armstrong biostride
TRANSCRIPT
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Innovations inGreen Floors and Coatings
Mary Kate Boggiano, Jeffrey S. Ross, Keith Quisenberry, Dong Tian
Armstrong World Industries2500 Columbia Ave, Lancaster, PA 17603
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AgendaAgenda
Introduction to Armstrong
UV Chemistry & Greenhouse Gases
Natural Oil Elastomers
BioBased Tile
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Introduction to ArmstrongIntroduction to Armstrong
Who we are• Armstrong is a global leader in the design and manufacture of
floors, ceilings and cabinets. In 2007, Armstrong’s consolidated net sales totaled approximately $3.5 billion. For more information, visit www.armstrong.com.
Armstrong’s Corporate Headquarters
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Where we are• Based in Lancaster, PA,
Armstrong operates 40 plants in 10 countries and has approximately 12,800 employees worldwide.
Introduction to ArmstrongIntroduction to Armstrong
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What we do• Members of the Innovation team work with Design, Marketing and
Manufacturing to develop new products that enable Armstrong to be an industry leader.
Installation Training
Design Consultation
Armstrong Avenue… a dynamic showcase of Armstrong products, featuring state-of-the art displays, new products and tradeshow exhibits.
Research new products and technologies, test theories and implement new ideas for introduction
Introduction to ArmstrongIntroduction to Armstrong
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A History of Environmental Commitment– In 1860, Armstrong began as a business that hand-cut cork
stoppers. Cork scrap accounted for about 65% of the raw cork that was used. It was wasteful and very costly. The company found an innovative solution by using the scrap to make corkboards, cork tiles and linoleum, which uses cork flour as a key ingredient. This led to our entrance into the flooring market.
– While UV coatings originated out of necessity to improve wear performance, the lower emissions (VOCs and HAPs) were quickly found to be of equal importance, especially for our California Plant which is located in an area of strict environmental controls.
– All our ceiling plants recycle used tiles in the manufacturing process. To date, more than 55 million square feet of tile has been recycled and kept from landfills.
Introduction to ArmstrongIntroduction to Armstrong
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Our Policy on the Environment articulates the operating fundamentals that support our commitment to sustainable growth. We have selected four Environmental Priorities to reduce our environmental footprint: Energy, Greenhouse Gases, Water, and Responsible Forest Management.
Armstrong’s Environmental CommitmentArmstrong’s Environmental CommitmentArmstrong’s Commitment to Environmental Sustainability:
Providing products and services to our customers that enable them to reduce the environmental impact of the buildings they create
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Armstrong’s Environmental GoalsArmstrong’s Environmental Goals
Develop an affordable, sustainable hard surface flooring product that performs like vinyl resilient flooringReduce the use of limited natural resources• Replace with rapidly renewable
ingredientsIncrease the recycled content to divert additional waste from landfills and to limit virgin material usageMeet low VOC emission standards to reduce impact on indoor air quality
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UV Chemistry & Greenhouse Gases
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UV Coatings & Environmental ResponsibilityUV Coatings & Environmental Responsibility
Greatly reduced or eliminated VOCs and HAPsNo “Greenhouse Gas” emissions from processDecreased total energy demand to dry and cureCoated flooring products meet IAQ guidelines • Certified by “FloorScore” to pass CA1350 • Compliant with requirements for LEED credits
100% Solids coatings reduce transportation energy requirements by >60% and eliminate water & co-solvent usage
Now operating UV/EB finish lines for wood & vinyl flooring and cabinets worldwideRecent -- New UV finish lines installed in Sweden, Germany, China and North America
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UV Wood Finishing System ExampleUV Wood Finishing System Example
Topcoats & Sealers
Wood Base
Stain
10 layer UV Coating
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0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80
Bulb Width (inches)
Lbs/
hour
600 W/in500 W/in400 W/in300 W/in200 W/in100 W/in
Assumptions• Includes CO2, N2O & CH4
• Uses Average (50 State) Equivalent Values
Greenhouse Gas Emission Equivalents from UV BulbsGreenhouse Gas Emission Equivalents from UV Bulbs
