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Ingeo and Circular Economy
NatureWorks LLC
Ian Toh
Commercial Director, Asia Pacific
September 15, 2016
2© 2016 NatureWorks
Circular Economy
THE NEW PLASTICS ECONOMY
Rethinking the Future of Plastics
The Foundation aims:
• “to bring together for the first time
a comprehensive global
perspective of the broader plastic
packaging economy,
• “to present a vision and propose
a roadmap as well as a vehicle
for progressing this roadmap
• “to provide a much needed global
focal point to carry this agenda
forward…
“looking for systemic change to
overcome stalemates in today’s
plastics economy in order to move
to a more circular model…”
Plastics & Plastics Packaging+
3© 2016 NatureWorks
• Production expected to double
again in 20 years, and quadruple
by 2050
• Plastic Packaging is single
largest application (26% of total
today)
Plastics Production Increased Twenty-Fold Over
The Last 50 Years
4© 2016 NatureWorks
“Plastic Packaging is an iconic linear application…”
“95% of plastic packaging material
value (US$ 80-120 bn) is lost annually
after a short first use …
5© 2016 NatureWorks
Ambitions of the New Plastics Economy: Capturing the opportunity
6© 2016 NatureWorks
Sourcing
Manufacture
Use
After Use
Definition of Sustainable
Packaging
7© 2016 NatureWorks
How the Plastics and Plastics Packaging Industry is
rethinking itself from a Circular Economy Perspective
0
20
40
60
80
100
plastic characteristics and packaging functionality
After
Use
Sourcing
Use
Manuf-
acture
How
plastic
packaging
is recovered
How the
plastic
is made
What the plastic is made from…
Ideal Material
Current, Incumbent Packaging
Plastic
Future…
Where do
Bioplastics
Fit ?
8© 2016 NatureWorks
Let’s talk about SOURCING…
After
Use
Sourcing
Use
Manuf-
acture
9© 2016 NatureWorks
Decoupling from Fossil Feedstocks: “revolutionary”
and “evolutionary change is needed
10© 2016 NatureWorks
Resins
Additives
(Modifiers)
Adhesives
Coatings
Printing Toners
Specialty
Lactates
Surfactants
Intermediates
CO2 CO2
CO2 CO2CO2
Plant
Sugars
Plants Manufacture
1st Generation
Ag feedstocks
are a short term
Bridging Tool
CO2 + H2O
At NatureWorks…We turn greenhouse gas feedstocks into
performance materials
11© 2016 NatureWorks
NatureWorks is committed to feedstock
diversification:
And next
CO2 to lactic acid
technology?
CH4 to lactic acid
technology
GENERATION NEXT
Developing
Lignocellulosics: Sugars
from bagasse, wood chips,
switch grass or straw.
GENERATION II
Investment in innovation and R&D collaboration to grow the Ingeo feedstock portfolio
GENERATION I
Today
Dextrose & Sucrose from
cassava or corn starch,
sugar cane or beet
“Bridging Crops”
Performance materials made by transforming whatever are the right, abundant, local resources
12© 2016 NatureWorks
NatureWorks “Moon Shot” innovation in feedstock
diversification
And next
CO2 to lactic acid
technology?
CH4 to lactic acid
technology
GENERATION NEXT
Milestone
June 2013: NatureWorks & Calysta partnership
June 2014: Lab scale lactic acid production
demonstrated
October 2014: $2.5MM DOE funding
January 2016: 1 MM investment in new MN based
methane fermentation lab, supported by state funding
13© 2016 NatureWorks
Handbook of Hydrocarbon and Lipid Microbiology (2010) Chen, Y & Murrell, J.C.
Methanotrophs:
• Bacteria that metabolize methane as their sole source of carbon and energy
How can this be made possible:
Methanotrophs in Nature
14© 2016 NatureWorks
By Brian Handwerk, for National Geographic News, January 6, 2011
Gulf Oil Spill Surprise: Methane Almost GoneNatural gas ingredient gobbled up by bacterial blooms, study finds.
