What are the underlying biases and preconceived notions that we have about the products labelled "bio" or "green"? Are there other “bio”s that we need to be wary of?
Dr Jem's talk will cover bioplastics from a holistic perspective, with a focus on: types of bioplastics, pro's and con's of PLA, how is PLA 'industrially' recycled or composted, innovations in the bioplastics world, other plant-based packaging alternatives, etc.
Dr. Jem received his Ph.D. and 2 Masters degrees in biochemical engineering, and numerous awards in the USA, and worked 15 years in engineering, biotech, and pharmaceutical companies such as Ratheon, Serono, Diversa, with excellent track record with multiple awards. In 2000, he moved back to China to work for biotech and bioplastic companies such as Cargill and NatureWorks PLA. He has served as the China General Manager for Total Corbion PLA JV and previously for Corbion Purac since 2007, and serves as a Visiting Professor for several local Universities.
2. August 9, 2018 2
Global Warming & Green House Gases
Data from Earth Systems Research Lab (ESRL)/NOAA
CO2 Level: 400 ppmCurrent Warming: 0.9 C above ave.
Data from +/- 2 C Movie
3. China’s urgent needs of environmentally friendly bio-plastics
August 9, 2018 3
600 kt of mulch film is “plowed under” every year
Beijing reported 755 µg pm 2.5
4. Mulch film: >20 years of PE film at 5 microns thickness. 1.4 million tons/yr now
E-commerce delivery package: >1 million tons/yr.
Non-degradable plastics: ~50 millions tons/yr. (+ Polymer fiber industry: > 60 million tons/yr
Serious local polution problems: mulch film, solid waste, air PM 2.5, water, etc.
Sustainability and Oil-shortage
China’s urgent needs of environmentally friendly bio-plastics
Extremely high extra corn supply and stocking
Food safety problems: Milk with melamine contamination vs. Melamine tablewares
Commitment on carbon reduction and global warming problem
Melamine tableware: 400 K tons/yr in the past for exporting along.
COP15 at Copenhagen on 2009, COP21 Paris 2015.
Extra corn supply stocking
Extremely high extra corn supply and stocking (confidential data not to be published)
Strong fermentation and polymer industries
Many over-supply Lactic acid plants: claimed >200 K tons/yr capacity with L and D LA.
6. Bioplastics
Represent a fraction of the total plastics market
August 9, 2018 6
Bio-PET
• Drop-in replacement for oil-based PET
• Currently only 30% biobased
• Used for bottles
Starch
• Biobased & biodegradable
• Cheap but with low property performance
• Used as a filler for other (bio)plastics
Bio-PE
• Drop-in replacement for oil-based PE
• 100% biobased
• Produced from bio-ethanol
PLA
• Biobased & biodegradable
• High stiffness but brittle
• Transparent
PBAT
• Biodegradable, made from oil
• Primarily used in blends with starch and PLA
PHA
• Early stages of commercialization
• Value as additive/polymer yet to be proven
1 million tons sold in 2017
7. PLA carbon footprint & feedstock efficiency
August 9, 2018 7
Carbon Footprint Emissions from production
of common polymers*
Carbohydrate Usage of Bioplastics
(kg sugar per kg plastic)
Sources: www.lca.plsaticseurope.org and Int. Journal Life Cycle Assessment, ‘LCA of the manufacture of lactide
and PLA ’ 3 Aug 2010.
8. Start with the best building blocks:
8/9/2018 8
L-lactide
D-lactide
L-lactic acid
D-lactic acid
O
O
O
O
(R,R)- lactide
or D-lactide
O
O
O
O
(S,S)- lactide
or L-lactide
O
O
O
O
(R,S)- lactide
or meso-lactide
Building blocks used to make
PDLA and PLLA homopolymers
Stereo-chemically pure monomers make the difference!
L-lactic acid
9. Improved PLA performance for high added value markets
August 9, 2018 9
Single use:
Standard PLA
Single use:
High Heat PLA
Time
Value &
Performance
Durable & consumer
products
10. PLA (Poly Lactic Acid) in commercial applications today
August 9, 2018 10
Cups & lids Gift cards Coffee capsules Packaging films & labels
Consumer goods
packaging
Food packaging containers Bedding Apparel
11. August 9, 2018 11
PLLA homopolymer resin – Hisun – 海正 PLLA 树脂
Hisun range of PLLA resins:
• Revode 290
for Injection molding
• Revode 190
for extrusion & injection molding
Hisun Revode product range
12. August 9, 2018 12
Lactide to Molten PLA to fiber. Low
cost 丙交酯聚合后,聚乳酸熔体直纺
纤维, 大幅降低成本
Skin-core Bi-Component fiber: Hot air
to seal the low optical purity skin
皮心纤维. 热风粘结低光纯外皮
2 KT line now.
Building 10 KT line due mid-2017
Hengtian-Yangtze: direct spinning from lactide to PLA to fiber
恒天-长江: 熔体直纺纤维
13. August 9, 2018 13
Benefits
• High heat resistance
• Biobased & recyclable
• Excellent high gloss finish
• Excellent impact resistance
• High dimensional stability allows
for tight tolerances
PLA housings for consumer electronics – 聚乳酸 注塑产品在电子领域
的应用
The worlds first PLA
touch screen computer
Sugar feedstock
LA &
Lactide
production
PLA
polymer
production
Compound
production
Conversion to
products
Brandowner Retailer Consumer
The worlds first
PLA speaker
14. Benefits:
• Biobased
• High heat resistance
• Recyclable
• Good processing economics
• Can be processed on existing PS lines
PLA for high heat thermoformed coffee cups & lids
August 9, 2018 14
Cups by Pacovis
Partner for lids:
15. PLA for injection molded root trainers for rubber trees
August 9, 2018 15
Benefits:
• Biobased
• Biodegradable
• Strength & stability
• Thailand: local for local
16. August 9, 2018 16
China PLA/Fiber phase 2: Into Industrial Scales
Application Technology Trends((((聚乳酸应用技术趋势聚乳酸应用技术趋势聚乳酸应用技术趋势聚乳酸应用技术趋势))))
Application of PLLA compound for disposable vs. semi/durable & food package
(3C/automotive/food package & tableware ) 高光纯聚乳酸改性料在一次
性或半耐久3C电子产品/汽车/食品包装及餐具等
Application of PLA/PBAT film bags, mulch film, BOPLA & casted film etc
聚乳酸/PBAT膜袋,农膜,双向拉伸膜,流延膜的应用
PLA/PBAT copolymerization & starch compounding technology development
聚乳酸/PBAT的共聚及淀粉共混技术的开发(解决目前膜应用及价格问题)
Application of PLA mold and extrusion foaming: instant noodle bowls (vs EPS)
聚乳酸挤出模压及发泡发泡的应用如方便面碗 (取代保丽龙)
Gas Barrier of PLA bottles: co-extrusion or carbon-coating
聚乳酸瓶的阻气性:多层共挤 或 碳涂层
Application of direct-spinning PLA fiber and non-woven fabrics: diapers, etc.
熔体直纺聚乳酸纤维及无纺布制品的应用如一次性尿布等
17. China’s PLA industry: from Phase 1 into Phase 2
Limited PLA producers: Mainly Natureworks (import), Hisun 5 KT plant, etc.
聚乳酸切片生产厂:NatureWorks (进口), 国内有海正等厂
Limited PLA fiber producers: Mainly FENC importing, FIT (XingNeng/XingGao) , BWC, CL
聚乳酸纤维生产厂:远东纺织(进口), 国内以新能新高为主,无纺布:必可成,昌隆
Limited local Government support: on PLA production, not PLA market
中国政府补贴:以聚乳酸生产为主,而非市场应用
Many PLA producers: Hisun, Hengtian-Yangtze, Jiuding, SUPLA, COFCO, Esun, TJL,
多个聚乳酸厂及技术:海正, 恒天长江, 九鼎 ,允友成 ,中粮,易生,同杰良 .
10K scale, supply chain, compounding plants,
万吨级厂,供应链建立,共混厂 ..
China SOE, Government regulation in Jilin and Jiangsu,
央企介入,吉林江苏限塑法规,
Phase 1: Developing PLA polymerization tech and building production plants
Phase 2: Mltiple PLA plants and compounders to develop PLA market
20. Luminy® PLA portfolio: commercially available
August 9, 2018 20
PLA L105 High flow for injection molding
PLA L130 Medium flow for injection molding or fiber spinning
PLA L175 High viscosity for film extrusion, thermoforming or
fiber spinning
PLA LX175 High viscosity, amorphous, transparent for
extrusion/thermoforming
PDLA D070 Nucleating agent for PLA homopolymer resins
PDLA D120 Medium viscosity PDLA homopolymer
Luminy® neat resins are compliant with
the most relevant regulations and
requirements related to bioplastics:
• EU food contact applications (EC No.
1935/2004 and No. 10/2011)
• EN13432 standard for industrial
composting (OK Compost & Seedling)
• Biobased content 100% ( EN16785-1)
• REACH compliant
• Reduced carbon footprint: LCA study
available
• Made from European sugar beet and
Thai sugarcane: these are always
GMO-free crops
7W2030
21. PLA homopolymers
The secret to obtaining high heat PLA
August 9, 2018 21
PLLA and PDLA homopolymers:
• Crystallize fast = improve processing economics
• Improve heat performance
PLA technology from
Total Corbion PLA can
replace PS, PP and
ABS-like materials in
applications where heat
performance is a key
requirement.
