Individual Report 01

Advanced Engineering Materials

Dated: May 4th, 2018

Bioplastic, Biofibres and Bio composites from renewable sources

BIOFIBERS AND BIOPOLYMERS FROM RENEWABLE SOURCES

First, we must ask ourselves two questions:

1.What are the biggest issues or challenges faced by communities? [1]
•Climate Changes
•Energy
•Water
2.What are the challenges for Engineers in R&D, Manufacturing [1]
•Lighter
•Quieter
•Greener
•Longer
•Faster
•Cheaper
Why biopolymers, biofibers and bio composites?

Certainly, bioproducts show advantages in terms of energy, climate change, greener, and cheaper,
but they also require a further analysis beyond the obvious advantages.

Sustainability, industrial ecology, eco-efficiency, and green chemistry are guiding the development
of the next generation of materials, products, and processes. Biodegradable plastics and bio-based
polymer products based on annually renewable agricultural and biomass feedstock can form the
basis for a portfolio of sustainable, eco-efficient products that can compete, and capture markets
currently dominated by products based exclusively on petroleum feedstock. Natural/Biofiber
composites (Bio-Composites) are emerging as a viable alternative to glass fibre reinforced
composites especially in automotive and building product applications [2]

During the past few decades, synthetic polymers and their materials have been used frequently as
attractive materials for several applications. Some of the advantages of these materials include
higher strength, resistance to corrosion, acid resistance, higher fatigue strength, impact energy,
absorption capacity, better fire resistance, acids resistance, longer service life, lower life-cycle costs,
non-conductivity and non-toxicity to name a few. However, most of the synthetic polymer-based
materials suffer from several drawbacks such as non-biodegradability, nonrecyclable, and non-
environment friendliness [3]

Generally, polymers from renewable resources can be classified into three groups: natural
polymers, such as starch, rubber, protein, and cellulose; synthetic polymers from natural
monomers, such as poly (lactic acid); and polymers from microbial fermentation, such as
poly(hydroxybutyrate). A major advantage of all these materials is that they are biodegradable. [4]

Natural polymers are produced in the growth cycles of cells of living organisms. Their synthesis
includes enzyme-catalysed polymerisation reactions of activated monomers, which occur within
cells as products of complex metabolic processes. For materials created by nature it applies that
they can also be degraded by nature.
All the natural polymers represent stored energy and matter, which is in decomposition
(metabolism) released and made available for reuse. Therefore, in nature, for natural polymers,
there are enzymatic systems for their degradation. [5]

Synthetic polymers from natural monomers

Polylactic acid(PLA) is the most common bioplastic in use today. First, corn, sugar cane or other
raw materials are fermented to produce lactic acid, which is then polymerized to make polylactic
acid(PLA). Bioplastics are expected to make major contributions to environmental protection,
because they reduce CO2 and because they are biodegradable. Moreover, PLA is a thermoplastic
polymer and can be conveniently processed using existing polymer-processing equipment and
techniques.
PLA can be processed into fibre, film, sheet, and 3D articles by fibre drawing, film blowing,
extrusion, and injection moulding. With the continual drop of resin prices, PLA is gradually gaining
the market share. Its clarity makes it suitable for biodegradable packaging, such as bottles, food
containers, and wrappers. Production process for polylactic acid(PLA)
There are two methods for manufacturing polylactic acid(PLA) from lactic acid: the first method
uses the cyclic lactic acid dimer called lactide as an intermediate stage; the second method is
direct polymerization of lactic acid. The method using the lactide intermediary yields polylactic
acid(PLA) with greater molecular weight [6]
PLA properties
Title: Handbook of Biopolymers and Biodegradable Plastics - Properties, Processing and Applications
Table: Table 2.6. NatureWorks Polylactic Acid, PLA Grades for Thermoform and Injection Molding (Data: NatureWorks)