“After months of speculation about what will happen to the Gulf oil spill, it turns out Mother Nature has rolled up her sleeves and dispatched with a lot of the gas released along with it—in just four months”
15© 2016 NatureWorks
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2
3
It starts with methane
which is supplied directly
to specialized bacteria
called methanotrophs
Methanotrophs convert
methane into lactic acid
through fermentation
NatureWorks converts
lactic acid monomers into
a family of Ingeo plastics
and green chemicals
From Methane to Ingeo
16© 2016 NatureWorks
Sustainable Packaging in the Circular Economy
means addressing feedstock sustainability too (not
just renewability)
BIOBASED CARBON CERTIFICATION
Verifies that 100% of carbon in Ingeo
comes from renewable ag resources via
USDA BioPreferred in the US & Vincotte
in Europe.
ISCC PLUS
3rd party (ISCC) certifies the sustainable
production of renewable raw materials
including chain of custody.
Certification
Renewability Sustainability
17© 2016 NatureWorks
Let’s talk about MANUFACTURE…
Sourcing
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20
40
60
80
100
After
Use
Use
Manufacture
Where do
Bioplastics
Fit ?
18© 2016 NatureWorks
“Bio-benign” materials choices for manufacture
THE NEW PLASTICS
ECONOMY
Rethinking the Future of Plastics
Greenpeace’s “Pyramid of Plastics”
http://www.greenpeace.org/usa/wp-content/uploads/legacy/Global/usa/planet3/PDFs/this-vinyl-house.pdf, p. 27
1.PVC
2. PU, PS, ABS, PC
3. PET
4. PE, PP
5. Biobased polymers
19© 2016 NatureWorks
Manufacture from Renewably Sourced -
Packaging Plastics Implications…
3.2
2.7
1.9
1.9
2.3
2.2
1.8
1.6
0.6
0 0.5 1 1.5 2 2.5 3 3.5
Polystyrene
PET
HDPE
Polypropylene
Ingeo
kg CO2 (eq) generated /kg material produced
US ProducersAPC - American Plastics Council
http://plastics.americanchemistry.co
m
EU ProducersPlasticsEurope
www.lca.plasticseurope.org
Peer Reviewed
Benchmarking
20© 2016 NatureWorks
Long term resource efficiency is critical in a
circular economy context…
1.05
1.25
1.63
1.80
2.13
2.77
3.22
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50
BIO-PBS
INGEO
BIO PA-11
BIO PEF
BIO PP
BIO PET
BIO PE
kg of sugar per kg of polymer
[Comparing Sugar to Polymer Yields]
Polymer Technology
Ingeo Sugar to PLA via lactic and lactides
PA-11 Veg Oil to Ricinoleic Acid
Bio PP Sugar to ethanol to propylene to PP
Bio PET Bio MEG + Bio PTA from sugar
Bio PE Sugar to ethanol to ethylene to PE
Nova paper #8 on bio-based economy 2015-11
Definition, Calculation and Comparison of the “Biomass Utilization
Efficiency (BUE)” of Various Bio-based Chemicals, Polymers and Fuels
Bioplastics Comparison:
21© 2016 NatureWorks
SOME EXAMPLES …
Life Cycle Analysis (LCA)
Implications of Manufacture
22© 2016 NatureWorks
23© 2016 NatureWorks
LCA - Global Indicator Results
41
54
93
0
10
20
30
40
50
60
70
80
90
100
Ingeo PP PET
g C
O2
eq
. / 1 c
up
& l
id
Climate Change
24© 2016 NatureWorks
LCA study conducted on Ingeo
Package for Danone by the
Heidelberg based
German LCA institute, IFEU
• Improves packaging
carbon footprint by
25%
• Uses 43% less fossil
resources
25© 2016 NatureWorks
Marketing: Communicating at the
Consumer Level
Wal-mart’s ask of NatureWorks: provide a simple POS
message on Ingeo packaged vegetable tray
Option 1: Quantitative,
environmental angle
Option 2: Qualitative,
emotive angle
26© 2016 NatureWorks
“Walmart Stores in 2010 has achieved a savings in fossil fuel usage of 25,971 barrels of oil per
year, and a reduction in greenhouse gas emissions equal to eliminating the CO2 emissions
from driving a car 20,885,635 miles”
Corporate Sustainability Reporting
27© 2016 NatureWorks
Let’s talk about bioplastics functional material
characteristics in use…
Sourcing
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20
40
60
80
100
After
Use
Use
Manufacture
28© 2016 NatureWorks
Key Properties
Utilizing inherent Ingeo properties in capturing the
opportunity
Opportunities
… EXAMPLES
• Ingeo categorised as G.R.A.S. (Generally Recognised As Safe), no perceived health issues, before formal food contact compliance status
• Excellent barrier resistance to large molecules: food fats/oils, flavorants, scents (flavor and aroma)
• High gloss and clarity, easily tinted or pigmented, excellent printability
Food contact applications and baby products (dishware, toys, etc.)
