooling



Forming characteristics on tools and part shrinkage like PET.



Matched metal, punch and die trim tools recommended Heated (250°F or 121°C) steel rule successfully used 38

Blow Molding 7001D

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Ingeoâ&#x201E;˘ Innovations in Bottles / Containers Bottles / Containers

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Process • ISBM process works well.

• Extrusion blow molding requires modified resin. – Increased melt strength

Injection Molding Preforms • • •

•

Lower processing temperature (180-220oC) than PET The cycle time will need to be optimized to minimize part stress Ingeo™ can be injection molded on typical PET gate designs (both valve or thermal gates) Stretch ratios similar to PET but may need to be optimized – – –

Axial: 2-3 Radial: 3-4 Areal: 8-11

Films 4043D 4032D 4060D 43

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Ingeo Innovations in Flexible Films

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Flexible and Rigid Films • Flexible (Blown)

•

– Typical PE applications – Ingeo by itself is too rigid. – Must be modified with other polymers. – Requires a compounding step. – EcoVio (BASF) is the most common polymer used for blown film.

Rigid (Oriented) – Ingeo works well in this application. – Stressed induced crystallization allows for higher heat. – Film stays clear. – Requires biaxial orienting assets.

Differences in Film Grades • 4032D – High crystallinity – Low shrink oriented films

• 4043D – Modest crystallinity – Higher shrinkage oriented films – Tamper bands, etc.

• 4060D – No crystallinity – Typically used for a heat seal layer – 46

Some Applications Develop Heat Resistance • Due to crystallization • Gift Cards – Develop crystallinity during a press polish step

• CPLA Thermoforming – Similar to thermoforming CPET using a nucleant

• Oriented films – Develop crystallinity during orientation and maintain clarity

• Fibers – High process speeds and drawing crystallize the fibers

Increasing MW

Expanding Ingeo capabilities with ‘HP’ (High Productivity) grades

2500HP

4032D

2003D 4043D 7001D

3100HP 6100D

3001D 6201D 6202D

3052D 6752D 8052D

3260HP 6260D

3251D 6252D

4060D

6302D

In Development

Extrusion grade

Fiber & inj molding grade

Increasing D-isomer level

•HP grades with very low D-isomer content will have significant impact on physical properties 48

Comparing High L to Low D

3100D (High L) vs. 3001D (Low D) • Practical Tm peak is increased by 8°C from 164 to 172°C • Melting shoulder is increased by 15°C • Practical crystallinity is increased from about 45 to 55 J/g (48 to 59%) • Quiescent crystallization rate increase by 3-4x • Lower stress required for stress induced crystallization 49

Injection molding results with High L pilot materials • NatureWorks internal lab studies show that formulations made with new High L pilot material vs. traditional Low D commercial material process with about half the required cycle time for high quality injection molding • Customer feedback confirms this finding, with High L pilot material at about 60% of the Low D cycle time at constant additive package • Optimal mold temperature is 80 to 120C, depending on the formulation • High L formulas have broader mold temperature windows, leading to more robust process parameters 50

•

Advantages of expanded offering for the durable & semi-durable market Compounders can produce more competitive materials – Higher productivity during molding – Wider processing window – Simpler & more cost effective formulations

• Potential for higher bio-content in formulations • Higher modulus above Tg, higher HDT • Improved performance in extruded & thermoformed durable applications 51

Agenda 1. 2. 3. 4.

NatureWorks Introduction The Biopolymers Landscape - An Overview Applications & Market Developments Why Ingeo?

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Ingeoâ&#x201E;˘ innovations transform parts from a functional commodity cost item to a differentiable marketing feature

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New Additional Dimensions with Ingeo Biopolymers

Value proposition for Ingeo Biopolymers Traditional Plastics

Environment

Performance

Emotion

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Marketing Message • Made from plants – not oil – An annually renewable resource

• Provides an improved environmental footprint – Reduced greenhouse gases – Requires significantly less fossil fuels – Offers the potential for more post consumer options

• Uncompromised performance • Provides a point of differentiation • Innovation 55

Ingeo™ Carbon Footprint Credentials

Environment

Review process for new Eco-Profile 1.

