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Bio-Based Nano Particle and a Greener Printing Industry
TAPPI Nanotechnology ConferenceSeptember 29th , Espoo, Finland
MontrealSeptember 12 , 2010
Dr. Hadi Mahabadi
VP and Director,Xerox Research Centre of Canada
“Green printing and sustainability are a definite focus in the printing industry ….” (PIRA)The focus has moved beyond recycled paper and environmental certifications to true lifecycle analysis and sustainability
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Xerox Innovation
Jointly with Fuji-Xeroxwe invest $1.5B R&D/year
IEEE Corporate Innovation Award
US National Medal of Technology
Breakthrough Innovation:
55,000 global patents
>10 US patents/week
500 awards in last 3 years
…our innovation commitment is strong2
Xerox Research Centres
… leveraging exceptional talent globally
Xerox Research Centre EuropeGrenoble, France
Xerox Research Centre of Canada Mississauga, Canada
Fuji Xerox Japan
Palo Alto Research CenterCalifornia, USA
Xerox Research Center Webster New York, USA Xerox India Innovation Hub
Chennai
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Begins operation – 1974
Global mission defined – 1977
Moved to this site in Sheridan Science and Technology Park -1980
Features 120,000 sq ft state-of-the art research labs and advanced research pilot plant
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…a world renowned materials research centre in Canada
Xerox Research Centre of Canada
In the past 35 years:
Hiring the best researchers from all over the worldChemistry, chemical engineering and physics
Training and developing researchers and providing them with advanced tools to be more effective
Leveraging creativity and capabilities of other researchers / organizations
Using forefront of science to execute ever-green materials strategy
Contributing in significant way to democratization of information sharing and to the advancement of materials science and technology
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60
80
100
120
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1974 1981 1999 2008
Physics
Chemistry
Engineering
Admin & Support
125 Employees; 42% Female; 26% minority
… grew to a world renowned materials research centre
Xerox Research Centre of Canada
35 different cultural origins
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Materials R&T Trends
Industry Trends for Chemistry and Materials Science & Engineering
1. Nanotechnology2. Smart Materials3. Greener Materials &
Material processing
Top 10 Mega Trends1. Ageing - More off- shoring & outsourcing and different
perception of immigration2. Globalization – expanded flows of people, capital, goods &
services, information, technology and culture. We will have a world of Nations and Regions
3. Technology development – in 2020, computers will be ~ 200X faster and have 1000X more memory, Nanotechnology will be the general term of technology
4. Prosperity – larger groups in formerly developing countries growing more prosperous. Middle class will grow in Russia, China, Brazil by 85%,40% and 50% in the next 10 years
5. Individualization – customers are increasing their demand for individual and personalized products, more employee turnover & demand for employee individual attention
