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Eastern Redcedar Mulch TileMeet the Team

OverviewMission StatementStatement of NeedMulch TileEastern Redcedar and Starch as Binding Agent

Mulch Tile ProcessExperiments and ResultsBusiness AnalysisCommunications Campaign

http://www.greenforestproducts.com/gallery_01.htmlMission StatementChip Incorporated created a value-added mulch product in the form of mulch tiles using a native Oklahoma invasive species, Eastern Redcedar (Juniperus virpiniana L.), to have a more practical and efficient use of mulch.

Statement of NeedSimplified the application of mulch for homeowners and landscape professionals, the proposed process also utilized Eastern Redcedar mulch, which developed an end product for an invasive species.

Mulch Tile19.5 x 19.0 x 0.75 mulch tilesEastern Redcedar6% Wheat starchPanel density of 0.65 g/cm3Press parametersTemperature: 350FPressure: 750 psiPress time: 5 minutes

Eastern Redcedar LogsEastern Redcedar Mulch TilesEastern RedcedarNative but invasiveThreat to OK water resourcesCan consume 55,000 gallons of water in a year over a 1 acre plotFire hazardCost OK $218 million dollars annually in damagesBe a Leader, Kill a CedarMulch tile will provide a beneficial end use for Eastern Redcedar

http://www.forestry.ok.gov/Websites/forestry/Images/ERC%20as%20Hazard%20Fuel.pdfEastern RedcedarStarch as Binding AgentAll natural, non-toxic, wheat starchStarch binds with natural oils in mulch when heated and pressedGelatinizes with heatForms resin-like bond with oilsHolds mulch tile together until exposed to water

Process to Create Mulch Tile

ExperimentsThickness swelling of mulch tilesASTM D1037 Water Absorption and Thickness Swelling Humid SwellingModulus of Rupture (MOR)

Ignition & flammability Outdoor testsWeather elementsPress temperaturesDifferent mulch typesCypressPine

Thickness Swelling of Mulch TilesEight mulch tiles were tested for thickness swelling as a function of timePlaced on bare soil200mL water was applied over top of each tileSwelling of the samples were measured every two hours for a total of eleven hours

Thickness Swelling Results5 grams starchMaximum swelling occurred after 2 to 4 hours10 grams starchMaximum swelling occurred after 2 to 6 hours

Water Absorption & Thickness Swelling Test ASTM D1037Method A 2 Plus 22-h Submersion PeriodWeighed tiles Thickness measurements taken at four points, midway along each side of tile, 1 in. in from edge of tileSubmerged horizontally under 1 in. of water for two hoursWeighed tiles and took thickness measurements againSubmerged again for 22 hoursNone of the tiles held together after 24 hours

Water Absorption & Thickness Swelling Test ASTM D1037 ResultsTiles appear to swell less at higher density; not desirableNeed more swelling for aesthetic purposesIdeal density is 0.65 g/cm3

Humid Swelling TestsTest to determine if tiles swelled under humid conditionsStorage and shelf lifePlaced in a sealed fish tank, over open water sourceApproximately 100% humidity5 and 18 day periodsTested 0.65 and 0.75 g/cm3 mulch tiles made with both wheat and corn starch

Humid Swelling Results5 days: dry to touch18 days: moist to touch

MOR TestsModulus of RuptureAbility of a material to resist against a maximum load

F = load at point of fracture, NL = length of support span, mmb = width of rectangular beam, mmd = thickness of rectangular beam, mm

Com-Ten Testing MachineMOR Tests ResultsVariation in MOR due to heterogeneity of samplesMOR Eastern Redcedar particleboard = 60.7 MPa

Flammability TestEastern Redcedar mulch highly flammableTested ignition and flammability of the mulch tileCheck to see if mulch tile posed a fire hazard for end usersPropane torch was used to ignite mulch tile

Will the mulch tile burst into flames?Flammability Test Results30 seconds to ignite; smolderedFlame height increased with wind exposureImage on lower right shows mulch tile after 12 minute time lapseMulch tiles do not pose a fire hazardMore dense than loose mulch

