The Current Situation and Future Outlook for Natural Fibres within the

Automotive Industry

Dr. Brett SuddellDr. Brett SuddellUniversity of Wales Swansea, IRCUniversity of Wales Swansea, IRC

(U.K.)(U.K.)

Joint Meeting of the 32nd session of the Intergovernmental group on Hard Fibres and the

34th session of the Intergovernmental group on Jute, Kenaf and Allied Fibres8 to 11th July 2003Salvador, Brazil

Presentation Format Short introduction to IRCShort introduction to IRC Background to surveyBackground to survey Intro to NF’s – Advantages/DisadvantagesIntro to NF’s – Advantages/Disadvantages Automotive SectorAutomotive Sector ApplicationsApplications European PerspectiveEuropean Perspective U.S. perspectiveU.S. perspective ConclusionsConclusions AcknowledgmentsAcknowledgments

Where are we based?

University of Wales Swansea

Interdisciplinary Research CentreCentre of ExcellenceSchool of EngineeringUniversity of Wales

SwanseaSingleton ParkSwansea SA2 8PPSouth WalesUK

Tel:+44 1792 295286Fax:+44 1792 295693

b.c.suddell@swan.ac.uk © Crown Copyright: Royal Commission on the ancient and historical monuments of Wales

Introduction to the IRC Established in 1989, 10 year funding via Established in 1989, 10 year funding via

EPSRCEPSRC £12m industrial funding over last decade£12m industrial funding over last decade Rolls Royce University Technology CentreRolls Royce University Technology Centre WDA Centre of ExpertiseWDA Centre of Expertise Materials CETIC Centre of ExcellenceMaterials CETIC Centre of Excellence Accredited by Rolls Royce plc for design Accredited by Rolls Royce plc for design

standard datastandard data

Activities

33rdrd Sustainable Composites Network seminar Sustainable Composites Network seminar (60+ people)(60+ people)

Work closely with Australian partnersWork closely with Australian partners Working with local SME’s and institutionsWorking with local SME’s and institutions Research with institution based in IndiaResearch with institution based in India Enquiries from Africa, Europe, Asia to work on Enquiries from Africa, Europe, Asia to work on

Natural Fibre composite research programmesNatural Fibre composite research programmes

Background to Survey

Welsh and Australian experts brought togetherWelsh and Australian experts brought together

New Wales in New South Wales technical New Wales in New South Wales technical programmeprogramme

IRC selected due to proven research track recordIRC selected due to proven research track record

Idea for this research borne out of this meetingIdea for this research borne out of this meeting

Background to Survey

Main Focus was the Automotive industry Main Focus was the Automotive industry

Identified fibres and respective applicationsIdentified fibres and respective applications

Identified Key Players in Academia and IndustryIdentified Key Players in Academia and Industry

Different Continents such as Europe; Australia; America Different Continents such as Europe; Australia; America (North and South); India; Africa and Asia (North and South); India; Africa and Asia

Conferences & Personal visits ““EcoComp” – London, September 2001EcoComp” – London, September 2001

““Bast Fibrous Plants..” – China September 2001Bast Fibrous Plants..” – China September 2001 LINK workshop – UMIST, Manchester October 2001LINK workshop – UMIST, Manchester October 2001 ““Global outlook for Natural Fibre reinforcements” – Orlando, USA Global outlook for Natural Fibre reinforcements” – Orlando, USA

December 2001December 2001 Central Science Laboratory focus meeting – London December 2001Central Science Laboratory focus meeting – London December 2001 ““The Industrial Application of Bioplastics 2002”, York, Feb 2002The Industrial Application of Bioplastics 2002”, York, Feb 2002 Composites Processing Association meeting, Birmingham Feb 2002Composites Processing Association meeting, Birmingham Feb 2002 ““High Performance Structures & Composites”, Seville, Spain. March 2002High Performance Structures & Composites”, Seville, Spain. March 2002 ““GreenTech”, Amsterdam April 2002GreenTech”, Amsterdam April 2002 ““Progress in woodfibre composites”, Toronto, Canada, May 2002Progress in woodfibre composites”, Toronto, Canada, May 2002 ECCM-10, Brugge, Belgium June 2002ECCM-10, Brugge, Belgium June 2002 Plant Fibres laboratory (Copenhagen)Plant Fibres laboratory (Copenhagen) BioComposites CentreBioComposites Centre Warwick Manufacturing GroupWarwick Manufacturing Group

