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UNCLASSIFIED #U15-459
Corey HauverMaterials Engineer
Combat Feeding Directorate
Update on Sustainable Packaging Research and Development Efforts
In the Combat Feeding Directorate
UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
Project Applications for the Military
3
UNCLASSIFIED #U15-459
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
4
UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
Previous Tensile Property Problems
Control LLDPE
10% Flour 20% Flour 10% Biosolids
20% Biosolids
14
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
)
6
UNCLASSIFIED #U15-459
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
UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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
)
9
UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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
UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
Multilayer Co-Extrusion Trials
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UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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
UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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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UNCLASSIFIED #U15-459
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
UNCLASSIFIED #U15-459
Questions?
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