2002 - Volume 1 - JEFF. Journal of Engineered Fibers and Fabrics
2002 - Volume 1 - JEFF. Journal of Engineered Fibers and Fabrics
2002 - Volume 1 - JEFF. Journal of Engineered Fibers and Fabrics
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TECHNOLOGY<br />
WATCH<br />
PLA — The Newest Generic Fiber<br />
To be designated as a generic fiber by<br />
the U.S. Federal Trade Commission<br />
means that the fiber has been given an<br />
<strong>of</strong>ficial name <strong>and</strong> classification that recognizes<br />
it as a unique <strong>and</strong> identifiable<br />
fiber in commerce, distinct from other<br />
fibers. In announcing the <strong>of</strong>ficial designation,<br />
Cargill Dow LLC indicated that the<br />
designation as “PLA” is to be used for the<br />
fiber <strong>and</strong> that their name “NatureWorks”<br />
will be used by them to identify their specific<br />
trade name product.<br />
As a part <strong>of</strong> receiving the new generic<br />
classification, Cargill Dow had to show:<br />
properties <strong>and</strong> chemical composition that<br />
is radically different from other fibers;<br />
what commercial use is foreseen; <strong>and</strong> that<br />
the new generic is <strong>of</strong> importance to the<br />
public. PLA now joins other fiber classifications<br />
including cotton, wool, silk,<br />
rayon, nylon, polyester, <strong>and</strong> others.<br />
For a fiber to be classified as PLA, it<br />
must be a synthetic fiber manufactured<br />
from polylactic acid or poly lactate<br />
derived from naturally occurring sugars,<br />
such as those in corn or sugar beets. The<br />
process used to create NatureWorks PLA<br />
fibers involves converting plant starches<br />
into natural plant sugar building blocks.<br />
Such monomers are then used to make a<br />
series <strong>of</strong> polymers called polylactide<br />
(PLA). The development <strong>and</strong> manufacture<br />
<strong>of</strong> PLA relies on basic fermentation<br />
<strong>and</strong> distillation as its core chemical<br />
process, followed by direct polymerization.<br />
NatureWork PLA fiber is distinguished<br />
as the first new generic fiber <strong>of</strong> the 21st<br />
century. The fiber is claimed to combine<br />
the most desired physical characteristics<br />
<strong>of</strong> natural <strong>and</strong> synthetic fibers. It shows<br />
very good in-use performance, as well as<br />
environmental benefits that result from<br />
using renewable resources like corn.<br />
Cargill Dow has indicated their<br />
NatureWorks PLA fiber will compete<br />
head-to-head with traditional fibers on a<br />
cost <strong>and</strong> performance basis <strong>and</strong> is generating<br />
worldwide interest among leaders in<br />
the textile <strong>and</strong> film packaging industries.<br />
NatureWorks PLA is the first commercially<br />
viable polymer produced from<br />
annually renewable resources that performs<br />
as good or better than traditional<br />
polymers <strong>and</strong> is fully compostable in<br />
industrial <strong>and</strong> municipal composting<br />
facilities.<br />
Founded in 1997, Cargill Dow LLC is<br />
based in Minnetonka, MN. It is a joint<br />
INJ DEPARTMENTS<br />
venture <strong>of</strong> Dow Chemical Company <strong>and</strong><br />
Cargill, the largest privately owned corporation<br />
in the U.S. Cargill is based in<br />
Minneapolis, <strong>and</strong> is an international marketer,<br />
processor <strong>and</strong> distributor <strong>of</strong> agricultural,<br />
food, financial <strong>and</strong> industrial products.<br />
In November <strong>of</strong> 2001, Cargill Dow<br />
began commercial operation in their<br />
world-scale polymer production facility<br />
to produce polylactide (PLA) polymers in<br />
commercial quantities. This PLA was the<br />
first to produce commercially viable polymer<br />
produced from annually renewable<br />
resources. Located in Blair, Neb., USA,<br />
the plant has a capacity <strong>of</strong> more than 300<br />
million pounds (140,000 metric tons) <strong>of</strong><br />
PLA annually. The plant supplies resin for<br />
use in global markets, including Europe<br />
<strong>and</strong> Asia Pacific.<br />
Within the past few weeks, Cargill <strong>and</strong><br />
Purac have agreed to a joint venture to<br />
supply lactic acid to Cargill Dow for use<br />
Meltblown Web As An Insect Barrier<br />
An interesting new application for meltblown <strong>and</strong> resin technology is emerging<br />
from the research work <strong>of</strong> the New York State Integrated Pest Management<br />
(IPM) program at Cornell University (Dr. Michael P. H<strong>of</strong>fman, Pr<strong>of</strong>essor <strong>of</strong><br />
Entomology <strong>and</strong> Director). This group is investigating the use <strong>of</strong> meltblown fiber<br />
webs as barriers to invading insects.<br />
Describing their webs as “cotton c<strong>and</strong>y” polymer, the scientists form a fibrous<br />
meltblown web around the stem <strong>of</strong> young plants that are susceptible to the attack<br />
by relatively large insect pests. The polymer that has been employed thus far is<br />
an ethylene vinyl acetate (EVA) resin, typical <strong>of</strong> a commercial hotmelt material.<br />
The web is formed by means <strong>of</strong> a h<strong>and</strong>-held nozzle (Dynatec System, ITW<br />
Dynatec, Hendersonville, TN) aimed at the base <strong>of</strong> the plant. A multi-dimensional<br />
barrier is formed at the strategic location on the plant where it can interfere<br />
with insect behavior.<br />
Without protection <strong>of</strong> chemical insecticides, onion <strong>and</strong> cabbage fields can be<br />
attacked by maggots, which will destroy 40-90% <strong>of</strong> the crops. In experiments<br />
with the mechanical meltblown barrier, webs <strong>of</strong> 5-50 micron fibers were applied<br />
directly to the soil around the plant’s base. The EVA barriers kept onion maggots<br />
with their hook-shaped mouth parts from feeding on young plants, resulting in<br />
significantly lower crop destruction, <strong>and</strong> fewer eggs laid. For cabbage maggots<br />
which attack roots, the EVA fiber was applied to broccoli plants with the same<br />
success.<br />
The researches are working to produce fibers with optimum characteristics<br />
(fiber density, diameter, color, etc.) for pest-repellence. Research is also underway<br />
on the incorporation <strong>of</strong> other beneficial materials in the polymer web. For<br />
environmental protection, timed-degradation <strong>of</strong> biodegradable formulations is<br />
being investigated.<br />
INJ Spring <strong>2002</strong> 9