Bulb power
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0
20
40
60
80
100
120
Lbs
/hou
r
Gas Oven UV Cure
Comparison of Greenhouse Gas Emissions for Solvent-Based Stain Application vs 100% Solids UVComparison of Greenhouse Gas Emissions for Solvent-Based Stain Application vs 100% Solids UV
Assumptions• Includes CO2, N2O & CH4• Uses average (50 State)
Equivalent Values • 18% Solids in solvent• All HAPs compliant• 60ft/min line speed• Does not includes indirect
energy contributions of make-up air & other process motors
• Oven is gas fired high velocity air heating, rated at 1.2MBTUH
• UV is two 300W/inch Hg arc lamps, 60 inch wide
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Biobased Elastomersfrom Plant Oils
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Raw Materials• Renewable resources
Properties• High Flexibility• Anti Tear/Abrasion• Good Tint/Low Odor
Process• Environmentally Friendly• Short Manufacturing Cycle
Price• Good Property-to-Cost Profile • Competitive with PVC-based floor-covering
materialIntellectual Property
Eco-Innovations in Floor Covering MaterialsEco-Innovations in Floor Covering Materials
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Plant oilsLinseed Oil: Linolein
O
O
OHRO
OR
Castor Oil: Ricinolein
Soy Oil
O
O
RO
OR
O
O
RO
OR
O
O
Natural Raw MaterialsNatural Raw Materials
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OOOO
O
O
OHHO
OH
OOO
O
O
O
O
OHHO
O
OHO
OOOO
O
O
OHHOHO OH
O
O
O
O
HO OH
Epoxidized
Acrylate
MAH
OOO
(CH2)n
O
O
O
OHHO
(CH2)
HO HO
O
(CH2)nO
O
OO
HO OHHO O
OH
O
O
OOO
O
O
O
O
OHHO
O
HO
O
O
O
O
O
O
OH
OH
OOOO
O
O
OHHO
OHOH
Peroxide
Ring Opening polymerization
Free Radical Polymerization
Polycondensation
Diacid, Diols, polyisocyanates
O
OH
O
OHOH
O
OHN
NH2NH2
H
O
OH
NH
OHOH
{
AmidationGlycerolysis
Polycondensation
O
OH
OO
O
O OO
O O
X
X=O or NH MAH
OOOO
O
OOH
OH
OHOH
OH
HO
HOHO
OH
Hydroxyl functionalities
Chemical Pathways via Triglyceride MoleculesChemical Pathways via Triglyceride Molecules
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Polyacid Catalyst Temp Time to reach Gel PointSebacic Acid - 190 °C 8-10hrs
Sebacic Acid p-TSA/peroxide 220 °C 1-4hrs
Citric Acid p-TSA/peroxide 200 °C 5-10min
Catalyst, peroxide, or enzymes
Polyester Prepolymers
O
O
OHRO
OR HO
O
(CH2)n
O
OH
O
O
ORO
OR
O
(CH2)nO
O
Interpenetrating network
Castor Oil PrepolymersCastor Oil Prepolymers
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0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.00
50
100
150
200
εσ
Ey
Elongation,%
OH+COC/COOHD-1 0.78D-2 0.95D-3 1.01
Mec
hani
cal p
rope
rtie
s,ps
i
CO/Citric acid prepolymer ID
0
50
100
150
200
Systematic changes in the formulation result in material property changes
Formula OptimizationFormula Optimization
Ey = Young’s modulus
ε = Percent elongation
σ = tensile strength
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MIGRATIONS ™
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The Journey to BioStrideThe Journey to BioStride
2005 • Funded two external research programs to develop rapidly
renewable materials into flooring• Invested millions in manpower and a new research lab in
Lancaster to focus on a sustainable solution
2006 • Completed year of 24 hour/six day a week development
program• The result was five patent applications and our New BioStride
Polymer
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MonomerGlucose
Natural Products to Manufactured ProductsNatural Products to Manufactured Products
HarvestCorn
Sugar extracted from corn
Endosperm• Starchiest part of
corn• Glucose (form of
sugar) is extracted
Fermentation – turning
sugar into a monomer
Monomerinto
Bio-based Polymer
Monomer: small molecule that can be come chemically bonded to other monomers to form a polymer
Polymer: a substance composed of molecules with large molecular mass composed of repeating monomers connected by covalent chemical bonds
Bio-based polymer &
other ingredients
Polymer
Manufacturer MIGRATIONS
Polymer used in manufacturing process
Kernels
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10% recycled limestone10% recycled limestone
Binder System:• Vinyl Resin (PVC)• Plasticizer: flexibility• Stabilizers: heat & light• Processing Aids
Binder System:• Polymer Resin (PVC)• Plasticizer: flexibility• Stabilizers: heat & light• Processing Aids
Filler:• Limestone
– Mass and thickness at reasonable cost– Adds dimensional stability– Improves fire and smoke properties
• Pigments: color
Tile IngredientsTile Ingredients
COMPOSITION TILE
Filler:• Limestone
– Mass and thickness at reasonable cost– Adds dimensional stability– Improves fire and smoke properties
• _____________________________• Pigments: color
85% limestone13% vinyl
1% recycled vinyl1% recycled vinyl1% pigments
75% limestone10% recycled
limestone
14% BioStride1% pigments
What is BioBased tile?What is BioBased tile?