Introductionto

Natural Fibres

Fibres

Vegetable Animal M inera l

Natura l

Synthetics

Man-made

Fibres

Vegetable fibre classification

Bast F ibres- F lax

- Hem p- Kenaf

Leaf F ibres- S isa l

- C uraua- Banana

Seed F ibres- Cotton- Capok

Fruit F ibres - C oconut

W ood F ibres - P inew ood

Vegetable F ib res- C e llu losic fibres

Bast Fibres – Bast is Best? Natural task to stabilise plantNatural task to stabilise plant Composed of an inner woody core Composed of an inner woody core

surrounded by bundles of long hollow surrounded by bundles of long hollow fibres and an outer protective skin each fibres and an outer protective skin each containing individual fibre cells or containing individual fibre cells or filamentsfilaments

Filaments = cellulose & hemicellulose, Filaments = cellulose & hemicellulose, matrix lignin or pectinmatrix lignin or pectin

Good mechanical propertiesGood mechanical properties Low density BF have potential to be Low density BF have potential to be

outstanding reinforcements in outstanding reinforcements in lightweight composite partslightweight composite parts

Leaf Fibres

In general coarser than Bast fibresIn general coarser than Bast fibres Sisal most important – Agave PlantSisal most important – Agave Plant Often applied with Flax in hybrid matsOften applied with Flax in hybrid mats

Provides good permeability when mat Provides good permeability when mat impregnated with resinimpregnated with resin

Interior applications sisal preferred due to Interior applications sisal preferred due to low level of odourlow level of odour

Natural Fibres Benefits and Limitations

Advantages

Environmental: Environmental: Plant fibres are a renewable resourcePlant fibres are a renewable resourceVery low Energy requirement in production Very low Energy requirement in production

(6,500BTU’s=2.2Kg Kenaf, (6,500BTU’s=2.2Kg Kenaf, 23,500BTU’s=2.2Kg of glass fibres)23,500BTU’s=2.2Kg of glass fibres)

Disposal can be by compostingDisposal can be by compostingCOCO2 2 neutralityneutrality

Advantages Biological:Biological:

Natural organic product Natural organic product No dermal or respiratory issues when compared to No dermal or respiratory issues when compared to

glass fibresglass fibresDo not pose a biohazard on disposalDo not pose a biohazard on disposal

Production:Production:Fibres are non-abrasive so extremely low wear Fibres are non-abrasive so extremely low wear

rates on toolingrates on toolingExcellent formability – deep mouldings can be Excellent formability – deep mouldings can be

producedproducedMoulding off cuts can Moulding off cuts can

be reusedbe reused

Advantages Component Weight:Component Weight:

Plant fibres have a max. density of Plant fibres have a max. density of 1.5g/cm1.5g/cm33 (that of Cellulose) (that of Cellulose)

Density flax=1.4g/cmDensity flax=1.4g/cm33

Density Glass fibres = 2.5g/cmDensity Glass fibres = 2.5g/cm33

Resulting in high specific strength and Resulting in high specific strength and stiffness = low component weightstiffness = low component weight

Injection moulded ABS 4 door panels = Injection moulded ABS 4 door panels = 9Kg, same panels utilising NF’s = 5Kg for 9Kg, same panels utilising NF’s = 5Kg for similar mechanical propertiessimilar mechanical properties

Advantages

Cost:Cost:Abundant resource in many nationsAbundant resource in many nationsBast fibres cost significantly less than Bast fibres cost significantly less than

glass fibresglass fibresNatural fibres 0.5-0.6 Euros/KgNatural fibres 0.5-0.6 Euros/KgGlass fibres 9.0 Euros/KgGlass fibres 9.0 Euros/Kg