Outdoor TestTwo sets of mulch tiles placed outside on bare soilSet 1 outside for a total of 23 days, 2.68 in. rainfallSet 2 outside for a total of 8 days, 1.25 in. rainfall

Time Lapse of Outdoor Tests, Set 1

March 31, 2010; Day 0April 2, 2010;Day 3April 15, 2010; Day 16Time Lapse, Set 1 & Set 2

April 15, 2010April 16, 2010April 17, 2010April 18, 2010April 22, 2010Day 16Day 0Day 17Day 24Day 19Day 18Day 8Day 3Day 2Day 1Conclusion of Outdoor TestsNoticeable thickness swelling and changes in textureRemained intact and did not wash awayFlexible once wetted and could tear apart easily

Press Temperature TestingOriginally pressed at a temperature of 350FPressed mulch at lower temperaturesUndesirable results at 180F, 200F and 250FAcceptable results at 275F

Cypress and Pine Mulch TilesTested creating mulch tiles out of Cypress and Pine mulchProof of concept used for Eastern Redcedar mulch also worked on the Cypress and Pine raw materialNo further work was carried out in this area since it was outside the scope of this project

Target MarketManufacturing facility would produce tilesLandscape professionals would install mulch tiles for homeowners/ businessesRetailers would sell mulch tiles to end consumers

Cost AssumptionsAll Used EquipmentKiln $18,000-$30,000Batch Mixer $500-$3,000Hot Press $100,000-$200,000Land/Facility 2,000 ft2 at $30/ft2, $60,000Consulted with Dr. Hiziroglu, Shea Pilgreen, Dr. Tilley for cost assumptions

$$$Variable CostsEastern Redcedar available for $20/yd3Assumed 360 yd3/day production rate; $7,200Wheat starch 50 lb bags available for $59

Material Cost per Tile50 lbs wheat starch will produce approximately 225 tiles $0.26/tile1 yd3 of Eastern Redcedar mulch will produce approximately 50 tiles$0.40/tile

Total variable cost per tile$0.6650 tiles = 1 yd3 of mulch$33Compared to $20Additional fixed costProfit marginBenefitsSimplified mulching processPotential reduction in shipping costAble to ship more mulch per loadDesired that price will be comparable with bagged mulchDependent upon manufacturing process chosen and resources available

Communications CampaignAudienceInvestorsLandscape ProfessionalsHome Owners

DesignCohesive designCommon design elements

Communications CampaignDesign ElementsWebsite3 page websiteBrochures3 versionsPowerPointFocused toward potential investors

Investor Brochures

User Brochures

AcknowledgmentsDr. Salim Hiziroglu, OSU NREM DepartmentFaculty of the Innovations Senior Design CourseDr. Tim Bowser, BAE DepartmentWayne Kiner and the BAE LabAaron Newton, Eastern Redcedar Company Shea Pilgreen, OSU Applications EngineerKay Watson, OK Alliance MEA

Starch TypePanel Density, g/cm3Water Absorption by Weight, %Average Swelling, %

Wheat, 3%0.6512985

Wheat, 5%120

Wheat, 6%105

Corn, 6%107

Wheat, 6%0.7511957

Wheat, 6%100

Corn, 6%101

Corn, 6%91

Sample TypePanel Density, g/cm3Average Swelling, %5 Days Average Swelling, %18 Days

Wheat, 3%0.651127

Wheat, 5%

Wheat, 6%

Wheat, 6%0.751216

Wheat, 6%

Corn , 6%

Corn, 6%

Starch TypeDensity, g/cm3Average Load, NAverage MOR, MPa

Wheat, 3%0.65

61.41.35

Wheat, 5%24.70.56

Wheat, 6%37.81.10

Wheat, 6%0.7566.71.30

Wheat, 6%76.11.86

Corn, 6%31.60.89

Corn, 6%66.72.99