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SKILLMAN, NJ -- Laurel BioComposite, LLC, a Nebraska company, claims to be the first to commercially produce a plastic resin enhancer or additive from lignin-based biomass feedstock. The initial feedstock is dried distillers grains with soluble (DDGS), a byproduct of corn ethanol production. DDGS is subjected to a proprietary lignin-conversion technology developed and licensed from LignoTech Limited of New Zealand. The resulting additive is called LignoMAXX®. A description of how this lignin-based additive can markedly enhance strength and weight loss of thermoset and thermoplastics resins will take center-stage at the BioPlastek 2011 Forum on Bioplastics Today and Tomorrow, June 27-29, 2011 at The Waldorf-Astoria in New York City.
Tim Bearnes, President, Laurel BioComposite shared, "This lignin-based additive can be used at higher loadings than most simple biobased fillers, and thereby replaces a large portion of the base substrate resin in some applications. Depending on the application, loading rates will vary between 20-40%. Moreover, because it is derived from a renewable feedstock that is consistently and readily available, the end product can qualify for the Federal Bio-Preferred Program." U.S. plant construction to produce the additive is expected to begin 3Q 2011, with U.S. based supply beginning mid 2012.
LignoMAXX is a resin enhancer or additive created from ligno-cellulosic biobased feedstock. The initial feedstock will be dried distillers grains with solubles (DDGS). The feedstock undergoes a molecular re-structuring that is further processed into in a product of either a fine powder for inclusion in thermosets or pellets for inclusion in thermoplastics.
LignoMAXX will primarily be used in formulations with more expensive oil-based resins and/or bio-based resins for use in plastic product manufacturing. The specific inclusion rate of LignoMAXX will depend on the required physical characteristics of the manufactured product and it is anticipated that the inclusion rates will range between 20% and 40%. LignoMAXX will be marketed in both a pellet and a powder form. The pellet form is used within thermoplastics while the powder is used in thermosets. The initial processing facility will produce LignoMAXX powder.
Commercial trials using LignoMAXX are ongoing in both thermoplastic and thermoset applications. Injection-molding trials have been conducted for a number of products including pallets and plant pots. Several trials are ongoing in thermosets with the applications in sheet molding and bulk molding showing the most immediate path to market. Commercial uses for sheet molding and bulk molding include products such as automotive body panels and construction components. As well, a number of compounders and manufacturers have conducted, and continue to run, their own tests to arrive at an optimal inclusion rate for their specific product or application.
Product attributes
LignoMAXX has the ability to be utilized for products within a wide array of industries and manufacturing, including but not limited to: shipping, lawn and garden, agricultural containers, and automotive. The following attributes further strengthen its market position:
- LignoMAXX utilizes lignin, the second most common organic material on earth; assuring an almost infinite, sustainable supply without competing with food products.
- It is suited for large production volumes as it is derived from a renewable feedstock that is consistently and readily available.
- During its life-cycle, LignoMAXX sequesters the carbon originally absorbed by the biomass, and if at the end of that life-cycle it is incinerated, it emits no more carbon than what the plants originally absorbed; thereby being carbon neutral.
- LignoMAXX enjoys economic independence from the price of crude oil.
- The initial feedstock (DDGS) is the by-product of a biofuels production process.
- LignoMAXX can be used at higher inclusion rates than most simple fillers; and actually replaces a portion of the traditional resin in some applications, thereby again further reducing crude oil consumption.
- LignoMAXX actually enhances certain qualities of the final product, e.g. less weight and greater strength.
- Processing characteristics include a high dispersion index and lower density which can result in more parts being produced, per pound, when compared to some filler/other materials.
- There are no toxic compounds added to the product or used during processing.
- At appropriate inclusion rates, it can qualify the end product for the Federal Bio-Preferred Program, thereby providing the user with the opportunity to receive price premiums in accepted, Federal contracts.
- LignoMAXX is easy to store and transport. LignoMAXX is derived from renewable feedstocks; with emphasis on those feedstocks that are non-food based. Agricultural crop waste will work. Lumber and paper production waste will work. Fruit processing waste will work.
About Laurel BioComposite
Laurel BioComposite, LLC is a Nebraska company formed in 2008. The headquarters are located in Laurel, Nebraska, the site of the first of several planned plants. Laurel BioComposite, LLC has entered into a Licensing Agreement with the patent owners, LignoTech Developments Limited of New Zealand, which provides the Company with the exclusive production and marketing rights of LignoMAXX in the United States. As well, the Company can expand its presence from the initial production facility to additional plants with total capacity in excess of several million pounds annually.
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