In addition, weight critical applications In addition, weight critical applications usually incur lower costs with any weight usually incur lower costs with any weight savingssavings

Further Advantages

Readily available worldwideReadily available worldwide Exhibit a safer crash behaviour in tests i.e. no Exhibit a safer crash behaviour in tests i.e. no

splinteringsplintering Hollow tubular (cellular) structure also provides:Hollow tubular (cellular) structure also provides:

Good acoustic propertiesGood acoustic propertiesGood thermal insulating propertiesGood thermal insulating properties

Limitations Concerns over fibre consistency/qualityConcerns over fibre consistency/quality Low impact strength (high concentration of fibre Low impact strength (high concentration of fibre

defects)defects) Fibres are hydrophilic Fibres are hydrophilic Issues of bonding with polymersIssues of bonding with polymers Previous 2 issues largely overcome by development of Previous 2 issues largely overcome by development of

effective fibre surface treatments – MAPPeffective fibre surface treatments – MAPP Emission issues – fogging and odourEmission issues – fogging and odour Processing Temps – natural sugars caramelise Processing Temps – natural sugars caramelise

between 150-205between 150-205ºC must keep below this levelºC must keep below this level

History &

The Automotive Sector

History

3000 years ago first composite material made in ancient Egypt - clay/mud reinforced by straw to build walls

Development of other more durable construction materials such as metals, NF interest was lost

History

Early 1930’s, Henry Ford walked into his Company’s research lab with a bag of chicken bones, dumped them on a desk and said, “See what you can do with these!”

Tried cantaloupes, carrots, cornstalks, cabbages and onions

Soybean stalks. In 1940, Soybean oil could be used to make high quality

paint enamel and could be moulded into a fibre based plastic with 10 times the shock-resistance of steel

If the material had not required a long cure time and had associated moulding problems, we might be driving around in soybean fords today!!

History 1939-45 WWII – shortage of Aluminium in England, led to the use of 1939-45 WWII – shortage of Aluminium in England, led to the use of

flax fibres impregnated with phenolic resin to form fuselage skins of flax fibres impregnated with phenolic resin to form fuselage skins of spitfires – “Gordon-Aerolite”spitfires – “Gordon-Aerolite”

1942 Henry Ford – prototype hemp fibre composite car – did not 1942 Henry Ford – prototype hemp fibre composite car – did not enter production due to economic limitations at that timeenter production due to economic limitations at that time

Trabant (1950-90) first production car to be built from NF’sCotton within a Polyester matrix

Only in the last 15-20 years have NFC’s seen renewed interest

“The most environmentally friendly thing that you can do

for a car that burns gasoline is to make lighter bodies”

Henry FordHenry Ford

Structure of Automotive components market

Important elements of the automotive component industry relevant to natural fibre supply:

OEM’s (Original Equipment Manufacturers) – Car manufacturers Tier One Suppliers – suppliers of specialised interior systems for

assembly by OEM’s Substrate Suppliers – non-woven producers in textile industry &

plastics producers in case of new natural fibre granulate technology

Natural Fibre Suppliers – Hemp, Flax, Jute, Kenaf etc.

To influence specification and usage of natural fibres, suppliers must work with all components identified above.

The actual customers for natural fibres are the substrate/non-woven producers.

