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BIO-BASED PRODUCTS AND BIO-COMPOSITES

SEMINAR At: Michigan State University

Sponsored by

Composite Materials & Structures Center (CMSC) MSU College of Engineering

December 18, 2001

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BIO-BASED PRODUCTS AND BIO-COMPOSITES SYMPOSIUM

organized by:

COMPOSITE MATERIALS AND STRUCTURES CENTER Michigan State University, East Lansing, MI 48824

December 18, 2001

A one-day symposium on Bio-based Product and Bio-Composites Research was held December 18, 2001 at the Composite Materials and Structure Center (CMSC) of Michigan State University.

Sixteen representatives from twelve firms attended the symposium. One purpose for the meeting was to acquaint industrial sponsors and partners with the ongoing composite materials research program within the CMSC. Another was to encourage feedback from industry partners regarding critical problems and research issues within the bio-based materials arena.

MSU faculty researchers, including Dr. Lawrence T. Drzal, Dr. Bruce Dale, Dr. Garry Lemme, Dr. Amar Mohanty and Dr. Ramani Narayan addressed the attendees.

Generally, faculty members highlighted the state of bio-based materials, in terms of current markets, potential markets and research issues. Specifically, they discussed the thrust of bio-based product research activities within the Center. A free-form discussion followed, providing participants to identify specific issues, potential applications, barriers to success and potential research projects within the bio-based products and bio-composite materials arena.

Later, 10 graduate and undergraduate researchers, working on various bio-based products and bio-composites research under the supervision of Prof. Drzal, presented 11 posters relating to their recent research activities.

Another symposium, open to the general public, is planned for spring of 2002.

CMSC Director Lawrence Drzal (standing) fields a question from a participant

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LIST OF PARTICIPANTS

INDUSTRIAL PARTICIPANTS KEMLITE:

Ronald A Robarts, Jr. R&D Manager Kemlite Company Inc. PO Box 2429 Joliet IL 60434 RRobarts@kemlite.com

Michael T. Miller Process Engineering Manager Kemlite Company Inc. PO Box 2429 Joliet IL 60434

Kemlite makes Glass Fiber - Unsaturated Polyester composites for Housing/Construction Applications. MSU is collaborating with KEMLITE to develop natural fiber - polyester composites to replace/supplement glass fiber-polyester composites for housing panel applications.

EASTMAN CHEMICAL COMPANY: Dr. Brian D. Seiler Development Associate B-50, CE Process Technology Group Leader, Cellulose Ester Development Eastman Chemical Company PO Box 511 Kingsport TN 37662-5150 bseiler@eastman.com

MSU faculty & staff and industrial participants

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Eastman Chemical Company is a leading international chemical company with headquarters in Kingsport, Tennessee that produces more than 400 chemicals, fibers and plastics. Their interaction with CMSC is in the area of Cellulosic Plastics, bio-composites and biodegradable green nanocomposites. MSU is collaborating with Eastman Chemical Co. to develop sustainable bio-composites for automotive applications. FLAXCRAFT: Hugh S. McKee V.P. Sales & Marketing Flaxcraft 210 Knickerbocker Rd. Cresskill NJ 07626 hmckee@flaxcraft.com Flaxcraft Inc., based in New Jersey, does natural fiber processing. MSU is collaborating with Flaxcraft in various research projects dealing with the development of natural fiber composites for Automotive and Housing Industries applications. HEMPLINE: Geofrey G. Kime President Hempline Inc. 11157 Longwoods Rd RR 1, Delaware, Ontario Canada NOL 1EO gkime@hempline.com

A discussion during the seminar

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Hempline, based in Canada, deals exclusively with the extraction, retting, and processing of Hemp fiber. Hempline is supporting MSU in providing various grades of hemp fiber and interacting on development of hemp fiber based biocomposites. JOHNSON CONTROLS INC.: Brian L. Erickson (Primary Contact) Manager, Advanced Materials and Process Engineering Johnson Controls, Inc. 5757 N. Green Bay Avenue P.O. Box 591 Milwaukee, WI 53201 Brian.L.Erickson@jci.com

David J Phillips Director, Advanced Materials and Process Engineering Johnson Controls, Inc. 5757 N. Green Bay Avenue P.O. Box 591 Milwaukee, WI 53201

