tsqiSynthetic StoneThe experiments were notgoing well. And if you hadheard what the Rho-Deltagroup was up to, you wouldn'thaae been surprised. They wereattempting to make structurallumber out of shredded newspapers.It sounds like a fraternityprank - the loony scheme of abunch of crackpots with too muchtime on their hands.But you might have started totake them seriously when you realizedthat Rho and Delta are theGreek letters for R and D, short forresearch and development. Ifs anappropriate name for agroup of scientists,all former professors fromMankato State University, workingto turn clever ideas into businesses.46 W'orkbench tlune 1997Mike Reibel, a RhoDelta member,saw some possibilities amidthese experiments. Instead of callingit a failed structural material, hereasoned, lefs call it a successfuldecorative product. He also suggestedadding soy flour as a binder.As a former engineering andphysics teacherwho also has farmingin his background, Mike ownsa unique perspective on developing environmentally-friendly, agriculturally-basedproducts.Further tests proved the value ofhis ideas. Food-grade soy flourhelped produce a durable panelwithout relying on a toxic bindingagent that includes formaldehyde(remember that smell from yourhigh school biology lab?). This fibreakthrough gave birth to a prod- €uct named Environ, and a new com- !pany, Phenix Biocomposites.Mix, Mosh & MoldEnviron is composed mainly ofrecycled newspapers and foodgradesoy flour. The panels areavailable in ten rich colors andthicknesses ranging from Vsrr toil. Virfuallv all the raw materials
for Environ are collected or harvestedwithin 50 miles of thePhenix manufacturing plant in St.Peter, Minnesota.After making sure the newspapersmeet the company's compositionand cleantness standards, apulverizing mill transforms yesterday'snews into a fluff that lookslike cellulose insulation. Ink is notremoved from the paper since thatwould require harsh bleachingchemicals that are hazardous touse and can generate toxic waste.The edible soy flour is blendedwith the newspaper pulp, then aprecisely brewed soup is added.The recipe for the soup consists ofwater, dyes, and other ingredients,including a wax that keeps the particlesfrom sticking to the press.To achieve the granite look, twoseparately dyed batches areblended, partially dried, and eventuallyreach the press. There,pressure and heat forms a pair of3-ft. x Gft. panels.Once the Environ exits the press,it dries slowly to reach an equilibriummoisture content of 6% to 10%.This is equivalent to the moisturelevel of kiln-dried hardwoods.Growing A MqrketThe story of Environ is much morethan engineering, chemisfy, andphysics. It is also a successtory inmarketing, forboth the rawmaterialsand the finished product.For example, the farmers whogrow the soybeans that go intoEnviron are more than suppliers -they're also members of a coopthat owns part of the Phenix manufacturingoperation. When the companysells more product the marketfor their soybeans increases.And on the distribution side,Phenix constantly searches for creative ways to use Environ. Thematerial has become popular formaking plaques and awards, interiorsigns, store fixtures, statuebases, pens, desk and table tops,and even flooring accent stips.To meet current demand, 50employees work two shifts in aEach of the tuo coollng racls plclc up and holds firee sheeb of Envlron afhr they exlt fiepres, The next steps - surface sandlng and edge trlmmlng - produce unlform panels.40,000 square foot building, manufacturingone million square feet ofpanels per year.But construction is alreadyunderway for a 150,000 square footplant, and additional productioncapacitywill take a quantum leap to45 million square feet per year -equivalento covering 355 miles oftwo lane Interstate highway.Not all of the production will beEnviron, however. Phenix will beginmanufacturing a panel to competewith medium-density fiberboard,and is poised to begin marketingnew floor tiles based on Environtechnology. There's also a solid surfaceproduct made with recycledplastics under developmenlPutfing Envircn To WorkGiven the newspaper content ofEnviron, ifs no surprise that itmachines a lot like lumber.Although Environ is 1% timesharder than oak, it can easi$ besawed, drilled, routed, and sanded.Join it to itself or solid wood withscrews, nails, dowels, biscuits, orglue. You can use yellow glue(aliphatic resin), but polyurethaneadhesive is recommended.Envlron ls flnlsh-sanded wlth 18o-gritpaper. A3-ft. x6-ft. panel goes$roughfils sandlng shtlon wery 30 seconds,Environ has about the samestructural strength as mediumdensityfiberboard, but its mainfeature is good looks, not brawn.One of the quirks of Environ is itsaroma. Although it doesn't have thenose-burning sting of formaldehyde, it has an earthy scent that fillsthe workshop. But Phenix is e: