Solvay buys Rhodia

Specialty polymers of Solvay. Source: Solvay

The main products of Brussels based Solvay are sodium carbonate, hydrogen peroxide and specialty polymers. It employs 16,800 people in over 40 countries and in 2010 its consolidated sales were €7.1 billion. The sale of its pharma business for €4.5 billion to Abbott was finalised. This sale focused the rest of the business in the chemicals sector and it has probably facilitated Rhodia’s acquisition. Rhodia employs 14,000 people worldwide and in 2010 its sales amounted to €5.23 billion. Its internal structure is a bit complicated, with 5 clusters and 11 business units. The main products of Solvay and Rhodia are summarised in the table below:

In the friendly buyout agreement, both companies consider that the resulting group will have sales of approximately €12 billion, of which 40% will be in emerging economies. To this respect, Solvay has a strong presence in China, while Rhodia is more active in Russia and Thailand. This will favour growth of the resulting company in these regions.

A year with plenty of acquisitions

But the acquisition of Rhodia by Solvay is not the only one we have seen this year. Bloomberg has calculated the overall value of deals in the chemical industry during 2011 to be $25 billion, the greatest of the decade. The average price tag of deals has been $720 millions. Many analysts believe that the boom in deals has not yet finished and that more chemical companies have the required cash to acquire other players. Some of the acquisitions taken place this year are listed below:

Acquisitions are usually motivated by one of the following reasons:

• Widen existing portfolio, incorporating added value products if possible. Products derived from renewable sources are very coveted nowadays, together with companies producing nutraceuticals or ingredients.
• Increase geographic coverage in a fast and efficient way.
• Enter new markets, creating synergies with existing products.

More information

Doubts over the buying of Danisco by DuPont

Clariant will buy 95% of Süd Chemie

DSM buys Martek Biosciences

BASF completes acquisition of Cognis

Product improvement

Bioplastics have entered the market, have been tested in several applications and are produced at industrial level. In following years bioplastics producers already established will have to focused on improving their products performance. In order to do this, they can focus on one of the following factors:

• Increasing the renewable content of the final product by using additives, paints and adhesives that are also renewable.
• Achieving certifications related to renewable content or compostability.
• Improving properties by blending with oil-based plastics.
• Penetrating the durable goods market, for example in electronic products or automotive sector.

For more information, do check the following presentation by Jim Lunt & Associates, with information regarding current bioplastic suppliers, applications and future trends.

Changes in raw materials

Today most bioplastics are produced from starch or sugar. The starch is obtained from corn or potato. The main sources for sugar are sugarcane, beetroot and corn. Bioplastics use sugar obtained from the same sources used by bioethanol producers and therefore certain trends will be shared by both. One of the clear trends in the biofuel market is the search for new raw materials that substitute or complement those already being used. Some of the reasons for this are:

• Perception that biofuels, and other chemical products, derived from the same sources as food results in price hikes and therefore can represent a danger for the final consumer. Or in other words, our cars may end up drinking what other people could eat. This is a very difficult question and honestly, I don’t feel qualified to raise an opinion on it. However, it is clear that public perception of the issue could be a problem.
• Reducing costs: Bioplastics production has become cheaper in the last years, mainly due to industrial production. The use of cheaper raw materials will be a more stable way to reduce the final cost of the product.
• The scale issue: If we plan to substitute an important part of our consumption or products derived from oil, we are going to need a lot of raw material. This can lead to an intensive agriculture that can be harmful for environment.
• Waste generation: The part of the plants currently used in the biorefineries is small and a considerable amount of organic waste is generated.
• Technology adaptation: The ideal technology can be implemented anywhere in the world, regardless of where it has been developed (USA and Europe, in the case of bioplastics).

Taking into account the aforementioned factors, 2 clear candidates appear as possible alternatives to current raw materials: cellulosic materials and waste of any kind.

From sugar and starch to cellulosic derivatives

Parts of the plant with low content in starch or sugar are discarded today. These parts, which include leafs, corncobs, etc. will start to be used too. Other cellulosic sources can be totally different from the crops used now, like forestry and agricultural wastes or grass. The use of cellulosic sources will increase the yield of current crops and reduce production costs.

