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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

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