22. Total a global leader in fossil energy and
plastics is since years active in and directs
a significant research effort towards PLA.
Total Corbion PLA - the rationale
August 9, 2018 22
Corbion the global leader in Lactic Acid is
invested in a Lactide plant and built
expertise in PLA over the past years.
On March 2nd 2017 Total and Corbion signed an agreement joining forces and forming a
50/50 JV called Total Corbion PLA.
The 75 kt Lactide plant will be part of the JV and a 75 kt/a
PLA production plant will be constructed.
To continue to serve our current Lactide customers, the
Lactide capacity will be increased to 100 kt/a.
Both plants will be operational in H2 2018 and are able to
produce any grade between 90% to 100% optical purity.
23. Position World’s 4th largest oil company World’s largest lactic acid producer
Headquarters Courbevoie, France Amsterdam, the Netherlands
Revenue $ 150 B $ 970 M
Employees 96,000 1,700
Profit $ 6 B $180 M
Main products Oil & Gas, Solar & Bioenergy Food Ingredients, Biochemicals,
Commodity & Specialty Bioplastics, Biomedical
Chemicals
Two parent companies with complementary strengths
August 9, 2018 23
24. Our role in the PLA value chain
8/9/2018 24
Sugar feedstock
LA
production
Lactide &
PLA
production
Compound
production
Conversion
to products
Brandowner Retailer Consumer
Market Pull
• PLA promotion & communication
• Create sustainability awareness
• Work with leading Corps &
(N)GOs
NGOs &
Governme
nt
Partnerships
- Development of PLA supply chain
- Development of markets and
applications
From
2018
Total - Corbion works with - and supports all players along the value chain
Technology Push
• Develop PLA polymerization
• Work with partners on PLA App’s
• Support conversion of PLA
25. • Timeline: Operational in 2H 2018
• Location: Rayong, Thailand
Corbion on track to forward integrate into PLA
2/3/2016 25
What we will build:
• PLA polymerisation: 75 kTpa – est. capex €
65M
• Lactide extension: +25 kTpa – est. capex €
20M
• Add distillation capacity to our existing
crystallization plant to enable production of
standard PLA
• Secure supply to lactide customers
26. • The JV produces and markets PLA (Poly Lactic Acid) resins and lactides
• Total Corbion PLA launched operations 02 March 2017, all regulatory approvals completed
• The JV owns the PLA polymerization plant with a global capacity of 75 kTpa, currently under
construction on the Corbion site in Rayong, Thailand
• Corbion’s existing PLA business and lactide production unit migrated to the JV
• Corbion supplies the lactic acid necessary for the production of PLA and lactide
• Your previous Corbion contact remains your key contact person.
Total Corbion PLA: a 50/50 PLA joint venture
August 9, 2018 26
27. Capacity 75 kTpa
Situation Under construction, next to the world’s
largest lactic acid and lactide plants
Location Rayong, Thailand
Timeline Start of operations 2nd half 2018
Status Groundbreaking ceremony took place
9 November 2016, construction is ongoing
Building a world scale PLA plant
August 9, 2018 27
29. Advantages of Total Corbion’s PLA supply chain
August 9, 2018 29
• Made from renewable raw materials
• Biodegradable/Compostable EN13432
• Recyclable
• Favorable CO2 footprint
• Made from non-GMO raw materials
• High heat performance
• Commercially available
• Offers a unique branding opportunity
30. Key commercial contacts at Total Corbion PLA
August 9, 2018 30
Sales Greater China
K. Jim Jem
jim.jem@total-corbion.com
+31 653 11 24 70
Sales Europe, Middle East & Africa
Hugo Vuurens
hugo.vuurens@total-corbion.com
+31 653 11 24 70
Sales Americas
Derek Atkinson
derek.atkinson@total-corbion.com
+1 201 396 0204
Sales Asia Pacific
Stefan Barot
stefan.barot@total-corbion.com
+31 652 411 835
Global Marketing
François de Bie
francois.debie@total-corbion.com
+31 6 11716895
31. www.total-corbion.com
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herein or as to their suitability for any purpose, condition or application. None of the data, information or opinions
herein may be relied upon for any purpose or reason. Total Corbion PLA disclaims any liability, damages, losses
or other consequences suffered or incurred in connection with the use of the data, information or opinions
contained herein. In addition, nothing contained herein shall be construed as a recommendation to use any
products in conflict with existing patents covering any material or its use. TOTAL is a trademark owned and
registered by Total S.A., used under license by Total Corbion PLA BV. CORBION is a trademark owned and
registered by CORBION N.V. used under license by Total Corbion PLA BV.