Rob Springer Advanced Process Development Engineer Johnson Controls, Inc. 5757 N. Green Bay Avenue P.O. Box 591 Milwaukee, WI 53201

Johnson Controls Inc. is a major designer, developer and builder of complex systems, including automotive interiors. Johnson Controls has already taken the steps in commercializing natural fiber based composites in car door panels. Their area of interest within the CMSC is in designing and developing more eco-friendly natural fiber - thermoplastic composites for automotive applications. CLARK-CUTLER-MCDERMOTT CO.: Mr. Nick Pastorelli Manager Clark-Cutler-McDermott Co. Michigan jmcdermott@ccmcdermott-ma.com Clark-Cutler-McDermott Co. is a major supplier of non-woven natural fiber mats to automotive industries in North America. They have been in the non-woven business since 1911 and are a major supplier to the auto industry. CCM is interested with CMSCs work on development of natural fiber composites for automotive applications CORN MARKETING PROGRAM OF MICHIGAN: Jody E. Pollok Executive Director Corn Marketing Program of Michigan 504 S Creyts Rd #A Lansing MI 48917-8230 corninfo@micorn.org

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Corn Marketing Program of Michigan explores new markets and applications for the states corn industry. Perhaps the most compelling of those new markets is within the biomaterials sector. The Corn Marketing Program is associated in one of the research projects of CMSC targeted to find value-added composite materials from corn-stalk fibers and bio-based resins. SMITH, ADAMS & ASSOCIATES LLC: Thomas M. Smith Smith, Adams & Associates LLC PO Box 4001 East Lansing MI 48823 517-202-3019

R.B. Adams Smith, Adams & Associates LLC PO Box 4001 East Lansing MI 48823 517-202-3019

Smith, Adams & Associates LLC, is a Michigan company specializing in the commercialization of university technology. Its focus is product development for industry utilizing bio-sustainable technologies. R.B. Adams is an MSU, 1974 MBA graduate and former president of a Detroit-area automotive sales and engineering firm. Thomas M. Smith is an MSU Adjunct Professor, 1979 B.S. 1985 M.S., Crop and Soil Science, Michigan State University. OVERBY FARM: Robert B. Adams Overby Farm PO Box 101 Bloomfield Twp. MI 49653 adamgarden@mediaone.net Overby Farm is a Michigan-based nursery specializing in production of native grasses and landscape ornamental grasses. Overby Farms interest with CMSC researchers is to find new applications of Michigan Grass-based Bio-Composites to develop economy of Michigan State through value-added applications. EUROTECH DESIGN, INC. & UNIFIED SYSTEMS Kevin T. Kerrigan President & CEO 26532 Groesbeck Highway Warren, MI 48089 Tel.: (248) 933-4111 e-mail: englishace@msn.com MICHIGAN PEAT: Matthew S. Drzal Manager, Grower Products & Tech Services Michigan Peat 302 Kerry Street Eaton Rapids MI 48827

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mdrzal@michiganpeat.com Michigan Peat harvests peat for use by gardeners and growers in North America.. Michigan Peat is partnering with CMSC to develop affordable and sustainable biodegradable flowerpots. GRASSROOTS: Tom Smith, President GRASS ROOTS PO Box 4001 East Lansing MI 48826 GRASSROOTS is a landscape design, construction and management firm specializing in Michigan native plants and native habitats CERTAIN TEED CORPORATION: David J. (Dave) Stucky Materials Engineer CertainTeed Corporation P.O. Box 860 750 East Swedesford Road Valley Forge, PA 19482 Dave.J.Stucky@saint-gobain.com

Paul Ruede Senior Polymer Chemist CertainTeed Corporation P.O. Box 860 750 East Swedesford Road Valley Forge, PA 19482 Paul.Ruede@saint-gobain.com

CertainTeed Corporation is a manufacturer of exterior building materials for new construction and home remodeling needs. Products include insulation, vinyl windows, vinyl siding, roofing, PVC pipe, fencing, decking, railing, attic ventilation and foundation systems LENOX POLYMERS LTD.: Mr. Karl Kurple Corporate Secretary Lenox Polymers Ltd. 3735 Dove Road Port Huron, MI 48060 e-mail: info@lenoxpoly.com Lenox Polymers works with Lignin based thermoplastic and thermoset resins. Lenox polymer and CMSU intend to develop in-depth collaboration to develop new ligninbased bio-composites of industrial attractions.

