ADDITIVES | NATURAL FIBRES AND FILLERS
Charts showing the notched Izod impact strength versus tensile strength (left chart) and density versus flexural modulus (right chart) for an unfilled PA66, a PA66 containing 30% calcium carbonate, and a PA66 containing 30% NeroPlast lignocellulosic filler from NPS
NPS. He says the novel advantage of the filler is that pyrolysis makes it hydrophobic, and so more compatible with polymers and longer-lasting than most natural fillers, which are hydrophilic and absorb water. Roesler and NPS cofounder Hans Korte first
proved this concept and launched NeroPlast masterbatches in 2011 but were limited by supply and cost issues.
“It seems our very first efforts with NeroPlast
were a little bit ahead of their time,” says Roesler. “I believe that we may be witnessing the start of a new era now, although actual changes will rather be gradual, of course. I see an increased willing- ness to look at solutions [that] would reduce the consumption of limited resources, reduce the dependence on petrochemicals, and to move us further towards a cyclical, sustainable economy.” The new generation of NeroPlast masterbatches have been optimised for use in thermoplastics, including polyolefins and polyamides. NPS plans to produce commercial quantities of masterbatch at its production facility in Florida in the second half of this year. Roesler suggests that the US will be capable of supplying a few million pounds per year (several thousand tonnes). “When the demand is there, we will be able to expand capacity extremely quickly,” he says. The NeroPlast filler, which is black in colour, will also be available as a precision-manufactured powder for use in thermosets and non-polymer applications such as cement and coatings. A sister company in Germany, PHK Polymertechnik, markets the products in Europe as Nerolit, and will be offering the powder version from April. Compared to mineral fillers used for resin-re-
58 COMPOUNDING WORLD | May 2023
Source: New Polymer Systems
placement, such as talc or calcium carbonate, or to glass fibres, NeroPlast is much lower in density. In addition, compared to other bio-fibres and bio-fillers that decompose at temperatures above 200°C, NeroPlast can be processed up to 290°C. “Furthermore, minimally processed bio-fillers (like dried wood flour) still possess most of their original organic volatiles, which can interact with the specific chemistry of the matrix resins. NeroPlast does no such thing as it is essentially purified carbon and [is] naturally very inert,” says Roesler. “In general, like every filler made of solid
particles, NeroPlast will make any polymer matrix stiffer but also more brittle. If needed, the in- creased brittleness can, of course, be countered with impact modifiers and other additives,” Roesler says. He suggests that in polyamides, for example, NeroPlast could be combined with reinforcing glass or carbon fibres. Compounds that contain at least 25% of
NeroPlast can be certified to qualify for the USDA BioPreferred Program, which means the products (depending on the end-use) would be preferred for purchasing by US federal agencies. In Septem- ber 2022, the US launched a National Biotechnol- ogy and Biomanufacturing Initiative that, among other actions, is designed to increase bio-based purchasing through the BioPreferred Program. An example could be using the filler in lightweight shipping pallets, suggests Roesler. The Maxxam BIO bio-based polyolefin product
line from Avient includes grades with up to 40% natural filler sourced from cellulose fibre or powder produced from recycled coffee grounds. These compounds are manufactured in Europe but commercially available globally.
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