Applications such as perfumes & cosmetics, tea & coffee, confectionary, etc.
Overwraps in luxury packaging, etc.
• Density at 1.25 advantage over 1.35 of APET/rPET
• 3.4 Gpa tensile modulus advantage over PS (3) and PET (2.7)
• Melt point at 171C vs. PET 255C downgaugingopportunities.
More material per kg, material savings
10% – 20% down-gauging opportunity vs. PS and PET, cost savings
Able to process with lesser energy, energy savings
29© 2016 NatureWorks
North American Retail Example: Sam’s Club
reduced resin use with Ingeo compared to r-PET
When made in
rPET
1) 55 grams
2) 16 mil
Mastronardi tomato clamshell
When made in
IngeoTM
1) 44 grams
2) 14 mil
20% Actual Weight Reduction due to Ingeo Lightness & Stiffness
30© 2016 NatureWorks
Dairy Packaging Example
• Carbon savings• 75% reduction in CO2 emissions
• Equivalent to 1,320 MT CO2/year savings
• Ingeo out performs polystyrene• Stronger/less breakage
• Better lid adherence
• Lower temperature filling (less energy use)
• Maintained line speed and shelf life
• Addresses consumer concerns• Well received by key opinion leaders
• Reduction in human toxicity
• Did NOT increase our retail price
31© 2016 NatureWorks
Applications in Flexible Packaging
Shrink Sleeves/Labels/tamper bands
Ingeo™ film shrink
at low temperature
Pouches
In combination with paper and/or cellophane provides
excellent seal ability with seal strength above 20 N/15
mm. Pouches for powder and chunks.
Can be AIOx treated for longer shelf life products
End fold wrap and twist
Folds tight around carton boxes, no wrinkles.
Folded film is closed by heated sealing device.
32© 2016 NatureWorks
Recent Innovation in
Ingeo Flexible Packaging …
33© 2016 NatureWorks
collaboration with
Multi-Functional Barrier Performance in Cost Effective Ingeo
Multilayer Structures
0.1 1.0 10 100 1,000
Increasing Barrier to Water Vapor (Water Vapor Transmission Rate (g/m2day), 38 C, 90% RH)
0.1
1.0
10
100
1,000
10,000
PLA
PET
metallizedPVdC
coated
BOPP
BOPP
BOPP
BOPP
EVOH
coated
PET
metallized
Metalvuoto’s Ingeo film
Inc
rea
se
d B
arr
ier
to O
xy
ge
n
(Oxyg
en T
ransm
issio
n R
ate
(cm
3/m
2day),
23
C, 0%
RH
)
34© 2016 NatureWorks
PAPERAUMINIUM, or Metalized PP/PET
LDPE
LDPE
PAPERPAPER
ALUMINIUM
PAPER
fossil based
Packaging Simplification
38© 2016 NatureWorks
collaboration with
Weight & Cost Reduction
• Ultra-Light Ingeo film as high performance sealant web
High performance sealant webs
Light on the environment, light on your pocket
9 micron vs typical 50-70 micron LLDPE sealant
Cost savings vs LLDPE sealant layers
PAPER or PET
ALUMINIUM or MET BOPP
LDPE 50-70 my
fossil based
PAPER or PET
ALUMINIUM or MET BOPP
INGEO 9 my
40© 2016 NatureWorks
PLA
INJECTION
MOLDING
GRADES
ABS
Medium Impact
(884-41-1)
High
Impact
(884-41-2)
INGEO PROFILE
EXTRUSION
FORMULATION
High
Modulus
(821-56-2)
ASTM
Method
Bio-Content (%) 100 0 89 88 76 6866
Specific Gravity