6. Commercialization – shorter time to market and faster growth for new products
7. Health and environment – growing sector, more resource will be allocated to it.
8. Acceleration- it is not enough to be change ready. Change oriented will be the norm. Speed & flexibility are other demands
9. Network organizing – challenges the way of thinking and traditional instaurations
10. Urbanization- 3.9B new people will be living in urban areas
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Small size → powerful properties
High surface to volume ratio → more powerful catalysts and more sensitive sensors
Quantum effects → Quantum dots
Smaller size devices → molecular electronics
Controlled assembly of materials/devices/systems:
Imparts new properties/functions
Enables versatility of design and performance
– Light-weight materials that are stronger than steel
– Carbon-based materials that are more conductive than copper
NANOTECHNOLOGY
ENERGY
HEALTH
ENVIRONMENT
IT
Why Nanotechnology
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… some customers are now willing to pay for green products
Green is now a ticket to the game
According to a recent survey, close to ¾of respondents will prefer green products and ½ will pay a premium for it
Use of renewable resources for material and energy consumption is a key green trend
Why Greener Chemistry
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Renewable Resources
Energy sources - Wind, solar, and biogas
Raw Materials; from bio-derived , renewable raw materials –replacing petroleum based raw materials
Bio-renewable Feedstock
•Products
CO2
Renewable Resources
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Bio-based Polymers
Biopolymers are less than 1% of the approximate 250 million tonnes of plastic in use today
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Opportunities for Bio-based Polymers
Need more investment and time to replace current manufacturing11
1. Renewable (Sustainable) Lessen the current dependence on
diminishing fossil resources
2. Environmentally-friendly Lead to a balanced CO2 level in the
atmosphere
3. Biodegradable Reduce the amount of persistent
plastic waste
4. Biocompatible Great potential for medical
applications
Bio-based monomers and polymers are now available from several producers
Difficult to replace all types of petro-based materials
Cost is still high
However future trend is toward use of bio-based polymers and more specifically bio based nanopolymers
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Bio-based Polymers
Bio-based nanopolymers are being examined in many existing industry sector
Coating, foams, composites and electronics are a few major areas of applications
Printing industries are also looking at this material to provide higher quality lower cost digital print that are ecofriendly
EA Toner Technology
Size Shape Structure
lightweight, renewable PP-composite from wheat straw)
Ford Motor Co. partnership with Ontario Bio-Car Initiative, and U Waterloo
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Business Opportunity for Bio-based NanoPolymers
Digital Production Print Market$
B
$665BRetail Value of Print $676B
(8% - 12% of Retail Value)
Mfg Rev $53B-$80B $54B-$81B
Source: Pira; The future of Global Printing Markets Forecast to 2014
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200
300
400
500
600
700
2009 2014
Letterpress
Screen
Flexo
Gravure
Offset
Letterpress
Other Analog
Digital
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...2009 digital was 12% and 2014 digital expected to increase to 19% (7.7 CAGR) of total print value
Greener Digital Printing
0.1
1
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1998 2000 2002 2004 2006 2008 2010
Tandem
Multi-pass
Weight Trend of Tandem and Multi-pass BW (High end Office)
Wei
ght/
BWpp
m
0.1
1
10
1998 2000 2002 2004 2006 2008
Weight Trend of A4 Tandem Engine
Wei
ght/
ppm
Significant weight reduction being achieved
• Less materials usage - less energy to make materials
• Less transportation energy and cost
• Less energy usage
Opportunity to reduce weight further by using nanopolymer fillers
Robust parts using cellulose-based materials
• ex: NCC, chitosanForest biomass
many cellulose chainsCellulose nanocrystals
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Nanopolymer playing a key role in many digital printing consumable technologies
Toner and inks• Less materials usage
• Better IQ
• Less energy consumptionManufacturing Printing
Key components• Longer life
Speciality media
Printable semiconductor inks based on nanopolymer for electronic devices
Precision Designed Toner at Particle Level
Building up from Individual Atoms/Molecules
Controlled Growth
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0.9
1
1.1
1 10 100
Diameter (um)
Nor
mal
ized
Cou
nt
Volume DifferentialNumber Differential
Alignment Surface
π-πStacking
Stabilization
Processability & Molecular Ordering
Side-chainInterdigitation
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Greener Digital Printing
Next Generation: Trends in Biobased Nanopolymers