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MSU FACULTY Dr. Lawrence T. Drzal University Distinguished Professor of Chemical Engineering and Materials Science Director, Composite Materials & Structures Center College of Engineering Michigan State University 2100 Engineering Bldg East Lansing MI 48824-1226 drzal@egr.msu.edu Dr. Lawrence Drzal is a leading expert in the field of powder processing of composite materials, fiber adhesion and surface treatments of petroleum-based and bio-based composites and their constituents. He has directed the Composite Materials & Structures Center at Michigan State University since 1985. The Center conducts leading-edge research and testing in the area of composites processing and design. Bio-based products and biocomposite materials currently represent the fastest growing thrust within the CMSC. Along with Dr. Martin Hawley, Dr. Drzal also co-directed an NSF-sponsored State/Industry/University Cooperative Research Center from 1991-2001. Dr. Bruce Dale Professor of Chemical Engineering College of Engineering Michigan State University 2527 Engineering Bldg East Lansing MI 48824-1226 bdale@egr.msu.edu Dr. Bruce Dale co-authored a major study published in March 2000 by the National Research Council entitled Biobased Industrial Products: Priorities for Research and Commercialization. The study concludes that biomaterials will make vast inroads within the $300 billion chemicals/materials market through 1) exploiting the cost and supply advantages biomaterials have over petroleum, and 2) development of cost-effectives processing methods to make crops more viable constituents for durable goods. Dr. Dale asserts that biological science can become the basis for producing a wide variety of industrial products from renewable plant resources. Dr. Amar K. Mohanty Visiting Associate Professor Composite Materials & Structures Center Michigan State University 2100 Engineering Bldg East Lansing MI 48824-1226 Tel.: (517) 353 5466 e-mail: mohantya@egr.msu.edu

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Dr. Amar K. Mohanty is a new addition to Michigan State University. Dr. Mohanty has extensive research experiences in the field of biopolymers, bio-composites and bio-based product-development research. Dr. Mohanty has more than 110 publications to his credit. He was the recipient of the prestigious Alexander von Humboldt Fellowship (Germany). During his two years at MSU, he has been responsible for conducting and overseeing bio-based product developments research within the CMSC. Under grants from industry and government agencies, Dr. Mohanty is currently directing five multi-year research and testing projects in the area of biopolymers and bio-composites for applications in housing and automotive industries. His main research area concentrates on Green bio-based product development research to find new materials to replace or supplement existing petroleum-based polymeric materials. Dr. Manjusri Misra Research Specialist Composite Materials & Structures Center Michigan State University 2100 Engineering Bldg East Lansing MI 48824-1226 misraman@egr.msu.edu Dr. Manjusri Misra joined Michigan State University, in January 2000. She directs and manages research projects on bio-based product developments. . She also trains undergraduate and graduate students in various aspects of bio-based product research of CMSC. She is a well-experienced researcher in the field of bio-polymers and bio-composites with more than 85 publications to her credit. She conducted research projects in India, where she was a faculty

Amar Mohanty of MSU and Brian Erickson of Johnson Controls

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member for 11 years. Dr. Misra was a visiting scientist at Iowa State University, Technical University of Berlin and Max-Planck Institute, Berlin, Germany. Dr. Ramani Narayan Professor of Chemical Engineering College of Engineering Michigan State University 2527 Engineering Bldg. East Lansing MI 48824-1226 e-mail: narayan@msu.edu Dr. Ramani Narayans research deals with polymeric materials from renewable resource, biodegradable polymer systems, engineering and design of natural-synthetic polymer graft and block copolymers, polymer blends, and studies in reactive extrusion processing.

Dr. Gary Lemme Associate Director, Michigan Ag Experiment Station 109 Agriculture Hall Michigan State University East Lansing MI 48824 lemme@msu.edu In addition to directing the Michigan Agricultural Experiment Station at MSU, Dr. Gary Lemme is involved with Project GREEEN ---a cooperative effort by plant-based commodities and businesses, with Michigan State University Extension and several state agencies. Project GREEEN is a rapid, integrated effort from Michigan State University to develop and implement improved management programs that increase profitability while reducing undesirable environmental impacts and improving food safety.