Waste as raw material

Domestic, or other, waste will become viable raw material sources thanks to the ability to adapt of bacteria and algae. The advantages: waste generation is reduced and is cheap! Furthermore, it would be a technology that can easily exported anywhere in the world, regardless of climate, arable surface or existing crops, as waste is created everywhere.

Market consolidation

Two markets coming together

Collaborations, already seen today, between companies from the agricultural and the chemical sectors will become even more important. If it is normal for a petrochemical company to have interests in oil extraction, it would also become normal for companies to ensure renewable feedstock availability.  Dow Chemicals, that aims to produce polyethylene from sugarcane, has been forced to change plans in Brazil as its joint venture with Crystalsev – a Brazilian sugar producer – was broken. In fact, even if Dow will continue with the project on its own, it has already announced it will look for a partner in order to obtain the raw material: sugarcane.

Agricultural companies that have entered the materials market will continue to follow allies in the chemical sector to improve their products and their distribution. Futerro, a joint venture of Galactic (global lactic acid producer) and Total Petrochemicals is a good example. Futerro produces PLA from lactic acid supplied by Galactic, using Total polymerisation technology, which also brings its knowledge of distribution and sales of plastics.

Big fish eats little fish

The bioplastics market is entering an unavoidable consolidation phase. In the last 5 years the number of companies dedicated to produce bioplastics or present in any way in the value chain has increased to reach hundreds. Consolidation will be driven in part by the benefits resulting from becoming industrial, together with a highly commoditised petrochemical industry that is actively searching added value products. It is therefore safe to assume that in the next 5 years those companies in the chemical or agricultural sector that can afford it, will buy smaller companies with product or technologies that complement their portfolio.

Conclusion

It remains difficult to forecast where such a dynamic market will reach, but I have no doubt it will continue to grow. Conventional plastics from renewable sources will become more common and those with different chemistries will find their niche markets. Bigger companies will be formed by the agglutination of small players, as alliances between chemical and agricultural companies will be strengthen. We will look further than the current crops for feedstock and there will be a stronger focus on process able to convert any type of feedstock into a viable material.

Related

Bioplastics, 5 years later

Bioplastics category in mundomaterial

Renewable category in mundomaterial

Source: Darwin Bell

An increasing number of competitors

In 2006 the number of “real” producers was reduced. There were several producers of starch based blends and Novamont was (and still is) the European market leader when considering production capacity. However, in the field of PLA production there have been important changes. In 2006 the sole producer was NatureWorks. It was the only company with an industrial production and there were only projects from other companies that were studying the possibility of using lactic acid to produce PLA. Nowadays NatureWorks continues to be dominating the PLA market, with a capacity of 140,000 tonnes per year, but there are other producers with smaller capacities and with plans to increase it in the next 2 years. Some examples are:

• Hisun, 5,000 tonnes per year
• BioAmber, 2,000 tonnes per year
• Futerro, 1,500 tonnes per year

Known chemistries, now from renewable sources

5 years ago bioplastics were new products, with a totally different chemistry, that have to find their way within the market of traditional plastics produced from fossil sources. The market was dominated by PLA, starch based blends and the big promise were PHAs. There were cases of traditional polymers produced from renewable sources, but in low volumes. Today there are 2 differentiated types of material, the “classic” bioplastics aforementioned and traditional plastics that instead of being produced from oil are derived from renewable sources.

It is worth mentioning Braskem cases, a big Brazilian petrochemical company, that is producing ethylene from sugarcane. Ethylene is then transformed into polyethylene or partially renewable PET. The current capacity of Braskem is 200,000 tonnes per year of polyethylene, overtaking NatureWorks and hence becoming the biggest bioplastic producer worldwide. Braskem has already announced it will also produce renewable PP, in a plant that will be operative in 2013 with a capacity of at least 30,000 tonnes per year.

Braskem’s advantage, similarly to other producers of traditional plastics from renewable sources, is that the market for its products is already there and its products only need to replace fossil-based alternatives. Even more, depending on the behaviour of the oil  and sugarcane price, its products may end up having the same price as conventional plastics or even cheaper. Although this is still uncertain, due to price fluctuations in the price of natural resources like sugarcane, corn, etc. in the last months.

Improving the products

Some bioplastics have been in the market for more than 5 years, but since 2006 several factors have been improved that have helped them to increase their market penetration. On the one hand, there are now tested commercial applications that act as success stories for new clients. Furthermore, the greater number of applications has allowed compounders and converters to test different grades and processing technologies. Even those applications that have been a bit of a fiasco have been a way to improve the materials or know their limits.

Another advance worth highlighting is the increase in renewable content in bioplastics. A good example is Novamont: 5 years ago it mixed starch with biodegradable polyester from fossil sources. Today it has the required technology to produce polyester from vegetable oils, maintaining the biodegradability of the final product and increasing the renewable content. Cargill, as well as owning 100% of NatureWorks, has been developing renewable polyols to produce polyurethane foam since 2005. The renewable content in the final product ranges from 5-25%. Cargill has focused part of its efforts in increasing such percentage. It recently announced its collaboration with Momentive to use one of its additives to achieve greater renewable content.

From plastics to everything else

The truth is that changes have been happening throughout the chemical industry, not only in the plastics field. The chemical industry has shown great interest in renewable sources. Some of the reasons are:

• Sustainability starts to be appreciated by the final consumers, becoming an added value to the product and a marketing tool.
• Oil price has increased, turning renewable raw materials into a more competitive alternative.
• Oil supply has demonstrated to be unstable, becoming an increasing factor in decision making.
• The technology behind renewable products has left the lab and has been tested at industrial level.

Therefore chemical companies are not only interested in semi-finished products, like PLA or other bioplastics, but also in building blocks or additives to improve the resin properties. We now see some companies basing their offer in the production of monomers, like Purac that plans to become a supplier of lactides for PLA producers. The number of plastic converters including bioplastic products in their portfolio has also multiplied and compounders supplying the market with blends of traditional plastics with bioplastics or with tailor-made additives is also increasing. Furthermore biofuel producers are starting to focus in going beyond ethanol and are developing methods to obtain more molecules from their biorefineries. Something that could be particularly important in the USA, where the biofuel production receives government help and where we see the first movements towards that help being extended to biochemicals other than biofuel.

Production in new regions

Although Europe still is, according to most market studies, the biggest consumer of bioplastics production has moved towards other world regions. Brazil is one of the most important ones due to the low cost of sugar produced there. Sugar can be transformed into lactic acid from which PLA is obtained or ethanol, from which ethylene is derived. Apart from Braskem, Dow is trying to start a new project in Brazil to produce polyolefins from sugarcane. Crystalsev, a Brazilian sugar producer, was going to be its partner, but the alliance was broken recently and now Dow is looking for another local partner to ensure supply.

Source: johnmcq

The other hope for the production of bioplastics is Asia. Although China could seem a main target, producers interested in renewable sources are choosing other countries. For example Purac is going to establish a new plant in Thailand for the production of lactides and has already announced that it will  join forces with Indorama Ventures to produce PLA in the region. Asia has, like Brazil, lower production costs than Europe or the USA, and it is also close to another major market for bioplastics: Japan.

What will happen in the next 5 years?

Although the future is full of surprises, some of the trends that will mark the following 5 years can already be appreciated. In my next post I’ll try to explain some of the changes that I think will take place in the bioplastics market.

• Pioneering work on green policy in California
• Identification of non-food sources of raw material for resin production
• Market overviews from the US and Europe
• Regulation, labeling and marketing
• End of life management options
• Technological innovation in packaging and beyond

Of particular interest to me are the sessions related to non-food sources of raw material for resin production and end of life management options. These areas could become a restraint in market growth due to negative public perceptions. Biopolymers appeal is based on environmental benefits. For biopolymers to continue growth in the medium term, the research into durable applications is a must too, as disposable applications are of little added value and not sustainable in the long term, regardless of the material used to manufacture them.

The sessions will be 20 minutes long, with 10 minutes for questions after each session. Here is a list of the diferent sessions, together with the person that will chair them:

• California’s Initiatives Leading the Way in Green Chemistry and Biopolymer Use; Maureen Gorsen, Partner, Alston & Bird LLP
• Consumer Applications; Derek Campbell, Manager of Footwear Future Concepts, Brooks Sports
• Technology Developments; Dr. Ramani Narayan, University Distinguished Professor, Michigan State University Department of Chemical Engineering & Materials Science
• Regulations and Metrics; Eric Koester, Attorney, Cooley Godward Kronish LLP
• Waste Stream, Recycling and End of Life; John Williams, Polymers & Materials Manager, National Non Food Crops Centre , York
• Lessons from Europe; Andy Sweetman, Chairman of the Board, European Bioplastics
• Developments on Existing and Emerging Feedstock’s; Jim Kleinschmit, Director of Rural Communities Program, Institute for Agriculture and Trade Policy
• Green Marketing and Eco-labels; Dr. Anastasia O’Rourke, Co-Founder, Big Room Inc .
• Developments in Packaging Applications; Scott A. Vitters, Global Director, Sustainable Packaging, The Coca-Cola Company
• Key Players in Bio-polyesters; Dr. Paul Fowler, Director, Welsh Institute for Natural Resources, Bangor Universit y
• Innovations in Materials; Mark Bünger, Research Director, Lux Research
• US Market Overview; Corey Linden, Research Scientist, Battelle
• Facilitating Markets for Bio-based Materials; Kate Lewis, USDA BIOPREFERRED

In the list of speakers, there are some important producers of polymers, like DSM, BASF or Arkema, with whom we’ve already discussed their range of renewables and that will be talking about the following:

• New and “greener” Plexiglas® acrylic polymers
• High performance hybrid thermoplastics with high bio-based content
• Performance enhancing additives for renewable thermoplastics

Some of the main bioplastic producers, i.e. FKUR, Telles, NatureWorks or Novamont will also speak, together with institutional and university speakers as well as end-users like The Coca-Cola Company, Pepsico, Intel and Chrysler Group. You can also check the figure below for the distribution of attendees per company type in the last edition of the Symposium.

More Information:

Biopolymers Symposium

Biopolymers Symposium pdf Brochure

Biopolymers Symposium Twitter

Biopolymers Symposium Linkedin Group

IntertechPira, a division of Pira International

Brazil

At the moment, production in Brazil is constraint to pilot scale. In 2009, the Bioplastics market in Brazil was composed mostly by the resins PLA, Starch-based, and PHB, representing revenues of US$ 4.4 million.However, large production scales in Brazil are expected to give a new shape to this market in the region, as for 2015, large scale production units are expected to be producing bioplastics, such as Braskem biobased polyethylene and Solvay bio-based PVC. Braskem bioplastics plant will be the largest in the world, providing to Brazil an expected CAGR of 140.7% in the period 2009-2015.

Note: All figures are rounded; the base year is 2009. Source: Frost & Sullivan

Brazil has easy access to cheap bio-based feedstock that can then be utilized to produce low cost bio-based plastics, such as sugarcane. This gives Brazilian companies an advantage in the commodity plastics market, where cost is one of the main deciding criteria for end users.  The Brazilian Association of Compostable Biodegradable Polymers (ABICOM) is being built in order to promote new legislation and government policies to support research and development of this market. This association was created in 2009, and it has still to gain strength to influence market movements.Note: All figures are rounded; the base year is 2009.
Source: Frost & Sullivan

Mexico

According to Frost & Sullivan‘s research, the Mexican bioplastics market represented 1,200 MT in 2009, it is in the growth stage in the product life cycle and the expected average annual growth rate for this market is higher than 20%. The growing environmental awareness and concern in Latin America is a driver for the market. Mexico’s bioplastics market is composed of 100% of PLA, different products from other companies are in a testing stage. At the moment PLA is imported from United States.

Corn based plastic is the most known resource in Mexico, but major problems arise since the country is the fourth world producer, and it still needs to import from 5% to 10% for local food demand. This is an important restraint, as bioplastics could be directly competing with a food resource and their image could be harmed if food prices increase due to corn’s industrial uses. Initiatives are being taken by research institutes to find different and productive sources to produce bioplastics.

About Frost & Sullivan

Founded in 1961, Frost & Sullivan has over 45 years of assisting clients with their decision-making and growth issues. Over 1,700 Growth Consultants and Industry Analysts across 32 global locations. Over 10,000 clients worldwide – emerging companies, the global 1000 and the investment community. Developers of the Growth Excellence Matrix – industry leading growth positioning tool for corporate executives. Developers of T.E.A.M. Methodology, proprietary process to ensure that clients receive a 360 perspective of technology, markets and growth opportunities. Three core services: Growth Partnership Services, Growth Consulting and Career Best Practices.

