Considerations for Manufacturing Bio-Based Plastic Products

One engine that drives the United States’ economic growth is an ever-increasing demand for manufactured products, both at home and abroad. This increase has created a major concern for the environment in terms of disposing used goods and ensuring that these products are safe. As environmental concerns grow, however, renewable resources are gaining increasing attention, especially as industrial ecology and product biodegradability gain importance. Added to this, biological materials are increasingly being utilized to replace traditional materials in manufacturing. To aid both educators as well as researchers, this paper examines several considerations that are essential for manufacturing plastic products that contain biomaterials. These include the selection of materials, the selection of manufacturing processes, manufacturing costs, and the quality of final products. Additionally, several standard methods that are commonly used for the determination of mechanical and physical properties are compiled; thus this paper should be a useful resource for both educators and researchers. The trends discussed here and their implications are critical for those involved in manufacturing, because contrary to conventional wisdom, simultaneously meeting the material production needs of our society, as well as that of the environment are not mutually-exclusive.     

Properties of Distillers Grains Composites: A Preliminary Investigation

Interest in renewable biofuel sources has intensified in recent years, leading to greatly increased production of ethanol and its primary coproduct, Distillers Dried Grain with Solubles (DDGS). Consequently, the development of new outlets for DDGS has become crucial to maintaining the economic viability of the industry. In light of these developments, this preliminary study aimed to determine the suitability of DDGS for use as a biofiller in low-cost composites that could be produced by rapid prototyping applications. The effects of DDGS content, particle size, curing temperature, and compression on resulting properties, such as flexural strength, modulus of elasticity, water activity, and color were evaluated for two adhesive bases. The composites formed with phenolic resin glue were found to be greatly superior to glue in terms of mechanical strength and durability: resin-based composites had maximum fiber stresses of 150–380 kPa, while glue composites had values between 6 kPa and 35 kPa; additionally, glue composites experienced relatively rapid microbial growth. In the resin composites, both decreased particle size and increased compression resulted in increased mechanical strength, while a moderate DDGS content was found to increase flexural strength but decrease Young’s modulus. These results indicate that DDGS has the potential to be used in resin glue-based composites to both improve flexural strength and improve potential biodegradability.     

Biopolymers in the Existing Postconsumer Plastics Recycling Stream

The existing plastic bottle reclaiming industry has working technology, satisfied customers, raw material, and investors. Adding new materials to the current mix requires satisfying all four needs for those materials. Rigid plastic container recycling focuses on high-density polyethylene (HDPE) and polyethylene terephthalate (PET) bottles, the overwhelming percentage of bottles sold in North America. Bottles of other resins, including polyvinyl chloride (PVC), polypropylene and biopolymers, lack critical mass necessary for independent reclamation. To be mechanically recycled, biopolymers must be either completely fungible with existing recycled resins or be available in sufficient quantity to achieve the needed critical mass. So far, biopolymer volume projections are not encouraging. Biopolymers, like all minor bottle resins, must pay their own way in sorting and processing without subsidy from PET and HDPE recycling. Based on limited data, some biopolymers may have little effect on recycled HDPE performance, but will represent a yields loss and added economic burden at some level of occurrence. Biopolymers have not been shown to be compatible with PET and likely will represent performance problems and economic burdens at even low levels of occurrence. Applications for biopolymers should be carefully selected so as to not interfere with currently recycled materials unless critical mass can be achieved quickly.

Study of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV)/Bamboo Pulp Fiber Composites: Effects of Nucleation Agent and Compatibilizer

In this study, poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV)/bamboo pulp fiber (BPF) composites were prepared by melt compounding and injection molding. The crystallization ability, tensile strength and modulus, flexural strength and modulus, and impact strength were found substantially increased by the addition of BPF. Tensile and flexural elongations were also moderately increased at low fiber contents (<20%). BPF demonstrated not only higher strength and modulus, but also higher failure strain than the PHBV8 matrix. Boron nitride (BN) was also investigated as a nucleation agent for PHBV8 and maleic anhydride grafted PHBV8 (MA-PHBV8) as a compatibilizer for the composite system. BN was found to increase the overall properties of the neat polymer and the composites due to refined crystalline structures. MA-PHBV8 improved polymer/fiber interactions and therefore resulted in increased strength and modulus. However, the toughness of the composites was substantially reduced due to the hindrance to fiber pullout, a major energy dissipation source during the composite deformation.     

Compression Molding of Phenolic Resin and Corn-based DDGS Blends

With the rapid growth in the ethanol fuel industry in recent years, considerable research is being devoted to optimizing the use of processing coproducts, such as distillers dried grains with solubles (DDGS), in livestock diets. Because these residues contain high fiber levels, they may be amendable to incorporation into bio-based composites. Thus, the goal of this study was to demonstrate the viability of using corn-based DDGS as a biofiller with phenolic resin, in order to produce a novel biomaterial. DDGS was blended with phenolic resin at 0, 10, 25, 50, 75, and 90%, by weight, and then compression molded at 51 MPa (3.7 tons/in²) and 174 °C (345°F). Molded specimens were then tested for tensile strength. Tensile yield strengths ranged from 32 MPa (4,700 psi) to 7.6 MPa (1,100 psi), while the engineering strain ranged from 0.6% to 1.25%. Results indicate that DDGS concentrations between 25% and 50% retained sufficient mechanical strength and thus represent reasonable inclusion values. Additionally, data were similar to those from other studies that have investigated biofillers. Follow-up studies should quantify the effects of altering molding parameters, including molding pressure, temperature, and time, as well as pretreatment of the DDGS. Additionally, strength of the DDGS composites should be optimized through the use of coupling agents or other additives. Mention of a trade name, proprietary product, or specific equipment does not constitute a guarantee or warranty by the United States Department of Agriculture and does not imply approval of a product to the exclusion of others that may be suitable.