(g/cm3)1.24 1.04 1.22 1.21 1.24 D792
Specular Gloss
(60°/20° geometry)125 / 112 89 / 68 72 / 48 73 / 47 77 / 56 D792
Tensile Modulus,
kpsi (MPa)494 (3,400) 336 (2,316) 414 (2,850) 414 (2,850) 454 (3,125) D638
Tensile Yield
Strength, psi (MPa)9,300 (64) 5,600 (39) 5,400 (37) 5,500 (38) 4,940 (33) D638
Tensile Elongation at
Break (%)3.6 5.5 32 21 38 D638
Notched Izod
Impact, ft-lb/in (J/m)0.4 (21) 5.19 (277) 2.6 (139) 8.3 (443) 6.6 (352) D256
Flexural Strength,
kpsi (MPa)16.4 (113) 9.9 (68) 9.5 (66) 9.4 (65) 8.6 (59) D790
Flexural Modulus,
kpsi (MPa)528 (3,640) 345 (2,381) 455 (3,140) 448 (3,100) 513 (3,550) D790
Heat Distortion
Temp @ 66 psi (°C)55 87 92 77 85 D648
INGEO INJECTION MOLDING
FORMULATION
Ingeo Durable SolutionsNew crystalline Ingeo formulations deliver a practical, bio-based alternative to ABS*
* Properties
benchmarked with
Terluran GP-35 ABS
41© 2016 NatureWorks
In addition to high bio-content, equivalent HDT and impact strength, Ingeo formulations
offer superior environmental stress-crack resistance (ESCR) to some common agents
Ingeo formulation’s advantage over ABS
42© 2016 NatureWorks
CHEMICAL INGEO ABS
Hand Cream Pass Pass
Sunblock Pass Pass
Insect Repellent Pass Fail
Acetone (nail polish) Pass Fail
Isopropyl Alcohol (hand sanitizer) Pass Pass
*Testing performed by Nypro, A Jabil Company
More ESCR test results
43© 2016 NatureWorks
Food Serviceware
Nonwovens / Fibers
Rigids Films & Cards
Durables Lactides New Biz
Additives
Adhesives
Coatings
Printing Toner
Lactates
Surfactants
3D
Building &
Construction
NatureWorks optimized grades towards specific
applications
44© 2016 NatureWorks
Let’s talk about bioplastics after-use
Sourcing
80
100
After
Use
Use
ManufactureGetting
Circular
45© 2016 NatureWorks
Mechanical
Recycle Feedstock
Recovery Compost Anaerobic
Digestion Energy
Recovery
Landfill X X
Incumbent
Plastics Ingeo
Recovery Options
46© 2016 NatureWorks
Organics Diversion from Landfill
• US – “the 28% Opportunity”
• Where Composting
infrastructure exists,
Compostable plastics like
Ingeo provide a tool for
organics diversion from
landfill
Food Scraps14.6%
Other3.3%
Paper27.0%
Glass4.5%
Metals
9.1%
Plastics12.8%
Rubber, leather & textiles
7.6%
Wood6.2%
Yard trimmings
13.5%
US Example: Total US MSW
Generation (by material), 2013
Source: Advancing Sustainable Materials Management:
Facts & Figures 2013, USEPA, June, 2015
47© 2016 NatureWorks
Recycling
• Routinely recycled at post industrial level
• Initial collection programs beginning at
consumer level
Collecting Converting End-Markets
• PLA bale
specification &
pricing set
• Flake specifications &
process development
underway
• r-PLA product
development
underway
“to avoid being part of the 86%”
48© 2016 NatureWorks
Rethinking Plastics Packaging with
After
Use
Sourcing
Use
Manufacture
49© 2016 NatureWorks
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