Publication in the Industrial Biotechnology Journal, August 2010. - Manuscript reviewed by several reviewers - Update of our 2007 publication

Peer review by Dr. Ian Boustead of Boustead Consulting. - Final report now available

Review by Dr. Alberta Carpenter of NREL followed by uploading the eco-profile as well as a process description into the US LCI database

www.nrel.gov/lci

Download: - Spreadsheets with the data files

- Report giving description of Ingeo production process 56

Eco-Profile Environment

CO2

Sequester CO2 by corn production

N2 O

CO2

CH4 Atmosphere

Corn Milling, Fermentation, Polymerization Corn/Feedstock Production

Ingeo™ biopolymer

Production of: fuels, power, steam, fertilizers, water, acids, base, waste water treatment, etc. 57

Calculation of the eco-profile means drawing a ‘box’ around the process from field to factory gate, and rigorously identifying and including anything which crosses the system boundary © 2013 NatureWorks LLC

Environmental Benefits Credentials

Environment

-60%-50%

Greenhouse Gases Greenhouse Gases Ingeo Ingeo Target Target 0.8 -60% Ingeo 2009 CITIngeo (current tech) 2009 CIT Ingeo Target

2.0

PVC PVC (suspension) (suspension)

1.9

1.3

Ingeo 2005

2.0

PVC (suspension)

1.9

Polypropylene

1.9

Polypropylene Polypropylene

PET 3.2 PET (amorphous) (amorphous)

PET (SSP)

3.4

Polystyrene (HIPS/GPPS Avg)

3.4

80 82 87

3.4

7.6 9.1

Polycarbonate Polycarbonate 0

3.4

Polycarbonate Polystyrene PS (HIPS/GPPS (HIPS/GPPS Avg) Avg)

Nylon 66

3.2

PET PET (SSP) (SSP)

Nylon 6

2.1

PET (amorphous)

1.9

LD LD Polyethylene Polyethylene

LD Polyethylene

-50%

1.3

Ingeo Ingeo 2005 2005

0.8

Ingeo 2009 CIT

Non-renewable energy use Non-renewable energy use 35

1137.6

7.9

Nylon Nylon 67 5 6 6

120

From cradle to polymer factory gate Nylon Nylon 66 66 [kg CO2 eq. / kg polymer]

9.1

7.9 138 120

2 40 3 60 4

80 5

100 6

7 120 8 1409

160 10

Continuous improvement process From cradle cradle to to polymer polymer factory factory gate gate From Ingeo 2005 Ingeo Current Ingeo Target [kg [MJ CO2/eq. / kg polymer] kg polymer] 58

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It’s the natural selection for fresh food packaging. Better for the planet, so better for you, your family and business too.

“

“Did you know that if you convert just 500,000 medium sized deli containers to ones made with Ingeo™ the fossil energy savings is equivalent to 5,400 gallons of gasoline, and greenhouse gas savings are equivalent to driving a car over 122,000 miles?” ²

”

² These benefits are provided as an example and are based on the Ingeo™ eco-profile and available data on PET. Assumes replacement of a 30 gram PET deli container, with an equal weight Ingeo™ with no changes in the eco-footprint associated with the downstream processing from polymer to finished container.

Danone’s Stonyfield - in their own words: “IMPACT OF INGEO CONVERSION”

• Carbon savings

Environmental

• 75% reduction in CO2 emissions • Equivalent to 1,320 MT CO2/year savings

Performance

• Ingeo out performs polystyrene • • • •

Stronger/less breakage Better lid adherence Lower temperature filling (less energy use) Maintained line speed and shelf life

The Consumer

• Addresses consumer concerns • Well received by key opinion leaders • Reduction in human toxicity • Did NOT increase our retail price

Stonyfield CEO Gary_Hirschberg, Innovation Takes Root Conference Keynote: “Inventing a WIN--WIN--WIN--WIN-WIN FUTURE”, February 21, 2012

Danone Ingeo Yogurt Cup Project Certified GM free feedstocks

Support from WWF-Germany

LCA comparing polystyrene with Ingeo Cups showing a benefit in GHG reduction

End-of-life for Cups: demonstration that Ingeo cups can be recycled:

Certification of Sustainable corn production & Chain of custody.

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Renewable Feedstock Evolution 1st Generation agricultural conversion route is short term Bridging Tool to bridge to 2nd generation and beyond

Gen I – 1st step

Gen I – 2nd step Where we’re going now

(Feedstock Generation #)

Gen II Next 3-5 Years . . .

Where we are today

Dextrose from corn starch

Dextrose from cassava starch and sugar cane

e.g. cellulose from wood chips, corn stover, switch grass and rice straw

Mechanical Recycle

Ingeo Cradle to Cradle Options

Incumbent Plastics

Ingeo



   

Feedstock Recovery Compost Anaerobic Digestion Energy Recovery

Landfill 63

Recycle Options

Mechanical Recycle

Incumbent Plastics

Ingeo



   

Feedstock Recovery Compost Anaerobic Digestion Energy Recovery

Landfill 64

Save the Date!

A Collaborative Biopolymers Forum for the Global Ingeo Community Orlando, Florida | February 17-19, 2014 Orlando World Center Marriott

www.innovationtakesroot.com @natureworks Follow us on Twitter!

February 17-19, 2014 ÂŠ 2013 NatureWorks LLC

Thank You

Terimakasih

www.natureworksllc.com

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