Dr. Lemme discusses Project GREEEN

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Dr. Martin Hawley Acting Chair, Department of Chemical Engineering & Material Science College of Engineering Michigan State University 2527 Engineering Bldg East Lansing MI 48824-1226 e-mail: hawley@egr.msu.edu Prior to his appointment as acting chair, Dr. Martin Hawley co-directed a National Science Foundation-sponsored center for polymer composites research. Dedicated to resolving processing issues within the burgeoning field of polymer composites, the S/IUCRC featured privately and publicly funded research in six core areas, including novel processing, liquid molding and recyclable/renewable materials. His expertise is in microwave processing of polymer composite materials.

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MSU STUDENTS: POSTER PRESENTATIONS

1. PLASTICIZED CELLULOSE ACETATE AND BIODEGRADABLE GREEN NANOCOMPOSITES R. Arief Wibowo(Advisors: L. T. Drzal, A.K. Mohanty, R. Schalek, M. Misra. 2. ENVIRONMENTALLY-FRIENDLY GREEN BIO-COMPOSITES FROM NATURAL FIBER AND CELLULOSIC PLASTIC Arief Wibowo and David Hokens(Advisors: M. Misra, A. K. Mohanty, Lawrence T. Drzal 3. BIO-COMPOSITES FROM ENGINEERED NATURAL FIBERS AND POWDER POLYPROPYLENE: EVALUATION OF FIBER-MATRIX ADHESION AND PHYSICO-MECHANICAL PROPERTIESDaniel Liong (Advisors: L. T. Drzal, A. K. Mohanty, M. Misra)

4. CORN STALK FIBER FOR BIO-COMPOSITES: EXPLOSION AND ALKALI TREATMENT OF CORN FIBERS - A MORPHOLOGY STUDY Ken Ferguson (Advisors: L. T. Drzal, M. Misra, A. K. Mohanty) 5. DEVELOPMENT OF BIO-BASED POLYURETHANES: CURING STUDY OF SOY POLYOL ISOCYANATEKen Ferguson (Advisors: L. T. Drzal, M. Misra, A. K. Mohanty).

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6. MICHIGAN GRASS REINFORCED POLYPROPYLENE BIO-COMPOSITES & HEMP-TPO BASED BIO-COMPOSITESStephanie Teich-McGoldrick, Benjamin Schreiber, William (BJ) Foster(Advisors: L. T. Drzal, M. Misra, A. K. Mohanty)

7. BIOCOMPOSTIES: SOY PLASTICS AND NATURAL FIBERDavid D. Hokens(Advisors: L. T. Drzal, M. Misra, A. K. Mohanty). 8. NATURAL FIBER REINFORCED POLYPROPYLENE COMPOSITES AND ITS INTERFACIAL ADHESION Guangda Shi (Advisor: L. T. Drzal) 9. NATURAL FIBER REINFORCED BIODEGRADABLE PLASTIC COMPOSITES: ECO-FRIENDLY BIO-COMPOSITES FROM KENAF & POLYESTER AMIDE BIOPLASTIC David Hokens (Advisors: L. T. Drzal, M. Misra, A. K. Mohanty)

10. POLYLACTIDE-BASED PLASTICS AND BIOCOMPOSITES

(A. K. Mohanty, L. T. Drzal, B. Rook, Manju Misra). 11. ALIGNED HENEQUEN FIBER REINFORCED BIO-BASED EPOXY RESIN COMPOSITES (L. Belcher, M. Misra, A. K. Mohanty, L. T. Drzal)

December 18, 2001LIST OF PARTICIPANTS

Corn Marketing Program of Michigan explores new markets and applications for the states corn industry. Perhaps the most compelling of those new markets is within the biomaterials sector. The Corn Marketing Program is associated in one of the research pSMITH, ADAMS & ASSOCIATES LLC:

MICHIGAN PEAT:Michigan Peat harvests peat for use by gardeners and growers in North America.. Michigan Peat is partnering with CMSC to develop affordable and sustainable biodegradable flowerpots.Dr. Lawrence T. DrzalDr. Manjusri Misra

Dr. Ramani NarayanDr. Gary Lemme

Dr. Martin Hawley