Route to the Automotive Market

Fibre Producer

Non-woven mat maker

Tier 1 supplier

Car Manufacturer

Automotive Market

To the natural fibre producer the To the natural fibre producer the automotive market is attractiveautomotive market is attractiveModel platform life is minimum 5 yearsModel platform life is minimum 5 years7-8 years7-8 years

Most important Processes Compression Most important Processes Compression Moulding and Injection mouldingMoulding and Injection moulding

Compression Moulding Most common use of bast fibres is in Most common use of bast fibres is in

compression moulding technologycompression moulding technology Medium-long fibres in non-woven mat or Medium-long fibres in non-woven mat or

feltfelt Mat produced by air laying or needle Mat produced by air laying or needle

punchingpunching Requires addition of polymers to act as Requires addition of polymers to act as

binders – blending prior to needling or binders – blending prior to needling or coating/impregnationcoating/impregnation

Injection Moulding Injection moulded composites reinforced Injection moulded composites reinforced

by short natural fibresby short natural fibres Short fibres (4-6mm) + PP in single/twin Short fibres (4-6mm) + PP in single/twin

extruder to produce granulate for injection extruder to produce granulate for injection mouldingmoulding

Examples Examples exterior apps – spoilers and fendersexterior apps – spoilers and fendersinterior apps – “hard” items - dash interior apps – “hard” items - dash

and instrument panelsand instrument panels

Miscanthus

Worlds largest GrassGrows up to 3mResembles sugar caneShort fibresBlended by handInjection mouldedStructural filler in plastic wheel trims

Applications

Fibre Applications

Applications

Mercedes-Benz ‘E’ClassMercedes-Benz ‘A’ Class

Audi A2 first mass produced vehicle with an all Al body,door panels reinforced with a flax/sisal mat

20% weight saving achieved with Flax/Sisal thermoset door panels

Natural fibres in automotive applications

Centre console trim

Various damping and insulation parts

C-pillar trim

Rear parcel shelf

Seat cushions

Door trim panels

Engine Shield

Bumper

Wheel arch

IENICA (ref. 1495) Summary ReportFibre Crops August 2000

Automotive Manufacturer

Model and Application

Audi A2,A3, A4, A4 Avant, A6, A8, Roadster, CoupeSeat backs, side and back door panel, boot lining, hat rack, spare tyre lining

BMW 3, 5 and 7 series and othersDoor panels, headliner panel, boot lining, seat backs

Daimler/Chrysler A, C, E and S-ClassDoor panels, windshield/dashboard, business table, pillar cover panel

Fiat Punto, Brava/Marea, Alfa Romeo 146, 156Ford Mondeo CD 162, Focus

Door panels, B-pillar, boot linerPeugeot New model 406Renault ClioRover Rover 2000 and others - Insulation, rear storage shelf/panelSaab Door panelsSEAT Door panels, seat backsOpel GM Astra, Vectra, Zafira

Headliner panel, door panels, pillar cover panel, instrument panel

Volkswagen Golf, Passat, BoraDoor panel, seat back, boot lid finish panel, boot liner

Volvo C70, V70

Plant fibre usage per vehicle

Front door liners: 1.2-1.8KgFront door liners: 1.2-1.8Kg Rear door liners: 0.8-1.5KgRear door liners: 0.8-1.5Kg Boot liners: 1.5-2.5KgBoot liners: 1.5-2.5Kg Parcel Shelves: <2KgParcel Shelves: <2Kg Seat Backs: 1.6-2.0KgSeat Backs: 1.6-2.0Kg Sunroof Interior Shields: <0.4KgSunroof Interior Shields: <0.4Kg Headrests: ~2.5KgHeadrests: ~2.5Kg

BMW 3, 5 and 7 Series3, 5 and 7 Series 20-24Kg of natural fibres20-24Kg of natural fibres ~16Kg coconut:sisal used as seat padding~16Kg coconut:sisal used as seat padding 80:20 flax:sisal blend for increased strength 80:20 flax:sisal blend for increased strength

and impact resistanceand impact resistance

Typical U.S. MaterialsApplicationApplication FibreFibre MatrixMatrix % %

FibreFibreDoor Door panel/insertspanel/inserts

Kenaf/Hemp, 50/50Kenaf/Hemp, 50/50Wood fibreWood fibre

PPPPPPPP

50505050

Rear parcel Rear parcel shelvesshelves

KenafKenafFlaxFlaxWoodWood

PPPPPPPPPPPP

505050508585

SeatbacksSeatbacks FlaxFlax PPPP 5050

Spare tyre Spare tyre coverscovers

FlaxFlaxWoodWood

PPPPPPPP

50505050

Other interior Other interior trimtrim

KenafKenafFlaxFlax

PPPPPPPP

50505050

Door PanelsInterior Door panels using Natural Fibres (manufactured by DLR Germany)

Chrysler Sebring convertible door panel – 25% Kenaf, 25% Hemp 50% PP

Ford Mondeo door insert

DaimlerChrysler

Exploring idea of replacing glass fibre with NF’s since 1991

Subsidiary Mercedes-Benz pioneered concept with “Belem project” in Sao Paulo, Brazil (Amazon delta)

Coconut fibres used in commercial vehicles for 9 years

DaimlerChrysler

2000 DC begins using NF in vehicle production in South Africa

Implemented transfer of technology from Germany to S.Africa for entire process chain

Sisal from local farmers to mat manufacturers to vehicle component supplies – none of these partners involved in sisal processing prior to this application

DC and South Africa

Sisal Farmer in South Africa

Sisal Fibres

Spent $1.5bn on environmental initiatives in 2000 alone

Researchers in Germany using NF’s to reinforce EXTERIOR components

A truck with flax-based rather than glass-based exterior skirting panels now in production

Tests carried out at DC research centre, Ulm panels stood up to impact without shattering into splinters

DC have a global natural fibre initiative program that benefits 3rd world nations by developing products made from indigenous agricultural materials

DaimlerChrysler

Exterior Applications

Mercedes-Benz Travego Coach

‘Travego’ coach equipped with flax reinforced engine/transmission covers Exterior components must be able to withstand extreme conditions – wetness and chipping First use of NF’s for standard exterior components in a production vehicle Represents a milestone in materials technology Benefits:

Weight reduction of engine/transmission cover of 10%Cost reduction of 5%

European Perspective

U.K. Govt. Division DEFRA (MAFF)

Study commissioned in 1999 Market for NFC has grown from nothing to a

considerable industrial infrastructure during the last 5-10 years

58m vehicles produced globally Up to 20Kg of NF’s could be used per car Each new car model requires 1,000 to 3,000 tonnes of

NF’s p.a. 1999 in excess of 15,000t of flax fibre being used in

auto industry in Europe

Situation in 2000 European market for fibreglass European market for fibreglass

composites ~300,000,000 Kg (2000)composites ~300,000,000 Kg (2000) 1/3 in automotive applications1/3 in automotive applications Cost £5.50/Kg Cost £5.50/Kg Natural fibres cost 0.30-0.35p/KgNatural fibres cost 0.30-0.35p/Kg Significant cost reductions can be Significant cost reductions can be

achievedachieved

Germany occupies a totally dominant market position in terms of Germany occupies a totally dominant market position in terms of product innovation, research and commercial productsproduct innovation, research and commercial products

Germany is clearly the leading country in the consumption of Germany is clearly the leading country in the consumption of natural fibres in the European Automotive industry [2/3 of all natural fibres in the European Automotive industry [2/3 of all fibres]fibres]

Due to government subsidies in 80’s to stimulate the domestic Due to government subsidies in 80’s to stimulate the domestic growing of plants such as flax and hemp as industrial crops – did growing of plants such as flax and hemp as industrial crops – did not lead to new markets but raised the profile of NF’s not lead to new markets but raised the profile of NF’s considerablyconsiderably

UK & France fall behind GermanyUK & France fall behind Germany In Germany, car manufacturers are aiming to make EVERY In Germany, car manufacturers are aiming to make EVERY

component of their vehicles either recyclable or biodegradable*component of their vehicles either recyclable or biodegradable*

*S. Hill, “Cars that grow on Trees”, New Scientist, Feb. 1997, pp.36-39

Germany

1982-2002 EU >$60m in subsidies 1982-2002 EU >$60m in subsidies directed towards development of new flax directed towards development of new flax and hemp appsand hemp apps

In Germany alone >$104m invested in In Germany alone >$104m invested in R&D – new harvesting, fibre processing R&D – new harvesting, fibre processing and refining technologiesand refining technologies

>$89m further investment planned in >$89m further investment planned in GermanyGermany

M.Karus et al. “Study on Markets and Prices for Natural Fibres (Germany and EU)”Nova Institute, March 2000

European consumption of Natural fibres (tonnes)

Fibre 1996 1999

Germany Rest of Europe

Germany Rest of Europe

Flax 1800 na 11000 4900Jute 1800 300 2000 1400Hemp na na 1100 600Kenaf 400 na 900 naSisal na na 500 na

Totals 4000 300 15500 6900

Projections*2005 W-Europe 50-70,000t2010 W-Europe >100,000t

G.C. Ellinson, R,McNaught, “The use of natural fibres in nonwoven structures for applications as automotive component substrates”, MAFF UK Government report NF0309, Feb 2000

*D. Plackett, “The natural fibre-polymer composite industry in Europe – Technology and Markets”, Proc. Progress in woodfibre-plastic composites, Toronto, May 2002.

Values for 2000Germany 17140Rest of Europe 11,160Total 28,300

European Usage

0

2000000

4000000

6000000

8000000

10000000

12000000

14000000

16000000

Kg

Flax Jute Hemp Kenaf Sisal Total (Kg)

1996 Germany

1996 Rest of Europe

1999 Germany

1999 Rest of Europe

Western Europe

0 10000000 20000000 30000000 40000000 50000000 60000000 70000000 80000000 90000000 100000000

Total Demand (Kg)

1996

1999

2000

2005

2010

Year

European Potential World automobile production of 58m vehicles World automobile production of 58m vehicles

p.a.p.a. 30% is Western Europe30% is Western Europe Potential market of 18m vehiclesPotential market of 18m vehicles Equates to 175,000-350,000 tonnes p.a.Equates to 175,000-350,000 tonnes p.a. Europe is ahead of North America in its use of Europe is ahead of North America in its use of

natural fibre composite applications by ~8 yearsnatural fibre composite applications by ~8 years

Consuming Petroleum resources at an Consuming Petroleum resources at an ‘unsustainable’ rate‘unsustainable’ rate

100,000 times faster than nature can 100,000 times faster than nature can create itcreate it

Governments have established laws to Governments have established laws to encourage use of green or recycled encourage use of green or recycled productsproducts

EU legislation ELV directive [2000/53/EC]ELV directive [2000/53/EC] Came into force Oct 2000Came into force Oct 2000 All member states required to transpose All member states required to transpose

into law by April 2002into law by April 2002 Directive aims to:Directive aims to:

‘‘depollute’ all scrapped cars ~10m/yeardepollute’ all scrapped cars ~10m/yearAvoid hazardous wasteAvoid hazardous wasteReduce landfill to max 5%/car by 2015Reduce landfill to max 5%/car by 2015

Driving Force - Government Legislation

Recycling concerns being driven by EU regulations [EU directive Article 7 on end of life vehicle disposal]

Pressure on manufacturers to consider environmental impact of products at all stages of their life cycle including the ultimate disposal

RecoveryRecoveryWt %Wt %

RecyclingRecyclingWt %Wt %

Jan 1Jan 1stst 2005 2005 8585 8080

Jan 1Jan 1stst 2015 2015 9595 8585

Driving Forces

CostCost Weight reductionWeight reduction Crash worthinessCrash worthiness Sound insulationSound insulation Green productsGreen products RecyclingRecycling

European Research Automotive Industry e.g. SAAB and Research Automotive Industry e.g. SAAB and Research

Institutions collaborating on EU growth projectsInstitutions collaborating on EU growth projects ““EcoFina”EcoFina” Addresses the substitution of mineral fillers and Addresses the substitution of mineral fillers and

fibres made with organic matrices, by Polymeric fibres made with organic matrices, by Polymeric Matrix composites based on annually renewable Matrix composites based on annually renewable natural fibresnatural fibres

