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1

Ingeo and Circular Economy

NatureWorks LLC

Ian Toh

Commercial Director, Asia Pacific

September 15, 2016

2© 2016 NatureWorks

Circular Economy

THE NEW PLASTICS ECONOMY

Rethinking the Future of Plastics

The Foundation aims:

• “to bring together for the first time

a comprehensive global

perspective of the broader plastic

packaging economy,

• “to present a vision and propose

a roadmap as well as a vehicle

for progressing this roadmap

• “to provide a much needed global

focal point to carry this agenda

forward…

“looking for systemic change to

overcome stalemates in today’s

plastics economy in order to move

to a more circular model…”

Plastics & Plastics Packaging+


• Production expected to double

again in 20 years, and quadruple

by 2050

• Plastic Packaging is single

largest application (26% of total

today)

Plastics Production Increased Twenty-Fold Over

The Last 50 Years


“Plastic Packaging is an iconic linear application…”

“95% of plastic packaging material

value (US$ 80-120 bn) is lost annually

after a short first use …


Ambitions of the New Plastics Economy: Capturing the opportunity


Sourcing

Manufacture

Use

After Use

Definition of Sustainable

Packaging


How the Plastics and Plastics Packaging Industry is

rethinking itself from a Circular Economy Perspective

0

20

40

60

80

100

plastic characteristics and packaging functionality

After

Use

Sourcing

Use

Manuf-

acture

How

plastic

packaging

is recovered

How the

plastic

is made

What the plastic is made from…

Ideal Material

Current, Incumbent Packaging

Plastic

Future…

Where do

Bioplastics

Fit ?


Let’s talk about SOURCING…

After

Use

Sourcing

Use

Manuf-

acture


Decoupling from Fossil Feedstocks: “revolutionary”

and “evolutionary change is needed


Resins

Additives

(Modifiers)

Adhesives

Coatings

Printing Toners

Specialty

Lactates

Surfactants

Intermediates

CO2 CO2

CO2 CO2CO2

Plant

Sugars

Plants Manufacture

1st Generation

Ag feedstocks

are a short term

Bridging Tool

CO2 + H2O

At NatureWorks…We turn greenhouse gas feedstocks into

performance materials


NatureWorks is committed to feedstock

diversification:

And next

CO2 to lactic acid

technology?

CH4 to lactic acid

technology

GENERATION NEXT

Developing

Lignocellulosics: Sugars

from bagasse, wood chips,

switch grass or straw.

GENERATION II

Investment in innovation and R&D collaboration to grow the Ingeo feedstock portfolio

GENERATION I

Today

Dextrose & Sucrose from

cassava or corn starch,

sugar cane or beet

“Bridging Crops”

Performance materials made by transforming whatever are the right, abundant, local resources


NatureWorks “Moon Shot” innovation in feedstock

diversification

And next

CO2 to lactic acid

technology?

CH4 to lactic acid

technology

GENERATION NEXT

Milestone

June 2013: NatureWorks & Calysta partnership

June 2014: Lab scale lactic acid production

demonstrated

October 2014: $2.5MM DOE funding

January 2016: 1 MM investment in new MN based

methane fermentation lab, supported by state funding


Handbook of Hydrocarbon and Lipid Microbiology (2010) Chen, Y & Murrell, J.C.

Methanotrophs:

• Bacteria that metabolize methane as their sole source of carbon and energy

How can this be made possible:

Methanotrophs in Nature


By Brian Handwerk, for National Geographic News, January 6, 2011

Gulf Oil Spill Surprise: Methane Almost GoneNatural gas ingredient gobbled up by bacterial blooms, study finds.

“After months of speculation about what will happen to the Gulf oil spill, it turns out Mother Nature has rolled up her sleeves and dispatched with a lot of the gas released along with it—in just four months”


1

2

3

It starts with methane

which is supplied directly

to specialized bacteria

called methanotrophs

Methanotrophs convert

methane into lactic acid

through fermentation

NatureWorks converts

lactic acid monomers into

a family of Ingeo plastics

and green chemicals

From Methane to Ingeo


Sustainable Packaging in the Circular Economy

means addressing feedstock sustainability too (not

just renewability)

BIOBASED CARBON CERTIFICATION

Verifies that 100% of carbon in Ingeo

comes from renewable ag resources via

USDA BioPreferred in the US & Vincotte

in Europe.

ISCC PLUS

3rd party (ISCC) certifies the sustainable

production of renewable raw materials

including chain of custody.

Certification

Renewability Sustainability


Let’s talk about MANUFACTURE…

Sourcing

0

20

40

60

80

100

After

Use

Use

Manufacture

Where do

Bioplastics

Fit ?


