Transcript deTerra ® Biobased Polymers

deTerra® Biobased Polymers
Next Generation Materials for Durable
Applications
Innovation Takes Root 2012
Dr. Jeffrey Cernohous
CTO, Chairman and Founder
Helping Innovators Innovate
Presentation Overview
• Brief overview of Interfacial Solutions
• Introduction to deTerra® Biobased Polymers
• Next Generation deTerra® Biobased Polymers
Helping Innovators Innovate
IFS Vision Statement
Be the best in class provider of polymer material and process solutions to
the plastics industry by:
1. Developing proprietary solutions that offer undeniable value propositions
2. Providing efficient technology development and transfer solutions
3. Operating with the highest level of integrity, honesty, and confidentiality
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Attracting and retaining world class people committed to our mission.
Helping Innovators Innovate
Our Mission:
Helping Innovators Innovate
Our Strength:
Delivering Material Science Solutions Quickly
Our Record:
>$300MM of Customer Sales Enabled in Several Markets
Our Business:
Flexible Business Models to Meet Customer Needs
Intellectual Prop. Creation & Development
Products and Contract Services
 Contract Research & Development
 Contract Melt Processing Services
 Contract Manufacturing Scale-Up
 Contract Laboratory Testing Services
 Manufacturing Modeling and Transfer
 Custom Compounding
 Patent and Know How Licensing
 IFS Products
(deTerra®, Xusto®, Moisture Scavenger)
Helping Innovators Innovate
Jeff Cernohous, Founder & CTO
• Ph.D. & B.S. Organic Chemistry
• 30+ Patents Issued
• 8 yrs Interfacial Solutions President
• 5 yrs 3M Technology Development
Gregg Bennett, CEO & Member
Brian Szymanski, CLO & Member
• Ph.D. Polymer Sci. & B.S. Ch.Engr
• 25+ Patents Issued
• 20 yrs 3M incl. VP R&D / Clinical
Affairs IPD & Genl. Mgr. of 3M Turkey
• Juris Doctor & B.S. Ch.Engr
• Registered Patent Attorney
• 17 yrs IP, incl. 3M Asst. Chief Counsel
• 10 Yrs Chemical Mfg
Kristi Cernohous, QC Director
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Todd Sarnstrom, VP Operations
• B.S. Computer Sci., B.A. Bus. Mgmt.
• 5+ Patents Issued
• 25 yrs production and tech. mgmt
• 5 yrs Anagram, 15 yrs Jostens
Adam Pawloski, Tech. Director
• Ph.D & B.S. Chemical Engineering
• 10+ Patents & 35+ Publications
• 10+ yrs matls dev., multiple industries
• 3 yrs with Interfacial Solutions
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B.S. Chemistry and Food
Science
7 yrs Forensic Evidence – MN
BCA
2 yrs Quality Engineer – General
Mills
Extensive method & instrument
dev.
Helping Innovators Innovate
Headquarters: River Falls, WI
(45 minutes from Minneapolis, MN)
Founded: 2003
Employees: 30 (14 Technical Degrees, 4 Ph.Ds)
Facility: 40,000 sq. ft.
Website: www.interfacialsolutions.com
Helping Innovators Innovate
Technical Compounding
• 2 lb Lab Samples
• 40,000 lb Truck Loads
• 3/4” Single Screw Extruder
• 2 x 27mm Lab Twin Screw Extruders
• 38, 50, 58mm Twin Screw Extruders
• Batch blending
• Side stuffing
• Liquid injection
• Super Critical Foaming
• Moisture sensitive materials
• Reactive Processing
Helping Innovators Innovate
Materials Characterization
Thermal Analysis
•DSC
•TGA
•DMA
•HDT
Molecular Structure
• GPC
• HPLC
• FTIR
• SEM
• Rheological Analysis
Physical Characteristics
•Color
•Moisture
•Specific Gravity
•Particle Size
•Flame Retardant Testing
Helping Innovators Innovate
Sample Preparation
Pellets
Injection Molded Parts
Blown Films
Cast Films
Extruded Sheet
Foamed Sheet
Foamed Pellets
Helping Innovators Innovate
Our Mission: Helping Innovators Innovate
Materials Expertise
Process Expertise
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Polymers
Natural Fibers and Fillers
Adhesives
Coupling Agents
Compatibilizers
Polymer Processing Additives
Flame Retardants
Moisture Scavengers
Nanoparticles
Biopolymers
Foaming Agents
Twin Screw Extrusion
Reactive Extrusion
Super Critical Foaming
Cast Films and Sheet
Blown Films
Injection Molding
Pelletizing
Grinding
Foaming
Process Development
Costing
Helping Innovators Innovate
Our Mission: Helping Innovators Innovate
Minimize Scale-Up Risks
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Business Model Understanding
Financial Modeling
Plant Design
Pilot Scale Production
Toll Manufacturing
Captive Production Models
• Technology Transfer
Helping Innovators Innovate
Our Customers
Announced Collaborations
2 Fortune 50 Companies
5 Fortune 500 Companies
More Public Disclosures Soon
Our Typical Customer
100-300 MM annual sales
Privately held
Profitable
Growth Oriented
R&D appreciation
Complimentary core competencies
Fundamental material science need
Helping Innovators Innovate
What We Promise
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Rapid product development and prompt responses
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Full service idea to production capabilities – minimize risk