Allow for the production of vehicle components Allow for the production of vehicle components with potentially complete recyclabilitywith potentially complete recyclability

www.ecofina.orgwww.ecofina.orgD. Puglia, J. Biagiotti, J.M.Kenny, “ECOFINA: Ecoefficient Technologies and Products based on Natural Fibre Composites”, D. Puglia, J. Biagiotti, J.M.Kenny, “ECOFINA: Ecoefficient Technologies and Products based on Natural Fibre Composites”,

Proceedings of ECCM-10, June 3-7 2002, BruggeProceedings of ECCM-10, June 3-7 2002, Brugge

United States Perspective

Total (All sectors) NF demand North Total (All sectors) NF demand North AmericaAmerica

1980 = 47.62M Kg1980 = 47.62M Kg1990 = 52.16M Kg1990 = 52.16M Kg

North America in 2000North America in 2000181m Kg of natural fibres used181m Kg of natural fibres used

3.5% (5.9-6.8m Kg) e.g. flax, hemp, 3.5% (5.9-6.8m Kg) e.g. flax, hemp, kenafkenaf

96.5% Wood flour and fibre96.5% Wood flour and fibre

0

50

100

150

200

Years

Kg

(Milli

ons)

1980 1990 2000

U.S. End Markets (2000)

75%

7%8%

10%

Building ProductsOther - Infrastructure, MarineAutomotiveIndustrial and Consumer

Forecast Growth outlook for natural fibres in automotive Growth outlook for natural fibres in automotive

products 2000-2005 50% per year*products 2000-2005 50% per year* $150M (2000) to $1.4bn (2005) North America $150M (2000) to $1.4bn (2005) North America

alone!! [54% annual growth rate]alone!! [54% annual growth rate] Market in Market in 20052005 will require will require 45.45M Kg45.45M Kg of of

natural fibresnatural fibres Processing and weight benefits compared to Processing and weight benefits compared to

glass fibres will particularly drive the growth of glass fibres will particularly drive the growth of NF’sNF’s

*Kline and Company Inc., report 2000

U.S. Companies Flexform Technologies LLCFlexform Technologies LLC

Blends Kenaf, Hemp and PPBlends Kenaf, Hemp and PPUses – door panels, dashboards, ceiling Uses – door panels, dashboards, ceiling

tiles, wall panels, z-truss structures for load tiles, wall panels, z-truss structures for load floors in RV’sfloors in RV’s

Demand is high among Tier 1 suppliers (2001) Demand is high among Tier 1 suppliers (2001) expected to double by end of 2003expected to double by end of 2003

Users include GM, Ford, Chrysler, International Users include GM, Ford, Chrysler, International Truck, Mack Truck, Volvo TruckTruck, Mack Truck, Volvo Truck

2003 dodge viper door panels and console 2003 dodge viper door panels and console made from flexform matsmade from flexform mats

U.S. Companies Kenaf industries of South TexasKenaf industries of South Texas

Produces wide range of kenaf productsProduces wide range of kenaf products Johnson Controls Tier 1 automotive supplierJohnson Controls Tier 1 automotive supplier

Began looking at nat.fibre composites for interior Began looking at nat.fibre composites for interior door panels 10 years agodoor panels 10 years ago

Developed EcoCor – 50:50 NF:PP 50% hemp, 50% Developed EcoCor – 50:50 NF:PP 50% hemp, 50% kenafkenafUsed in full door panel of 2001 Chrysler sebringUsed in full door panel of 2001 Chrysler sebring

Findlay Industries (tier 1)Findlay Industries (tier 1) Door package trays, trunk liners & hard trim Door package trays, trunk liners & hard trim

(kenaf/PP blends)(kenaf/PP blends)