Chitosan
• 2nd most abundant biopolymer in the world; unique solubility properties
• Sourced primarily from marine organisms (tunicate), but yield is low
Nano-Crystalline Cellulose (NCC)
• Forest & biomass industry by-product, extracted from cellulosic fibers of wood pulp (40 -50 wt-% cellulose)
• Nanoscale crystallites (“nano-whiskers”) of cellulose ( ~ 10 nm x 200 nm )
• High tensile strength due to hydrogen-bonding between cellulose (polysaccharide)
chains
• Properties that can offer value-add applications:
• Reinforcing nano-filler → in high-impact lightweight plastics for auto parts (Ontario Bio-Auto Council); ultra-durable coatings/varnishes; ceramics
• Tunable optical properties → dispersants & additives for coatings and other applications
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Xerox’s Efforts in Sustainability
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Sustainability Priorities
We focus on four areas where we can have themost impact:
1. Climate protection and energy
2. Preserving biodiversity and the world’s forests
3. Preserving clean air and water
4. Waste prevention and management
Assessment Tool • The Sustainability Calculator
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Xerox Environmental Record of Achievement
Introduces first product to make two-
sided copies
1969
Introduces "power down"
mode
1982
Introduces a recycled grade
of cut sheet paper
1973
Joins ENERGY STAR as charter
partner
1993
Waste toner recycling starts;
ISO 14001 for major
manufacturing sites
1997
2003
Joins EPA Climate Leaders; Paper Supplier
Rqmts launched
2007
Achieves > 10% reduction in Greenhouse Gas Emissions; boosts goal to 25% by 2012
Introduces Xerox High Yield Business Paper
2008
Introduces Sustainability
Calculator
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Reducing Energy and Materials Consumption
Bottom-up assembly process to make toner particles → “EA Technology”
–Precision particle design with control of morphology & structure–Toner particles of smaller size, tunable shape, and narrow size
distribution–Enviro-friendly toner (less toner per printed page) and toner
manufacturing
Precision Designed Toner at Particle Level
Building up from Individual Atoms/Molecules
Controlled Growth
Monomer . ......
.2-10 A
Latex Polymer
40 – 200 nm
Emulsion Polymerization
Pigment
Wax
Coalescence
3-7 microns
Toner Particle
Heating
Aggregation
Mixing/Heating
Shell Latex
Xerox Ecofriendly Toners
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Xerox Ecofriendly Toners
Emulsion Aggregation (EA) Toner
40% – 45% less toner mass
Small and Spherical EA Toner
Conventional Toner
Paper
Breakthrough process for producing color and black toners: Less toner mass per page Less toner waste for spherical toner Less energy to produce and to print
(>70% combined savings in energy/page)
Paper
“Intelligent” building
Building is packed with > 3000 sensors that feed into network to control energy use throughout “zones”
Variable speed chillers, compressors & variable intensity lighting
Process design maximizes throughput, minimizes energy use
Xerox’s EA Toner Plant DesignPlant designed around the process to be ultra-efficient
… enabling long-life, high-quality and low-energy printing22
Xerox Toner Technology Roadmap
1st Gen.
2nd Gen.
Continuous innovation enables higher value and greener toner for Xerox office and production products
EA-2Extending application to high speed production•15-30% reduction in printing energy
Time
EA-1 for officeImproved PQMore prints with the same amount of toner
•>70% less energy for printed page
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Next Gen.
Xerox Solid Ink: Easy on the Environment
90%Less Waste
815 lbs.88 lbs.Total waste produced printing 22k pages per month over 4 year life
Laser Printer
Xerox inkjet
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Xerox Ink Technology Roadmap 30
1st Gen.
2nd Gen.
Next Gen.
•Enhanced IQ and color stability•90% less waste
•Extension to high end of office•A 15% reduction in printing energy
•Extension to high speed production• A Green Paper Story
Time
Continuous innovation enables higher value greener solid ink products from office to production
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SummaryNanotechnology offers significant opportunities for developing new useful products,
Nanointermediates are a fast growing area within nanotechnology
Investment in nanointermediates including nanopolymer is growing steadily and most Fortune 500 companies have launched nanotechnology plans
Key applications of nanopolymers areas include: • Coating and composites
• Efforts by industries to replace bio-based nonopolymers gaining momentum
• Xerox Research Centre of Canada has been applying nanotechnology to advance Xerox’s core business and to create new businesses
Nano-enabled toner materials Nano-enabled printable organic electronicsActivities to replace biomaterials as nanointermediates initiated
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Thank You
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