melt tensile tensile notched crystallin glass

index strength yield tensile tensile Izod flexural flexural e melt transition
specific (g/10 at break strength modulus elongatio impact strength modulus temperat temperatur
grade gravity min) (MPa) (MPa) (MPa) n (%) (J/m) (MPa) (MPa) ure (°C) e (°C) applications
General extrusion for
thermoform production of food
packaging, dairy containers,
food serviceware, transparent
containers, hinged ware and
2003D 1.241 5 - 72 534 604 35004 64 12.816 cold drink cups
Injection molding applications for
clear cutlery, cups, plates, etc.
with heat deflection temperature
3001D 1.241 10 - 303 485 2.55 0.166 837 38287 <55 °C
Injection molding applications
with the requirement for clarity
and heat deflection temperature
3051D 1.251 10 - 252 485 2.55 0.165 837 38287 150 - 1658 55 - 659 <55 °C
Injection molding applications
with higher melt flow capability.
High gloss, ultraviolet, UV-
3251D 1.241 70 - 852 485 2.55 0.165 837 resistance and stiffness
Injection molding for high-heat
and high-impact applications.
More rapid crystallization
kinetics for shorter cycle time.
Application at heat deflection
temperatures 65 -140 °C without
3801X 1.331 83 25.95 29805 8.15 1446 447 28507 160 - 1708 food contact
Handbook of Biopolymers and Biodegradable Plastics - Properties, Processing and Applications © 2013 Elsevier

Polymers from microbial fermentation

In nature, a special group of polyesters is produced by a wide variety of microorganisms for

internal carbon and energy storage as part of their survival mechanism (Hocking and
Marchessault, 1994; Scholz and Gross, 2000; Suriyamongkol et al., 2007).

Poly(b-hydroxybutyrate) (PHB) was first mentioned in the scientific literature as early as 1901 and
detailed studies began in 1925. Over the next 30 years, PHB inclusion bodies were studied
primarily as an academic curiosity. The energy crisis of the 1970s was an incentive to seek
naturally occurring substitutes for synthetic plastics, which then sped-up the research and
commercialization of PHB. This biopolymer has received much research attention in recent years,
with a large number of publications concerned with biosynthesis, microstructure, mechanical and
thermal properties, and biodegradation through to genetic engineering.

Biofibers

Can a natural fiber or natural Polymer substitute the traditional petroleum-based components?

For centuries, mankind has been clothed using natural cellulose and protein fibres that have been
almost entirely derived from dedicated sources. Cultivation of fiber crops and rearing of silkworms
and sheep have been the traditional methods of obtaining cellulose and protein fibres,
respectively [7]

Typical Natural Fibers

Comparison of Natural Fibers Vs. Synthetic Fibers

As we can appreciate there are some fibres such as Ramie, Banana and Jute that have a slightly
lower performance in terms of mechanical properties.
To name one of the most common examples when we talk about composites, fibre glass has a
undoubtable wide range of applications, is strong and long lasting, easily takes the shape of the
mould, in terms of appearance and cost effectiveness has no competitors, but it is also well known
the difficulty to treat it once is not usable, and the disposal of this composite is always a last long
problem to deal with.

There are a lot of services in which we will not be able to substitute it, but there are also a lot of
unnecessary or simply esthetical services that should be replaces by more friendly materials.

Engineers are developing a wide range of materials based on biological sources such as soy
polymers reinforced with several combinations of fibres [8]
Bio Composites or Composites from renewable sources

There are now many well-developed techniques that are used to produce conventional polymer
blends and composites, and various products have been widely commercialized. There are also
numerous papers, patents, books, and handbooks that introduce and discuss the development
and application of various polymeric blends and composites. Over the past two decades, however,
polymers from renewable resources (PFRR) have been attracting increasing attention, primarily for
two major reasons: environmental concerns, and the realization that our petroleum resources are
finite. A third reason for the growing interest in polymers from renewable resources relates to
adding value to agricultural products, which is economically important for many countries [2]

Examples of composites
Case of study, Composite layered from PLA (See biopolymers section) and Banana Fibres

For this case of study was selected the Poly Lactic Acid as a matrix, due to its market availability

And banana fibres due to its mechanical properties, although fibres may need special treatment
for improving the adhering properties to the matrix, this example can give us a general idea of the
potential of bio composites.

Software available

For precision purposes it was used a free software specially developed for composites analysis.

