sustainability | PLA Right: Heat-stable
technology from Natureworks allows PLA to compete with ABS in some applications
moulding grade resistant to 120°C and designed for microwaveable and dishwashable tableware, as well as toys and stationery.
ABS is also in the sights of the three-year EU-spon-
sored Naturtruck research project, which began last year. Researchers are investigating how to make completely bio-based automotive parts. Various technological centres and manufacturing companies are collaborating to develop thermoplastic composites using PLA and natural fibres as an alternative to ABS for parts for truck cabin interiors. The main objective is to develop injection moulded parts with improved thermal proper- ties and flame retardance as well as high-quality surfaces. “Those biocomposites will be a real alternative to low-gloss standard ABS grades at a competitive cost,” says a spokesperson at Aimplas, the Spanish technology institute which is one of the project members. Early work in the project has involved treatment of
natural fibres to improve their properties and compat- ibility with the PLA. This was carried out by IWNiRZ, a fibres institute in Poland. “The best results were achieved for degummed hemp fibres treated first with silanes and then with plasma,” says Miguel Angel Valera, a compounding researcher at Aimplas. Aimplas has also developed injection mouldable fire
retardant PLA/hemp fibre composites that achieved HB classification according to the UL94 standard. “The thermal stability of the composites was drastically improved by the use of natural antioxidants (polyphenol extracts),” Valera says. A third member of the project, CTAG (Automotive
Centre of Galicia in Spain), designed two prototype truck cab interior parts. The final design has already been
validated through Moldflow simulation and injection moulding trials. CTAG used an infrared annealing process of the parts (applied on-line and post-injection) to improve the crystallinity and hence the heat deflec- tion temperature (HDT) of the biocomposites. The post-injection process raised the crystallinity of the biocomposites from 13% to 65%, Valera says. Aimplas has also studied annealing using microwave
irradiation. Valera says this raised the crystallinity of PLA/kenaf composites by 30% and increased the HDT under a load of 0.45 MPa from 56°C to 154°C. Germany-based bioplastics compound specialist
FKuR developed its Bio-Flex 9533 grade for injection moulding applications, claiming properties similar to PS. The biodegradable compound is being used by US-based Soma to manufacture the filter in its carafe filtered water system. The PLA blend is used to injection
Corbion takes next step in PLA plans
Corbion said in May it has signed letters of intent covering one third of the volume from the proposed 75,000 tonnes/year PLA polymerisation plant it aims to build in Thailand, meeting the target it had set for moving ahead to the next stage of the planned €60m investment. Tjerk de Ruiter, CEO of
Corbion, said: “There is an attractive demand outlook for PLA, albeit at a lower growth pace than previously as- sumed. Given our strong
50
Corbion CEO Tjerk de Ruiter
PLA producer.” Corbion has already begun
to test, validate and sell pre-marketing volumes of PLA. “The pre-engineering is in full progress and is expected to run till end of the year,” said Tjerk de Ruiter. According to Corbion,
position in lactic acid, our unique high heat technology and the market need for a second PLA producer, we plan to forward integrate in the bioplastics value chain, from being a lactide provider to a
INJECTION WORLD | July/August 2015
worldwide PLA capacity is almost sold out and, with the PLA market expected to grow to 600,000 tonnes/year by 2025, the market is seeking additional PLA suppliers. The company will continue selling
lactides to both existing and new PLA polymerisation customers. Natureworks is the world’s
leading PLA producer. Its plant at Blair in Nebraska has a nameplate capacity of 140,000 tonnes/year. The company announced plans to build a second production unit in Asia (with Thailand the preferred location) back in 2011. However, it is yet to commit to construction. ❙
www.corbion.com ❙
www.natureworksllc.com
www.injectionworld.com
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