“Bio-benign” materials choices for manufacture

THE NEW PLASTICS

ECONOMY

Rethinking the Future of Plastics

Greenpeace’s “Pyramid of Plastics”

http://www.greenpeace.org/usa/wp-content/uploads/legacy/Global/usa/planet3/PDFs/this-vinyl-house.pdf, p. 27

1.PVC

2. PU, PS, ABS, PC

3. PET

4. PE, PP

5. Biobased polymers


Manufacture from Renewably Sourced -

Packaging Plastics Implications…

3.2

2.7

1.9

1.9

2.3

2.2

1.8

1.6

0.6

0 0.5 1 1.5 2 2.5 3 3.5

Polystyrene

PET

HDPE

Polypropylene

Ingeo

kg CO2 (eq) generated /kg material produced

US ProducersAPC - American Plastics Council

http://plastics.americanchemistry.co

m

EU ProducersPlasticsEurope

www.lca.plasticseurope.org

Peer Reviewed

Benchmarking


Long term resource efficiency is critical in a

circular economy context…

1.05

1.25

1.63

1.80

2.13

2.77

3.22

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50

BIO-PBS

INGEO

BIO PA-11

BIO PEF

BIO PP

BIO PET

BIO PE

kg of sugar per kg of polymer

[Comparing Sugar to Polymer Yields]

Polymer Technology

Ingeo Sugar to PLA via lactic and lactides

PA-11 Veg Oil to Ricinoleic Acid

Bio PP Sugar to ethanol to propylene to PP

Bio PET Bio MEG + Bio PTA from sugar

Bio PE Sugar to ethanol to ethylene to PE

Nova paper #8 on bio-based economy 2015-11

Definition, Calculation and Comparison of the “Biomass Utilization

Efficiency (BUE)” of Various Bio-based Chemicals, Polymers and Fuels

Bioplastics Comparison:


SOME EXAMPLES …

Life Cycle Analysis (LCA)

Implications of Manufacture


LCA - Global Indicator Results

41

54

93

0

10

20

30

40

50

60

70

80

90

100

Ingeo PP PET

g C

O2

eq

. / 1 c

up

& l

id

Climate Change


LCA study conducted on Ingeo

Package for Danone by the

Heidelberg based

German LCA institute, IFEU

• Improves packaging

carbon footprint by

25%

• Uses 43% less fossil

resources


Marketing: Communicating at the

Consumer Level

Wal-mart’s ask of NatureWorks: provide a simple POS

message on Ingeo packaged vegetable tray

Option 1: Quantitative,

environmental angle

Option 2: Qualitative,

emotive angle


“Walmart Stores in 2010 has achieved a savings in fossil fuel usage of 25,971 barrels of oil per

year, and a reduction in greenhouse gas emissions equal to eliminating the CO2 emissions

from driving a car 20,885,635 miles”

Corporate Sustainability Reporting


Let’s talk about bioplastics functional material

characteristics in use…

Sourcing

0

20

40

60

80

100

After

Use

Use

Manufacture


Key Properties

Utilizing inherent Ingeo properties in capturing the

opportunity

Opportunities

… EXAMPLES

• Ingeo categorised as G.R.A.S. (Generally Recognised As Safe), no perceived health issues, before formal food contact compliance status

• Excellent barrier resistance to large molecules: food fats/oils, flavorants, scents (flavor and aroma)

• High gloss and clarity, easily tinted or pigmented, excellent printability

Food contact applications and baby products (dishware, toys, etc.)

Applications such as perfumes & cosmetics, tea & coffee, confectionary, etc.

Overwraps in luxury packaging, etc.

• Density at 1.25 advantage over 1.35 of APET/rPET

• 3.4 Gpa tensile modulus advantage over PS (3) and PET (2.7)

• Melt point at 171C vs. PET 255C downgaugingopportunities.

More material per kg, material savings

10% – 20% down-gauging opportunity vs. PS and PET, cost savings

Able to process with lesser energy, energy savings


North American Retail Example: Sam’s Club

reduced resin use with Ingeo compared to r-PET

When made in

rPET

1) 55 grams

2) 16 mil

Mastronardi tomato clamshell

When made in

IngeoTM

1) 44 grams

2) 14 mil

20% Actual Weight Reduction due to Ingeo Lightness & Stiffness


Dairy Packaging Example

• Carbon savings• 75% reduction in CO2 emissions

• Equivalent to 1,320 MT CO2/year savings

• Ingeo out performs polystyrene• Stronger/less breakage

• Better lid adherence

• Lower temperature filling (less energy use)

• Maintained line speed and shelf life

• Addresses consumer concerns• Well received by key opinion leaders

• Reduction in human toxicity

• Did NOT increase our retail price


Applications in Flexible Packaging

Shrink Sleeves/Labels/tamper bands

Ingeo™ film shrink

at low temperature

Pouches

In combination with paper and/or cellophane provides

excellent seal ability with seal strength above 20 N/15

mm. Pouches for powder and chunks.

Can be AIOx treated for longer shelf life products

End fold wrap and twist

Folds tight around carton boxes, no wrinkles.

Folded film is closed by heated sealing device.


Recent Innovation in

Ingeo Flexible Packaging …


collaboration with

Multi-Functional Barrier Performance in Cost Effective Ingeo

Multilayer Structures

0.1 1.0 10 100 1,000

Increasing Barrier to Water Vapor (Water Vapor Transmission Rate (g/m2day), 38 C, 90% RH)

0.1

1.0

10

100

1,000

10,000

PLA

PET

metallizedPVdC

coated

BOPP

BOPP

BOPP

BOPP

EVOH

coated

PET

metallized

Metalvuoto’s Ingeo film

Inc

rea

se

d B

arr

ier

to O

xy

ge

n

(Oxyg

en T

ransm

issio

n R

ate

(cm

3/m

2day),

23

C, 0%

RH

)


PAPERAUMINIUM, or Metalized PP/PET

LDPE

LDPE

PAPERPAPER

ALUMINIUM

PAPER

fossil based

Packaging Simplification


collaboration with

Weight & Cost Reduction

• Ultra-Light Ingeo film as high performance sealant web

High performance sealant webs

Light on the environment, light on your pocket

9 micron vs typical 50-70 micron LLDPE sealant

Cost savings vs LLDPE sealant layers

PAPER or PET

ALUMINIUM or MET BOPP

LDPE 50-70 my

fossil based

PAPER or PET

ALUMINIUM or MET BOPP

INGEO 9 my


PLA

INJECTION

MOLDING

GRADES

ABS

Medium Impact

(884-41-1)

High

Impact

(884-41-2)

INGEO PROFILE

EXTRUSION

FORMULATION

High

Modulus

(821-56-2)

ASTM

Method

Bio-Content (%) 100 0 89 88 76 6866

Specific Gravity

(g/cm3)1.24 1.04 1.22 1.21 1.24 D792

Specular Gloss

(60°/20° geometry)125 / 112 89 / 68 72 / 48 73 / 47 77 / 56 D792

Tensile Modulus,

kpsi (MPa)494 (3,400) 336 (2,316) 414 (2,850) 414 (2,850) 454 (3,125) D638

Tensile Yield

Strength, psi (MPa)9,300 (64) 5,600 (39) 5,400 (37) 5,500 (38) 4,940 (33) D638

Tensile Elongation at

Break (%)3.6 5.5 32 21 38 D638

Notched Izod

Impact, ft-lb/in (J/m)0.4 (21) 5.19 (277) 2.6 (139) 8.3 (443) 6.6 (352) D256

Flexural Strength,

kpsi (MPa)16.4 (113) 9.9 (68) 9.5 (66) 9.4 (65) 8.6 (59) D790

Flexural Modulus,

kpsi (MPa)528 (3,640) 345 (2,381) 455 (3,140) 448 (3,100) 513 (3,550) D790

Heat Distortion

Temp @ 66 psi (°C)55 87 92 77 85 D648

INGEO INJECTION MOLDING

FORMULATION

Ingeo Durable SolutionsNew crystalline Ingeo formulations deliver a practical, bio-based alternative to ABS*

* Properties

benchmarked with

Terluran GP-35 ABS


In addition to high bio-content, equivalent HDT and impact strength, Ingeo formulations

offer superior environmental stress-crack resistance (ESCR) to some common agents

Ingeo formulation’s advantage over ABS


CHEMICAL INGEO ABS

Hand Cream Pass Pass

Sunblock Pass Pass

Insect Repellent Pass Fail

Acetone (nail polish) Pass Fail

Isopropyl Alcohol (hand sanitizer) Pass Pass

*Testing performed by Nypro, A Jabil Company

More ESCR test results


Food Serviceware

Nonwovens / Fibers

Rigids Films & Cards

Durables Lactides New Biz

Additives

Adhesives

Coatings

Printing Toner

Lactates

Surfactants

3D

Building &

Construction

NatureWorks optimized grades towards specific

applications


Let’s talk about bioplastics after-use

Sourcing

80

100

After

Use

Use

ManufactureGetting

Circular


Mechanical

Recycle Feedstock

Recovery Compost Anaerobic

Digestion Energy

Recovery

Landfill X X

Incumbent

Plastics Ingeo

Recovery Options


Organics Diversion from Landfill

• US – “the 28% Opportunity”

• Where Composting

infrastructure exists,

Compostable plastics like

Ingeo provide a tool for

organics diversion from

landfill

Food Scraps14.6%

Other3.3%

Paper27.0%

Glass4.5%

Metals

9.1%

Plastics12.8%

Rubber, leather & textiles

7.6%

Wood6.2%

Yard trimmings

13.5%

US Example: Total US MSW

Generation (by material), 2013

Source: Advancing Sustainable Materials Management:

Facts & Figures 2013, USEPA, June, 2015


Recycling

• Routinely recycled at post industrial level

• Initial collection programs beginning at

consumer level

Collecting Converting End-Markets

• PLA bale

specification &

pricing set

• Flake specifications &

process development

underway

• r-PLA product

development

underway

“to avoid being part of the 86%”


Rethinking Plastics Packaging with

After

Use

Sourcing

Use

Manufacture


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www.natureworksllc.com

Naturally advanced materials made from

locally abundant and sustainable natural

resources

THANK

YOU

ingeo and circular economy natureworks llc · ingeo and circular economy natureworks llc ian toh...

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