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COMPOSITION TILE
Tile IngredientsTile Ingredients
85% limestone
13% vinyl 1% recycled vinyl1% recycled vinyl
1% pigments
______ limestone _____ recycled limestone
_____ BioStride_____ pigments
____ of the BioStride is rapidly renewableor
______ of total weight of the BBT tile
13%13%
2%2%
75%75% 10%10%
1%1%14%14%
What is BioBased tile?What is BioBased tile?
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What is BioBased tile?What is BioBased tile?
A revolutionary new ________ of flooring made with _______ _________ __________rapidlyrapidly renewablerenewable resourcesresources
Breakthrough patent-pending polymerContains biobased, rapidly renewable ingredientsUnique plant-based compositionReduces reliance on:• Petroleum• Fossils fuels
“We knew rapidly renewable was the right thing to do, for both its
environmental payback and practical benefits to end-users.”- Frank Ready, President Armstrong
Floor Products
categorycategory
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Introducing MigrationsIntroducing Migrations
Why Composition Tile Format?
Why Composition Tile Format?
“Our aim in applying this development initially to composition tile, the most used category of resilient flooring is to exert maximum pro-environmental impact on the
market, with a greener product option at a more affordable price point.”- Frank Ready – President, Armstrong Floor Products
Enhanced range of green benefits
An affordable greener option
Enhanced performance over Composition Tile with classic looks
No additional maintenance on installation requirements
Industry leading quality from the most trusted name in the industry
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Introducing Migrations BBTIntroducing Migrations BBTEnhanced Range of Green BenefitsEnhanced Range of Green Benefits
MIGRATIONSMIGRATIONS™
Patent-pending PolymerMade with rapidly renewable US-grown plant ingredientsReduces reliance on petroleum & fossil fuels
Low VOC emissionsFloorScore™ certified to CA 1350
10% preconsumer recycled content (limestone)Reduces use of virgin materials
Contributes to 4 LEED credits• Recycled content• Regional materials
(depending on location)• Rapidly renewable• Low VOC emissions
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Introducing Migrations BBTIntroducing Migrations BBTEnhanced Range of Green Benefits
– What Does it Mean?Enhanced Range of Green Benefits
– What Does it Mean?
East Side Health Clinic
20,000 sq. ft.
VCT vs. BBT20,000 sq ft job
BBT saves energy and natural resources equivalent to ___ gallons of gasoline7272
2,800 lbs2,800 lbsBBT diverts ________ of waste from landfills – (recovered limestone used in manufacturing)
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Introducing Migrations BBTIntroducing Migrations BBTEnhanced Performance over
Composition TileEnhanced Performance over
Composition Tile
Migrationsvs.
Comp Tile
WINNER
IMPACTRESISTANCE
__________ greater resistance to impactFive timesFive times
Migrationsvs.
Comp Tile
WINNER
INDENTATIONRESISTANCE
_______ the indent resistanceTwiceTwice
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I’m confused with all of these “green” claims. Which floors
have bio-based content?
RUBBER TILE
RUBBER SHEET
LVTLVT
VCT
Vinyl sheet -homogeneousVinyl sheet -
homogeneous
Vinyl sheet -heterogeneous
Vinyl sheet -heterogeneous
Vinyl sheet -inlaid
Vinyl sheet -inlaid
LINOLEUMLINOLEUM
BBTBBT
Amtico - Canada
Amtico
Technical InformationTechnical Information
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SummarySummary
Armstrong has a legacy and ongoing commitment to environmental initiatives
UV-cured coatings reduce energy and materials use, as compared to solvent and water-based coatings
Bio-based elastomeric materials from renewable resources were developed
• Polymerization of castor oil
• Structure-Property relationships found through formulation optimization
Bio-based polymer developed for composition tile products
• Polymer contains components derived from corn
• First product …Migrations
Opportunities for future work at Armstrong
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AcknowledgementsAcknowledgementsGreen Chemistry Centre of Excellence
Richard W Tock and Harry W Parker, Texas Tech University
AFP North America Innovation Team
AFP Europe Innovation Team