Also, I started my professional career as a consultant a few years back with Frost & Sullivan, in one of their UK offices.

More info:

Strategic Assessment of the Bioplastics Market in Brazil and Mexico, Frost & Sullivan

Bioplastics in Brazil: Beyond the Green Speech, by Alessandra Lancellotti, Frost & Sullivan

Search for Bioplastics, Frost & Sullivan

The approved potato variety is Amflora, developed by BASF for industrial applications such as lubricants, sprays and animal feed. When the news came out, some people suggested that it was to be used in the production of bioplastics. I always considered a bit risky to used GMO in the production of a product that bases part of its market appeal on environmental benefits and considered that European producers of bioplastics have an advantage over producers elsewhere that do use GMO crops as feedstock. It has to be said that resistance towards GMO is mostly a European concern and that public resistance to them in other world regions is not that high.

Naturally produced starch is a combination of amylose and amylopectin, both polymers of glucose. The main difference is that amylose is a linear polymer while amylopectin is branched. Amflora is genetically modified to produce only amylopectin, the more interesting component for most industrial applications, as it is not water soluble. However, for production of bioplastics in particular, amylose is more interesting than pure amylopectin, so the Amflora variety is not of particular interest for bioplastic producer. For example, Plantic Technologies products are made with high amylose corn starch as base. In my opinion, there is no need for genetic modifications to obtain better, sustainable materials. In some cases, there isn’t even the need for a crop to be used to produce a bioplastic. Rodenburg Biopolymers for example use as feedstock for their product, Solanyl, the waste generated by the Dutch potato processing industry, which discards 40% in weight of the potatoes. I think this approach is a much more sustainable one than any other, instead of modified crops or even crops that may compete with the food stream at all.

You can find more information on the science of starch based materials in the excelent blog by Luc Averous, to whom I have to  thank for sharing this particular link with me: http://www.biodeg.net/biomaterial.html through our Bioplastics group in Linkedin.

photo credit: FreeRangeLife

ANAIP y COFACO are two of the oldest trade associations in Spain, with 53 and 61 years of existence each. Their decision to join forces has been motivated by the need to reduce the effect of the economic downturn in one of the most important manufacturing sectors in Spain. Plastic and rubber manufacturing decreased by 17% during the first 9 months of 2009. This has to be added to the 12% drop already registered by the segment during 2008.

The recently created federation, FEITCAP, represents more than 4,450 companies that directly employ 118,000 people. Its volume of business in 2008 was over 19,000 million euros, i.e 1.8% of Spanish GDP.

José Antonio de la Cruz, former President of ANAIP will be the first to preside FEITCAP and José Luis Solórzano, former President of COFACO, becomes Vicepresident. José Antonio de la Cruz explains the reasons behind the foundation of FEITCAP

During these challenging times we need to find the greater critical mass of institutional representation possible, to find the support of authorities needed by our industry. - José Antonio de la Cruz, Presidente FEITCAP

Related links:

ANAIP

COFACO

EuPC (European Plastics Converters)

ETRMA (European Tyre and Rubber Manufacturers Association)

09-11-2009: Just a couple of days after I published this post, Twitter launched its lists, a new feature that allows users to create groups of twitterers with something in common. I’ve created one with contacts related with materials, which I’ve been updating.  You can find my materials list here.

@IslemYezza: Packaging innovation and biomaterials

@LucAverous: Expert in Bioplastics, Biomaterials and Biobased Materials

@EuropaBio: The European Association for Bioindustries

@ArgosBiotech: gateway to worldwide biotech which opens up resources to the best free available biotech information

@ICISchemicalbiz: The global chemical trade publication of leading chemical and energy information service provider ICIS.com

@Chem_Processing: Chemical Processing serves engineers designing and operating plants in the chemical industry.

@Bioplastics: Providing global bioplastics market research, strategy and sales consulting.

@biopolymers: IntertechPira’s Biopolymers Summit 2009

@ChemistryWorld: Chemistry magazine bringing you the latest chemistry news and research every day

@materiaLisam: Managing Editor of Wiley’s materials science journals. Making sure everything gets published OK

@NatureChemistry: A journal dedicated to publishing high-quality papers that describe the most significant and cutting-edge research in all areas of chemistry

@ICISgreenblog: Currently working full time as associate editor for ICIS Chemical Business, a global chemical trade magazine, and has been covering the renewable-based chemical

@materialsdave: Editor-in-Chief of the materials science journal Advanced Functional Materials. Solar cells, organic electronics, and more!

