Any time since mid-2009, a growth rate of 5.4 percent has sounded mighty good. That number happens to be the expansion rate for the global market for reinforced and filled plastics. Or, to say it another way, it amounts to 25 billion pounds of sales for high performance composites, most of which could be a target market for advanced natural fiber composites (ANFC). One central Ohio company, Natural Fiber Composites Corporation (NFCC), is an active participant in this market due to its proprietary technology for pre-processing commercially available bast fibers for manufacturing ANFC materials.  These ANFC materials can be compounded into thermoplastic pellets for various injection molding, compression molding, and extrusion product applications in important market areas including building and construction, automotive, packaging and industrial goods.

At a PolymerOhio-sponsored Emerging Technology Forum (ETF), Dr. Prabhat Krishnaswamy, NFCC president and founder, discussed opportunities for ANFC materials which span the interfaces of two mature industries – agriculture and polymers. For instance, there are opportunities for combining manufacturing processes in innovative ways as well as opportunities for the development of novel formulations with unique properties due to the inclusion of advanced natural fibers.

Through its partnership with the Ohio BioProducts Innovation Center (OBIC) at The Ohio State University, NFCC applied for and won an Ohio Wright Project award (in 2009) to advance its technology and the natural fiber industry. PolymerOhio introduced NFCC to OBIC and the partnership led to the establishment of a pilot manufacturing facility in Wooster, OH.

A strong consortium, led by OBIC, has integrated innovative bioprocess engineering, nanomaterials, and polymer molding technologies; novel natural fiber technologies developed by NFCC; and extensive industry networking capabilities to accelerate industry innovation (PolymerOhio, The Ohio Corn Marketing Program, and The Ohio Small Grains Marketing Program). NFCC is focused on essential research, piloting, and commercialization activities – all of which have the potential to help Ohio become the world leader in bio-based advanced natural fiber composite materials. The commercialization of NFCC technology will be improved through strong industry collaboration (including a number of other Ohio companies in NFCC’s supply chain) representing relevant applications, integration of innovative bioprocess engineering, and composite engineering technologies.

The driving forces for enhancements in the ANFC technology, said Krishnaswamy, “…include weight reduction (more parts per unit weight), its use of a renewable resource, the ease of recycling and disposal of ANFC materials, the ability of ANFC to replace conventional reinforcements in some applications, the decrease in abrasion to equipment when using ANFC, and the material’s design flexibility and modularity.”

“At present, cost and performance targets for ANFC materials have been proven in the European marketplace for electronic housings,” he said. “Weathering studies show that ANFC materials can be formulated to not degrade in ultraviolet (UV) light.” “However, the economies of scale have yet to be achieved with ANFC production, and we still are working to optimize the manufacturing process for these materials.”

In discussing the current advantages and disadvantages of ANFC materials, Krishnaswamy said that the fiber is beige and is very difficult to lighten to white. The material does, however, take color very thoroughly and evenly. He added that the ANFC material is extremely resilient and can be added up to 40 percent by weight to achieve composites that work well with injection molding, extrusion, and compression molding.

Krishnaswamy said that ANFC material has been shown to flow very well into a mold that was almost five feet long. A commercialization trial for a similar-sized single shot automotive panel was successfully performed on existing equipment with no change needed in cycle time. Commercialization trials for ANFC materials have been conducted for applications in various market sectors.

NFCC’s Wright Project involves the commercialization of biobased and nano-tailored composites for industrial applications. Krishnaswamy said that the project goal revolves around job creation through technology and innovation. He and his company are focusing on commercializing existing technology with the background intellectual property already available. They expect to improve existing technology in ways that will reduce costs and enhance performance for the ANFC materials. They also hope to develop new technologies with other biobased fibers and resins.

“From our present vantage point within the technology,” said Krishnaswamy, “we perceive a market need for thermoplastic-based ANFC materials.” “To get there we have to achieve improved natural fiber compatibility, particularly in terms of wetting and adhesion.” He added, “We also have to develop ‘drop in’ applications and good flow for molding machines. And we have to control odor as the material is heated.”

NFCC is exploring the potential for several classes of natural fibers and fillers. They are investigating flax and hemp that can grow in temperate climates along with the potential use of soy hulls as a filler material and they also are exploring the uses for jute and kenaf that grow in tropical climates, which can include some of the most southerly areas of the United States, but more typically are supplied from south Asia and Bangladesh.  Additionally, while work to date has concentrated on thermoplastic applications, work on developing thermoset applications is expected to be a key long term component of NFCC’s business strategy.

To date, there are various applications for ANFC materials being developed for the building and construction industry. For these and other market areas, NFCC is working to demonstrate the advantages of ANFC materials as compared to traditional fillers and reinforcements for thermoplastics.

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The Ohio BioProduct Innovation Center is a Wright Center funded by the Ohio Department of Development. OBIC focuses on enhancing Ohio’s leadership position in bioproduct commercialization. A novel market pull model integrates academia in support of comprehensive supply chain collaborations across agriculture, specialty chemical and polymer industry sectors. For more information, go to www.bioproducts.osu.edu.

PolymerOhio, Inc. is a polymer industry-specific Ohio Edison Technology Center, which is funded by the Ohio Department of Development.  PolymerOhio focuses on enhancing the global competitiveness of the polymer industry, including companies from the plastics, rubber, bioproducts, and advanced materials segments.