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Best in Class Polymer Science Materials and Process Expertise
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Breadth and Experience across multiple markets
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Strong Strategic Alliances and Connections
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Strong Ability to “Cross fertilization” Technologies
Helping Innovators Innovate
Our Branded and Proprietary Products
• deTerra® Biobased Polymers
• Xusto® Natural and Renewable Fiber Composites
• Interfacial Solutions Moisture Scavengers
Helping Innovators Innovate
deTerra® Biobased Polymers
Helping Innovators Innovate
deTerra® Biobased Polymer Product Line
• deTerra® is the trade name given to a series of
biobased hyperbranched polymers developed
and manufactured by Interfacial Solutions
• Based on polylactic acid (PLA) polymer
• The deTerra® product line is based on high
biobased product content (> 80%)
Helping Innovators Innovate
deTerra® Product Line
• Initial grade developed for building and construction
industry – non-halogenated FR grade to meet UL
723/ ASTM E-84 class 1/A
• FR grades to meet UL-94 class V-0 rating
• Considered as a “green” alternative to PVC and FR
grades of PA, PP, and ABS
• High impact grades
• Extrusion and molding grades
Helping Innovators Innovate
deTerra® Biobased Polymers
Currently sold or sampled into
• Molded articles
• Extruded articles
• Flame retardant articles
• LEED certified buildings
• Consumer goods
• Appliances
Example articles made using deTerra®
• Electronics
• Others
Helping Innovators Innovate
deTerra® Molecular Characteristics
deTerra® Characteristics
• Reactive extrusion process
• Hyper-branching chemistry
• Major increase in Mz and Mw
• Patents pending
• Tailored rheology
Helping Innovators Innovate
Melt Strength
Natureworks 2003D
deTerra® XP759
Helping Innovators Innovate
deTerra® Biobased Polymers
Next Generation
Helping Innovators Innovate
Key Development Opportunities-PLA
• Improving impact strength
• Improving UL94V FR performance
• Improving melt strength
• Improving heat resistance (HDT)
• Expanding to other biopolymers (PHA)
Helping Innovators Innovate
Impact Strength-Unnotched Izod
50
43.0
45
40
35
Unnotched
Izod
(ft-lbs/in)
30
25
20
15
10
10.5
11.0
XP696
XP345
8.0
4.5
5
0
Ingeo 2003D
PLA
PR146
deTerra® FR
Wall Protection
deTerra® FR
Molding
XP698
deTerra®
High Impact
Helping Innovators Innovate
Impact Strength-Notched Izod
18
16.5
16
14
12
Notched
Izod
(ft-lbs/in)
10
8
6
4
2
0.3
0.7
0.7
1.0
PR146
XP696
XP345
XP698
deTerra® FR
Molding
deTerra®
High Impact
0
Ingeo 2003D
PLA
deTerra® FR
Wall Protection
Helping Innovators Innovate
UL94 Flammability
Grade
Biobased
Content
(%)
Specific
Gravity
(g/cc)
E84
Results
UL94 V
Results
UL94 H
Results
Limiting Oxygen
Index
PR146
93
1.25
0 Flame
Spread, <70
Smoke Index
V2
HB
24
XP345
76
1.30
Not
Determined
V0
HB
28
XP696
93
1.26
Not
Determined
V2
HB
23
Ingeo
2003D
100
1.24
Not
Determined
Not Rated
HB
22
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High biobased content for all FR deTerra® grades
Comparable specific gravity to PLA
Outstanding E84 fire ratings and characteristics
V2 and V0 deTerra® options for molding and extrusion
LOI results correlate with flame performance observed
Helping Innovators Innovate
deTerra® Biobased Polymer
Property Summary
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Grade
Biobased
Content
(%)
Specific
Gravity
(g/cc)
Flexural
Modulus
(psi)
Flexural
Strength
(psi)
Notched Izod
Impact Strength
(ft-lbs/in)
Melt Flow Index
(g/10 min @ 190C, 2.12 Kg)
PR146
93
1.25
450,000
12,000
0.8
1.0
XP345
76
1.30
500,000
11,200
0.95
18.0
XP698
85
1.25
330,000
8,600
16.5
28.0
XP696
93
1.26
460,000
12,600
1.2
1.0
Ingeo
2003D
100
1.24
400,000
14,000
0.3
7
FR deTerra® grades offer excellent flexural strength and modulus
Comparable specific gravity to PLA
The impact strength for deTerra® FR grades are improved vs PLA
Injection molding grade has impact performance comparable to PVC
deTerra® melt flow index/rheology can be tailored for extusion or molding
Helping Innovators Innovate
Future Development Challenges
Helping Innovators Innovate
Challenge 1-Thermal Resistance
4500
Generation 1 deTerra® PR146
4000
3500
Storage Modulus (MPa)
3000
2500
2000
PETG
1500
1000
500
0
25
35
45
55
65
75
85
95
Temperature (°C)
Helping Innovators Innovate
Challenge 3-Impact Strength
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
deTerra PR146
PVC
PETG
Helping Innovators Innovate
Challenge 2-FR + Impact
Material
Notched Izod Impact
(ft-lbs/in)
PVC
~15
PETG
~10
PR146
~1
Helping Innovators Innovate
Challenge 3-Economics
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
deTerra PR146
PVC
PETG
Helping Innovators Innovate
Next Steps
Other FR Biopolymers (PHA)
Improved FR/Impact Combo
Improved Temperature Resistance
Helping Innovators Innovate