Non-Woods in Today s Marketplace. Specialty Papers 2017 Mark Lewis

Transcription

1 Non-Woods in Today s Marketplace Specialty Papers 2017 Mark Lewis

2 Overview Why Non-Woods Environmental Impact Fiber Properties Tissue Containerboard Specialty Papers Molded Pulp Products

3 North American Biomass Potential

4 Why Non Wood Fibers Shortage of Hardwood Fiber in NW Hardwood Fiber Length More Biomass Available Higher Production Rates per Acre Doug Fir 2 tons per acre per year Ag Residue and Fibers 2 to 35 tons per acre per year Utilization of Residual Agricultural Waste Higher Strength than Hardwood Fibers Potential for Lower Weight Packaging and Products

5 Environmental Benefits of the Phoenix Process Traditional Wood Pulp Kraft Mills Sulfur Compounds NOX & SOX emissions High Energy Consumption Generally run at 170 C High Water Usage 40-45% Yield High Capital Costs Large Pressure Vessels Lignin for Energy Phoenix Process /Columbia Pulp Sulfur Free/Environmentally Benign Low Energy Atmospheric Conditions Lower Water Usage 10% of Equivalent Kraft Mill 60-65% Yield Low Capital Cost ~ Zero Effluent By Products Back to Farmers Other Commercial Uses

6 Environmental Impact Approximately 1 million tons of wheat straw are burned every year in Washington releasing 45,000 tons of ash, carbon dioxide, carbon monoxide and particulates into atmosphere every year. Columbia Pulp s usage of wheat straw could eliminate up to 15,000 tons of those compounds being released. Additionally, the use of wheat straw will replace over 300,000 tons per year of wood chips. There will be the potential replacement of over 50,000 tons of fossil fuel-based products annually. State-of-the-art manufacturing using self-contained energy efficient processes 6

7 Raw Material Supply Ag Residue Wheat Bagasse Barley Fiber Specific Crops Arundo donax Bamboo Kenaf Crops from Bio-Ethanol Plants Miscanthus Energy Cane Energy Sorghum

8 Fiber Length WAFL (mm) Alfalfa 0.87 Arundo 1.21 Bagasse 0.81 Bamboo 1.39 Miscanthus 1.05 Wheat 1.10 Aspen 0.8 Maple 0.6 Spruce 2.6

9 Wheat Straw SEM

10 Bagasse SEM

11 Tensile Index Results 500 CSF 400 CSF 300 CSF Wheat Straw Bagasse Bamboo Arundo donax Miscanthus Energy Sorghum Aspen Maple Eucalyptus

12 Tear Index Results 500 CSF 400 CSF 300 CSF Wheat Straw Bagasse Bamboo Arundo donax Miscanthus Energy Sorghum Aspen Maple Eucalyptus

13 Tissue and Toweling Low Coarseness Higher Tensile Strength than NBHK Can provide bulk on TAD machines dependent upon fiber used

14 Kimberly-Clark This video tells the story of why it s important for Kimberly-Clark Professional* to focus on alternative, non-tree fiber sources. Our GreenHarvest* products contain 20% plant fiber which supports our commitment to reduce pressure on natural forests and to reduce our reliance on recycled fiber. The use of plant fiber supports our goals to transition to 50% non-tree fibers by Join us in Cultivating for Future

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16 Raw Material Initial Evaluation for Tissue Sorghum Cook 1 Cook 2 Bleached Fiber Quality Analyzer: HiRes AFL, arithmetic LWAFL WWAFL Width Coarseness Curl, length weighted Kink index Percent fines, < 0.2 mm, arithmetic Percent fines, < 0.2 mm, length weighted

17 Containerboard and Folding Boxboard Inner plies of Fourdrinier machine Outer plies on cylinder machines Can add bulk and drainage in middle plies

18 Container Board and Folded Box Board Cleaner, Brighter, Stronger than OCC One Company looking at top two plies on cylinder machine Currently has 5 tons in place for a commercial trial Same company looking to replace OCC and virgin Currently runs low freeness to make STFI, wheat gives the opportunity for thicker stronger sheet. Very successful run at U Maine machine. Phoenix facility currently unavailable for large volume trials (over 20 tons)

19 Sustainable Packaging on the Rise 12 States in U.S. with city bans on polystyrene packaging today cities 5 additional states in process 7 cities (including Boston, Philly, and Chicago) Experts estimate that goods made in part from renewable resources will make up 10 percent of all American manufacturing by 2020 and 50 percent by ~ sustainable-future.org.