Mechanical Analysis of Composites and LAMinates ©

Copyright © Alberto Díaz Díaz, Jean-François Caron, Alain Ehrlacher; 2007.

http://maclam.cimav.edu.mx/maclam2.htm

During the analysis there were selected similar geometry characteristics for the following
composites

 Glass Fibre- Epoxy Matrix

 Banana fibre- Poly Lactic Acid Matrix
10 layers 1mm each
Symmetric distribution 0,45,90, -45,0
The results show the following information

Glass Fibre- Epoxy Matrix

Banana Fibre – PLA Matrix

If bio polymers, bio plastics and natural fibres offer a potential and feasible solution to the disposal
issue about composites, without seriously compromising the mechanical properties then why aren’t
we using it in a macro scale instead of limiting their use to laboratories and research centres?
The true is that a lot of reasons delay the use of composites like that, but one of the strongest
arguments is related with ethic matters.

In the case that a polymer in use is also suitable for food, we encounter an ethical dilemma: is it
appropriate to use food to produce materials? In addition to the use of polymers, the use of sugars
or other natural substances which can be fermented and thus converted into biopolymers (e.g.
PHA), or useful monomers (for example, lactic acid for PLA), also falls into this category. [6]

Agro-waste to produce Biopolymers

One of the more promising solutions is in the use of the waste, thus reduces the consumption of
raw material and sometimes energy, a certain number of processes have been reviewed but only a
few of them have scale into an industrial environment

Industrial Examples of Bio polymers and Bio composites

A clear example of this is a company in China called Ebei, who provides coffee mugs designed with
rice husk this company has developed a composite able to be either frozen, or heated without
suffering damage, durable and most of all, hygienic, meeting all of the international standards for
export demonstrating that composites made from renewable sources can meet the synthetic
performance[9]

They can also be manufactured with the traditional methods for thermoplastic materials, which
make them even more attractive

Another example of agro-waste to production is the biggest plan in the world for bio plastics, called
BIOFASE in Mexico, the raw material used for the production is the avocado seed, the process is
similar to the one used for the production of plastic from potatoes, but the product offers good
enough mechanical properties to produce pellets and then the plastic can be injected, moulded and
manufactured as any conventional plastic.[10]

Conclusions: We can conclude that society demands and requires the technological parallel work of
industry, bio-technology, and materials engineering to make professional, sustainable and feasible
the way in which plastic materials are produced. The development of bioplastics, bio composites
and resins offer alternatives with the processes that we already know such as extrusion, layering
injection etc., and is an exciting trajectory to develop new composites to substitute the currently
used. Engineers and Scientifics have the responsibility of developing processes and materials that
meet the international standards in terms of mechanical properties and sustainable supply.

References:

1. Lin. Y. (2018). MECH5310 Advanced Engineering Materials. Sydney, NSW: The University of
Sydney.

2. A. M. (2002). Sustainable Bio-Composites from Renewable Resources (Vol. 10). Journal of

Polymers and the Environment.

3.Thakur, V. K. (2016). Handbook of Sustainable Polymers. Pan Stanford Publishing.

4.Yu, L. (2009). Biodegradable polymer blends and composites from renewable resources.
Hoboken, N. J.: John Wiley & Sons.

5.. P. M. (2016). BIOPOLYMERS AND BIOPLASTICS. National Institute of Chemistry, Ljubljana, 1-32.

6. Z. J. (2013). Handbook of Biopolymers and Biodegradable Plastics.

7.. REDDY, N. (2016). Innovative biofibers from renewable resources. Place of publication not
identified: SPRINGER-VERLAG BERLIN AN.

8. B., Cocchieri, E., Carlos, S., & Almeida, R. (2006, September). A review on the development and
properties of continuous fiber/epoxy/aluminum hybrid composites for aircraft structures.
Retrieved from http://www.scielo.br/scielo.php?script=sci_arttext&pid=S1516-
14392006000300002

9. Rice Husk Fiber Water Cup/ Coffee Mug. (2018). Retrieved from https://eco-supplier.en.made-
in-china.com/product/eSHEBFTDAbhU/China-Rice-Husk-Fiber-Water-Cup-Coffee-Mug.html

10. BIOFASE. (n.d.). Retrieved from https://www.biofase.com.mx/