@blancourgoiti

@Verdezyne: We are an industrial biotechnology company directing the power of biology to create bio-based processes for clean and sustainable fuels and chemicals.

@HuntingDynasty: We are an advertising agency for sustainable products and services. Discover more about us »

@WI_Bioplastic: Use Bioplastic

@BioPreferred: BioPreferred is a Federal program that aims to increase the purchase and use of biobased products in the Federal, commercial and consumer markets.

14-10-2009

@BritishPlastics: the news headlines feed from British Plastics & Rubber magazine, which carries recycling issues as and when they are news topics (thanks to Ken Grace)

15-10-2009

@FransVos & @materialsfuture: Thanks to Frans Vos, General director of Materials Consult.

@NatureMaterials: A multi-disciplinary journal for cutting-edge research across the entire spectrum of materials science and related disciplines

@Polimerica_it: (Italian) Tutte le news pubblicate su Polimerica.it, notiziario online sul mondo delle plastiche e gomma (thanks to Carlo for the suggestion)

@polimericanews: (Italian) Notizie in tempo reale sul mondo della plastica e della gomma (thanks to Carlo for the suggestion)

Please feel free to tell me about any other interesting twitterers you may know and I’m yet to discover.

Today I’d like to present the upcoming conference “Biopackaging: From Feedstock to Waste Stream”. This conference, held in London 8-10th September 2009, will be of special interest for Small and Medium Enterprises (SME). The event will gather representatives of the whole supply chain of bioplastics, as well as investors, researchers and regulator bodies.

On the 8th of September there will be a workshop on the “Principles and Concepts of Biobased and Biodegradable Materials/Plastics”, which should be a splendid opportunity for those new to the subject.

The diagram below identifies the type of attendees that will attend this venue or have done so in previous editions.

I have gone through the list of previous attendees and all areas are well represented, with the exception of investment institutions. Of course, other attendees have plenty of experience with investors and can give you insight and even hindsight on these.You can download the full agenda here.

Although most attendees are European, this should not detract people from elsewhere in the world, as many of the institutions present have an international presence and supplier base, inherent to the area of bioplastics. So, even if you are in Africa, you might, in fact end up meeting your future customer.

Another point is that traditionally the European Union spearheads the regulation for new products (materials, services, etc.), which means that in the future countries in Africa, Asia or elsewhere may come to adopting European Union standards, especially if their products will be used in the European Union.

The event is particularly a great opportunity for entrepreneurs or SME, because they can listen and talk to all of the relevant people who can help them start or expand their business!

As a last note, if you do decide to attend, just make sure you pack enough business cards, company brochures and questions.

Traditionally considered a coarse fibre, kenaf is finding its place in the automotive and electronics market thanks to its use as reinforcement in composites. Its combination with PLA, a bioplastic sourced from corn, may illustrate the new focus of materials’ development nowadays. 2009 has been declared by the FAO the International Year of Natural Fibres. This is post is the third in a series dedicated to natural fibres.

What is Kenaf?

Kenaf, or Hibiscus Cannabinus, belongs to the Malvacean family and producers are based around the globe, although India and China are the major producers. Often compared with jute and hemp, kenaf applications could be classified as it follows:

• traditional uses, low value: rope, twine, clothing, animal bedding and feed
• Innovative Applications, medium value: Paper, engineered wood, environmental mat, oil and liquid absorbent material
• Kenaf Oil: edible oil, can also be used in cosmetics, lubricants and production of biofuel
• Composite materials, high value: kenaf fibres can be used as filler or reinforcement, with either epoxy or thermoplastics

Apart from these applications kenaf also shares its condition as hardy plant with jute or hemp. Thanks to it, it requires little water, pesticides or fertilizers to grow, making it a truly environmental crop to grow.

Production

Samsung Cheil in Malaysia

Samsung Cheil, a Korean affiliated company of the Samsung Group, launched in August 2008 a kenaf centre for collection, processing, packaging and distribution of the fibre. Samsung Cheil has traditionally being involved in the textile industry, but has diversified its business to cover all types of materials and chemicals. The strategic importance of the Malaysian centre, which is a collaborative effort between Malaysia’s Symphony Advance Sdn Bhd (SASB) and Samsung Cheil, is that it aims at the development and commercialisation of kenaf/plastic composites. The initial target of 1,000 tonnes exported per month is expected to double once shipments to Japan begin. The added value of the kenaf fibre when used in composites may allow tobacco farmers to replace their crops with kenaf.

Kenaf Green Industries

Based in Israel, Kenaf Green Industries licenses its current knowledge in kenaf production, trasnformation and commercialisation, helping new kenaf producers to establish their business. Kenaf Green Industries started a pilot project in Ethiopia for Global Energy, which aims at setting up a kenaf project of 10.000 hectares as complimentary crop for an existing castor bean project.

Better Paper

According to Treehugger, and the US Department of Agriculture, kenaf improves yield and performance of trees to manufacture paper. Kenaf fibres have less ligning than wood pulp, hence easing processing. The use of kenaf fibres in paper also improves its properties, making it more resistant, whiter and easier to print. It is due to these properties that kenaf fibres are also used to improve the quality of recycled paper. Kenaf is not the only natural fibre competing to substitute trees in the making of paper. Other strong candidates are hemp, bamboo and sugar cane.

Vision paper is a tree-free paper producer in the US that uses kenaf for its production. Vision paper has been affected by the closure of paper mills in the US and it has been looking to purchase its own mill equipment since March 2008. This should allow the company to maintain the production of kenaf-based quality paper.

Composites

Toyota

Toyota has been researching the use of kenaf in automotive applications for almost a decade now. Toyota used kenaf as a door trim base material first in 2000, but as 2008 kenaf was being used for five components in a total of 27 car models, mainly high-end cars. Some of the early examples of parts where kenaf was used in Toyota models are listed below:

• 2000: Celsior door trim. Kenaf and polypropylene composite
• 2001: Brevis door trim. Kenaf and polypropylene composite
• 2003: Harrier door trim and seat back board. Kenaf and polypropylene composite
• 2003: Raum spare tyre cover. Kenaf and polylactic acid

In May 2008, Toyota entered a kenaf seed development agreement with the Indonesian Tobacco and Fiber Crops Research Institute to embark on a full-scale seed development program. Toyota’s target to make all interior parts from plant materials means that having inside knowledge on kenaf production has become more vital than ever.

NEC

The combination of PLA and kenaf fibres to create a biocomposite, as the one used to manufacture the spare tyre cover on the Raum model is a strong trend in the materials market. We have seen it not only in automotive, but also in electronic devices, like mobile casings composed of a bioplastic and a natural fibre as reinforcement, as in NEC Eco-Mobile. Below NEC definition of its Eco-Mobile:

A mobile telephone whose entire casing is made from a kenaf-fiber-reinforced bioplastic consisting of a corn-based polylactic acid to which kenaf fiber and NEC’s original additive have been added as reinforcing agents. The new bioplastic features better strength and heat resistance characteristics than previous bioplastics consisting only of polylactic acid and its production process halves the CO2 emissions of conventional oil-based plastics. This is the first time in the world such an environmentally sound material has been used for a mobile phone casing. The Eco-Mobile was launched on the market on March 10, 2006, by NTT DoCoMo under the commercial name “FOMA(R) N701iECO”.

Conclusion

Kenaf, like most other natural fibres, still holds unexploited potential as a modern material. Its use in combination with bioplastics could enhance materials’ properties, opening up new applications for both materials.

Related posts in mundomaterial:

2009 International Year of Natural Fibres

2009 International Year of Natural Fibres: Fique in Colombia

Renewably sourced polymer in automotive part

Other sources of information:

Samsung Cheil Kenaf Malaysian project: http://www.bernama.com/bernama/v5/newsindex.php?id=354548

Try Out the 5 Best Kinds of Tree-Free Paper: http://planetgreen.discovery.com/work-connect/tree-free-paper.html

Composites with PLA used in automotive; http://www.toyota.co.jp/en/environment/recycle/design/recycle.html

Presentation on kenaf and automotive applicatiosn by Toyota: http://www.bc.bangor.ac.uk/suscomp/assets/pdf/car%20components.pdf

NEC Eco-Mobile: http://www.nec.co.jp/eco/en/annual2006/02/2-1.html

Photo: photo credit: MShades