20 Waste and Opportunity Report: Environmental Progress and Challenges in Food, Beverage, and Consumer Goods Packaging January 2015 Demand: More sustainable and economical packaging formats that do not disrupt the natural ecosystems. The U.S. has a reported an overall packaging recycle rate of 51%, lagging behind all other developed countries. Starbucks, McDonald s, Coca-Cola, Nestle Waters NA, New Belgium Brewing, and PepsiCo all emerge as relative leaders in their business sectors, taking proactive steps to recycle, use recycled content, or generate less waste. Starbucks and McDonalds are the two U.S. leaders in recycle programs and overall use of recycled content Large brands like Dunkin Donuts, Burger King, KFC, MillerCoors, and Kraft Foods are wasting valuable materials through poor packaging sustainability policies to the tune of $11.4 billion a year. Report Available Upon Request

21 Opportunity SFT Technology provides a sustainable more economical raw material to produce packaging for food and non-food consumer goods without compromising hardwood supply. Common products made from molded pulp fiber include cups, food containers, plates, utensils, bowls, protective coverings, and cases. SFT technology uses rapidly-renewable plant biomass materials including alfalfa, arundo, bagasse, bamboo, miscanthus, wheat, which can all be harvested without disrupting natural ecosystems. This technology provides an outlet for a biomass product that has traditionally been an added cost to farmers to dispose of. There is also a tremendous environmental impact in the reduction of field burning of straw. Increasing numbers of food retailers are embracing more eco-friendly forms of packaging. With two-thirds of all packaging waste attributed to food packaging, the need for more sustainable food packaging options is a must have moving forward. Outside of the food industry, non-wood pulp fiber has been deployed in packaging consumer goods. Due to improvements in drafting technology, pulp fiber can be formed into a variety of shapes and sizes, suitable for a number of electronic applications. Examples can be seen in the packaging of earphones, cell phones, and computers.

22 Burst Strength Burst Strength (kpa) % Wheat Straw

23 Short Span Compression % Wheat Straw Short Span Compression (KN/m)

24 %5 Wheat and 95% Blend 10% Wheat 90% Blend 25% Wheat 75% Blend Control 50 Wheat/50 OCC 100% Wheat Control STFI, psi-md STFI psi MD % difference from Control 29.2% 63.2% 8.4% 8.9% 9.5% 0 STFI, MD lb/lb Basis Weight STFI, MD lb/lb Basis Weight % difference from Control 8.9% 28.1% 1.9% 5.2% 6.4% 0 STFI, psi-cd STFI psi CD % difference from Control 34.6% 58.9% 3.8% 2.4% 9.5% 0 STFI, CD lb/lb Basis Weight STFI, CD lb/lb Basis Weight % difference from Control 13.5% 24.7% -2.4% -1.0% 6.5% 0 STFI Ratio

25 50% Wheat 50% OCC 100% Wheat Straw 5% Wheat 95% Blend 10% Wheat 90% Blend 25% Wheat 75% Blend T1612 Control Tensile lbs/in - MD % difference from Control 18.6% 41.5% 11.2% 8.5% 22.8% 0 Tensile, psi - MD Tensile, psi - MD % difference from Control 48.6% 83.2% 13.2% 10.4% 30.4% 0 Tensile lbs/in - CD % difference from Control 20.5% 44.0% -1.0% 4.1% 10.0% 0 Tensile, psi - CD Tensile, psi - CD % difference from Control 51.0% 86.4% 0.8% 6.0% 16.8% 0

26 Phoenix Wheat Straw Pulp for Blister Pack

27 Molded Pulp Packaging Replacing Blister Pack

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32 Specialty Papers Various Fibers Add Various Properties Fibers with lengths over 5 mm Replace Cotton or Rag Increased Smoothness Increased Opacity High Tensile Strength High Tear Strength

33 Arundo Photomicrograph

34 Locations of Current SFT Licensees Washington State Two facilities currently being built Two ton per day facility running Twenty ton per day integrated facility started in 2008 Florida Start up Nov 2017 Tennessee Wisconsin Saskatchewan North Dakota

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39 Questions For Further Info: Mark Lewis Papermakers wanted for various grades of paper with wheat and other nonwood materials