Non-automotive research TeelGRTTeelGRT Based in Baraboo, WisconsinBased in Baraboo, Wisconsin Using Jute, Sisal, Wood, Coir, flax, straw, Using Jute, Sisal, Wood, Coir, flax, straw,

kenaf and denimkenaf and denim Plastic wood, tables, shipping pallets and Plastic wood, tables, shipping pallets and

piggy bankspiggy banks

Example of U.S. Research

Prof. Wool (Univ. of Delaware) recently Prof. Wool (Univ. of Delaware) recently awarded (2001) $11m (over 4 yrs) from US awarded (2001) $11m (over 4 yrs) from US department of Energy to develop department of Energy to develop ALLALL natural natural compositescomposites

One current project – development of a One current project – development of a monolithic, aerodynamically shaped roof for monolithic, aerodynamically shaped roof for hurricane resistant housing. Made from NF’s, hurricane resistant housing. Made from NF’s, natural foam insulation and soy-based resinsnatural foam insulation and soy-based resins

Interesting to note that 350,000,000 Kg of flax worth US$ 400m is converted to US$ 3bn worth of finished goods as value is added along the production chain

In Summary

World Potential 58m vehicles produced p.a.58m vehicles produced p.a. Max natural fibre consumption 50:50 Max natural fibre consumption 50:50

natural:synthetic ~800,000 tonnes/yearnatural:synthetic ~800,000 tonnes/year If each vehicle used every possible If each vehicle used every possible

application of Nf’sapplication of Nf’s

Advantages to using Bast Fibres in the Auto Industry

Reduction in weight between 12-30% (primary importance)

Reduction in cost (secondary importance) Renewable and sustainable plant fibre

resources Recyclable Abundant supply, accessible to car

manufacture areas

Conclusions Natural fibres have enormous potential to be Natural fibres have enormous potential to be

used in composites for automotive industryused in composites for automotive industry Offer Offer cost savingscost savings, , environmental benefitsenvironmental benefits

and and reduced component weightreduced component weight Issues of toughness and variable properties Issues of toughness and variable properties

must be resolved in order that these must be resolved in order that these composites see more widespread usecomposites see more widespread use

NF products are NOT confined to the NF products are NOT confined to the automotive industryautomotive industry

…the future… “ “The car of the future could be moulded from The car of the future could be moulded from

cashew nut oil and hemp. And that’s not all. In cashew nut oil and hemp. And that’s not all. In the boot could be a set of golf clubs built the boot could be a set of golf clubs built around Jute fibres, nestling next to a tennis around Jute fibres, nestling next to a tennis racket stiffened with coconut hair. The bicycle racket stiffened with coconut hair. The bicycle frames strapped to the flax-based roof rack frames strapped to the flax-based roof rack may derive their strength from any one of the may derive their strength from any one of the 2000 other suitable plants. The truth is, natural 2000 other suitable plants. The truth is, natural fibres are undergoing a high tech revolution that fibres are undergoing a high tech revolution that could see them replace synthetic materials in could see them replace synthetic materials in many diverse applications”many diverse applications”

S. Hill, “Cars that grow on trees”, New Scientist, Feb 1997. pp.36-39

Partners & Publicity

Cartoon courtesy of Western Australian Newspaper [22/05/01]

Collaborative programme with University of New South Wales, Sydney (Australia)

Objective – to produce a lightweight natural composite car suitable for use as an inner city taxi

Future Work

Survey into other sectorsSurvey into other sectors Construction of item of sports Construction of item of sports

equipmentequipment NATURAL FIBERS, BIOPOLYMERS NATURAL FIBERS, BIOPOLYMERS

& THEIR BIOCOMPOSITES& THEIR BIOCOMPOSITES(Editors: A. K. Mohanty, M. Misra, L. (Editors: A. K. Mohanty, M. Misra, L. T. Drzal)T. Drzal)Publisher: CRC PressPublisher: CRC PressExpected Date December 2003Expected Date December 2003

Acknowledgements Engineering and Physical Sciences Engineering and Physical Sciences

Research Council (EPSRC) for Research Council (EPSRC) for funding the researchfunding the research

The many people who contributed The many people who contributed to the surveyto the survey

FAO, andFAO, and To your goodselves for listeningTo your goodselves for listening

muito obrigada e qualquer questões?