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Corey HauverMaterials Engineer

Combat Feeding Directorate

Update on Sustainable Packaging Research and Development Efforts

In the Combat Feeding Directorate

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United Soybean Board Check-Off Program

• Research and development program for soy-based products

• Soybean check-off program which funds research on new soybean applications from soybean sales

• 3.5 Billion bushels of U.S. grown soybeans in 2010 which accounts for 22.6 billions pounds of soybeans per year farmed on 75 million acres of land

• Examples of products developed through this Check-Off program include all-purpose lubricants, soy biodiesel, adhesives, carpet backings, inks, paint strippers, waxes, and industrial plastics.

• NSRDEC project listed under the Fibers and Thermoplastics technical advisory panel (TAP)

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Project Applications for the Military

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Why Military Packaging?

Executive Order 13514 – President Barack ObamaFederal Leadership in Environmental, Energy, and Economic Performance

Section 2(H) – Promote Sustainable Acquisition through Bio-based Materials

2008 Farm Bill“Increase Federal procurement of bio-based products to promote rural economic

development, create new jobs, and provide new markets for farm commodities. Bio-based and sustainable products help to increase our energy security and

independence”

February 2012 Presidential Memorandum - Driving Innovation and Creating Jobs in Rural America through Bio-based and Sustainable Product Procurement

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Materials

Bio-Solids Waste Stream

• Byproduct of food grade soy fiber from 100% soybean hulls

• Approximately 80% moisture as collected from the process

• Contains Nitrogen, Sulfur, Sodium, Magnesium, Calcium, Potassium,

Phosphorous

Defatted Soy Flour 7B

• 53% Protein• Supplied at approximately 9%

moisture• Milled to approximately 5-10

microns prior to drying and compounding

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Previous Tensile Property Problems

Control LLDPE

10% Flour 20% Flour 10% Biosolids

20% Biosolids

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14.5

15

15.5

16

16.5

17

17.5

18

18.5

Te

ns

ile

Str

es

s a

t Y

ield

(M

Pa

)

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Compatibilizer Development for Improved Mechanical Strength

Biosolids waste stream and soy flour compounded into linear low density polyethylene with various percentages of compatibilizer

Compatibilizer Investigated at Loadings of 1-5% by weight- Ethylene Vinyl Alcohol

- Maleic Anhydride Grafted Polyolefins7

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Compatibilizer Efficiency

Control LLDPE

LLDPE-20%

Biosolids

1% 2% 3% 4% 5%13.5

14

14.5

15

15.5

16

16.5

17

17.5

18

18.5

Te

nsi

le S

tre

ss a

t Y

ield

(M

pa

)

Increase in tensile strength (tensile stress at yield) minimizes after 3% by weight loading in the final compounded formulation

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Effect of Maleic Anhydride Compatibilizer

Control LLDPE 10% Flour 20% Flour 10% Biosolids 20% Biosolids14

14.5

15

15.5

16

16.5

17

17.5

18

18.5 0% Compatibilizer

3% Compatibilizer

Te

ns

ile

Str

es

s a

t Y

ield

(M

Pa

)

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Milling and Drying

Particle Size Analysis Scan of Milled Soy Flour

Mean Particle Size: 5.7 micronsDv100: 19 microns

Wyssmont Company Turbo Dryer

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Compounding

Linear Low-Density Polyethylene pellets containing 20% by weight soy flour and 3% compatibilizer without vacuum assist (left) and with vacuum assist (right)

Pre-Compounding Soy Moisture Content: 0.81%Maximum Compounding Melt Temperature Recorded: 161°C

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Multilayer Film Design

SKIN

SKIN

CORE

Lower viscosity polymers migrate to the area of higher stress (die wall), so in most cases, the lower viscosity material should be used as skins

Materials Selected

Skin Layers: LLDPE SLH118 (MFI: 2.8)*Core Layers: LLDPE SLL218 (MFI: 1.0)

* Allowed us to process cast film at lower temperatures without surface instability due to contact with die wall

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Multilayer Co-Extrusion Process Sample Design

5% Total Soy Content 10% Total Soy Content

15% Total Soy Content 20% Total Soy Content

Denotes Layer with 20% Soy Master-Batch

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Multilayer Co-Extrusion Trials

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Mechanical Properties of Multilayer Films with Compatibilizer

Control LLDPE Multi

5% Flour 10% Flour 15% Flour 20% Flour0

2

4

6

8

10

12

14

Tensile Stress at Yield Point (MPa) MD

TD

Te

nsi

le S

tre

ss a

t Yie

ld (

Mp

a)

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Mechanical Properties of Multilayer Films with Compatibilizer

Control LLDPE Multi

5% Flour 10% Flour 15% Flour 20% Flour0

100

200

300

400

500

600

700

800

900

1000

Ultimate Elongation (%) MD

TD

Ulti

ma

te E

lon

ga

tion

(%

)

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Prototype Meals Ready to Eat (MRE) Menu Bags

Meal Ready-to-Eat (MRE) menu bag (top) and prototype LLDPE-soy bags containing soy at 0%, 5%, 10%, 15% and 20% by weight (left to right)

* Menu bag contains brown pigment not included in prototype samples17

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Summary

• Successful in identifying a proper compatibilizer technology to increase the tensile stress (strength) of the film material at yield to a level that is comparable to the neat film. Efficiency testing was carried to establish the minimum amount of compatibilizer needed, which in this case was 3% by weight.

• Use of the compatibilizer technology allowed for the successful compounding and multilayer film processing of a linear low density polyethylene (LLDPE)/soy flour blend containing up to 20% by weight of soy flour. These films demonstrated tensile stress values at yield that were higher than the neat film. Ultimate elongation of the soy films was less than the neat film control.

• Successful drying and compounding operations were identified and carried out in order to minimize bubbles in the extruded product and soy degradation during the extrusion process.

• Prototype Meal Ready to Eat (MRE) packaging has been constructed from the films and will be tested according to military specifications for rough handling and insect infestation.

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Planned Work for Remainder of the Project

• Carry out rough handling and insect infestation testing according to military packaging specifications for the MRE and other packaging products.

• Identify proper manufacturing locations to construct prototype items and/or films using larger volumes of compounded product.

• Continue to work with the packaging industry to identify non-military uses for these films in the commercial sector.

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Acknowledgements

The United Soybean Board

Principle Investigator: Dr. Christopher Thellen

Omni Tech International: Robina Hogan

TensTech Incorporated: Thomas Theyson

Archer Daniels Midland: Russ Egbert

FKUR Plastics: Ms. Kelly Lehrmann, Carsten Niermann, Julian Schmeling, Carmen Michels

Aveka CCE Technologies: Tony Nelson

Wyssmont Company: Joe Bevacqua, Bob Schuit, Maynard Ignacio

U.S. Army NSRDEC: Jo Ann Ratto Ross, Paul Krusell20

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Questions?

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