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Department of Natural Resources - UNESPCaixa Postal 237, Botucatu, SP 18603-970, BRAZIL

e-mail: alcidesleao@fca.unesp.br

Natural Fibers in Extrusion Process for Profiles Production

A.L. Leão, J.C. Caraschi, S.M. Sartor, V.L. P. Salazar

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Searching

Key words: Natural Fiber; Polymercomposite; Plastics Composite2000-2005Language: english

Rigail, 2005

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Where are the Technologies in FPC

Fiber Plastics Composites

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1076

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16USAGermanyIndiaJapanCanadáNetherlandsItalyOthers

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Centers/Universities LeadersUniversities No. ReferencesMichigan State University, USA 20University of Kassel, Germany 6University of Delaware, USA 4Kyoto University, Japan 4Tech. Univ. of Berlin, Germany 4University of Auckland, New Zealand 4Chemnitz Univ , Germany 3Inha University, South Korea 3Univ. of New Brunswick, Canada 2University of Toronto, Canada 2Utrecht University, Netherlands 2Doshisha University, Japan 2UNESP, Brazil 2Others 50SciFnder

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Scientific and Technological Research?

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101520253035404550

Patents Papers Meetings

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Which Natural Fibers are Used in Composites?

Natural Fibers No. Of PapersBamboo 8Banana 6Hemp 38Coir 18Flax 46Jute 37Kenaf 28Sisal 30Pinneapple 4Curauá 4 SciFnder

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FONTE: VEJA, ANO 32(11):60-62, 17/03/99

Processes Utilized in Composites at UNESP - Botucatu

Extrusion (profiles and pellets)Injection moldingThermoformingBMC (partnership with private companies)SMC (partnership with private companies)RTM (partnership with private companies)LFRT – Long Fiber Reinforced Thermoplastics – profilesand railroad crossties)

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Fox Models: parts made of curauá

FOX Moulded Headliner

Carrier: 50/50 Curauá Fiber + Polymeric Resin

FOX Trunk Lid

FOX Sliding RoofDeveloped in partnership with UNESP

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ECOMENESECOMENES((oikosoikos--menesmenes))

eECOMENY

Resulting

ProcessesOf Low

Environmental Impacts

Use natural resources based on an ecological intuition of non linear biological processes- SUSTAINABILITY

Extrativism – low pressure of natural resources

Economics – high pressure;

making money at any cost

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Engineering Materials (Repetitive, Homogenous, Predictable)

Engineering Materials

Classics Non-classics

Wood GlassCeramics Metals Man-made Polymers

MANO, 2000

Natural Fibers Composites or FPC (Fiber Plastics Composites)

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Vegetable Fibre Classification

Vegetable Fibres- Cellulosic fibres

Bast Fibres- Flax

- Hemp- Kenaf- Abaca-Banana-Bamboo

- Jute- Totora

Leaf Fibres- Sisal

- Curaua- Fique

- Phormium- Palm trees

- Caroa- Kurowa

- Pineapple

Seed Fibres- Cotton- Capok

Fruit Fibres- Coir

African palm

Wood Fibres- Pinewood-Hardwood- Eucaliptos

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Natural Fibers in South America Brazil is the biggest producer and consumer

Abaca – EcuadorFique – Colombia, EcuadorTotora – Ecuador, Peru andBoliviaFlax – Argentina (?)Embira – BrazilCaroá – BrazilBamboo - BrazilPhormium (imbira, New Zealand Flax) - BrazilCurauá – Brazil, VenezuelaKurowa (curaua) - GuianaSugar cane bagasse –Brazil, Cuba and Colombia,

Sisal – Brazil, Cuba, Haiti MéxicoBuriti, Carnauba, Buriti, andTucum – NE of Brazil (nativepalm treesMalva & Jute – BrazilCoir – BrazilBanana – BrazilHemp – ChileTaboa (Typha) - BrazilPiteira – Brazil and EcuadorTagua – EcuadorJarina – Brazil (Vegetable ivory)Piaçava – Bahia, Brazil

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Curauá Plantation (High Density Stand)

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Application of Natural Fibers Composites

Marine12%

Construction26%

Automotive31%Aerospace

1%Miscellaneous

4%

Appliances8%

Consumer products

8%

Electronic components

10%

Racz, 2005

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FPC Fibers

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FPC PropertiesMaterial Plastics Wood FPC

Mechanical Properties

++ ++ ?

WaterAbsorption

+++ - ?

FungiResistance

++ - ?

FacingQuality

+ ++ ?

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Most Used Fibers

Wood (hardwood residues; Eucalyptus and pine)Rice husksPalm Tree fibers …Sugar cane bagasseSisalCurauáCoir

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Target Sectors in Brazil for FPCAutomotive Industry – 40,000 tons/year (23 kg/car in Europeand 13 kg/car in Brazil) – the Brazilian demand is about8,000 tons/yearRailroad crossties – replacement of solid wood and concretecrosstiesCivil Engineering – door frames, doors, window frames, fences, decksGeotextile – 100 millions m2 – 500.000 km roads & 50.000 km of railroadsFurniture Industry – cabinets, back seats, etc..Electro/Electronics – injection molded parts (computermonitors, mobile phonesPackaging Industry – fruit boxToys industry- injection molding of several articlesPens, pencil, etc…

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Soap and lipstick container using Injection Molding Technique

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Advantages of FPCEnvironmentalist pressure over more utilisation of Natural Renewable ResourcesBetter eficiency in converting raw-materials in productscompared to other man-made fibersProducts based on Life Cycle Analysis (ISO 14.000)National strategy to create rural jobs in economicallydeprived areasGood mechanical properties relations: Weight versus ResistanceComposites/EcomenesRecyclabilityGreenhouse EffectMarketing – Lignocelullosics Composites = LowTecnology

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Advantages of FPCExcellent specific strength and high modulus. High flexural and tensile modulus - up to 5× base resin, high notched impact strength - up to 2× base resin Reduced density of products.Biodegradable (?!)Renewable source of raw-material.Lower price of polymer composites reinforced with natural fibres than those reinforced with glass fibre.Reduced tool wear.Safe manufacturing processes, no airborne glass particles, relief from occupational hazards. Reduced dermal and respiratory irritation. No emission of toxic fumes when subjected to heat and incineration.Most thermoplastic composites are recyclable. Possibility of recycling the cuttings and manufacturing wastages.Energetically recyclable. Racz, 2005

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Limitations of FPCConcerns over fibre consistency/qualityLow impact strength (high concentration of fibre defects)Problem of storing raw material for extended time– Possibility of degradation, biological attack of fungi and

mildew– Foul odor development

Fibres are hydrophilicUV resistance – similar to plasticsLow surface hardness – Quinch-kinchIssues of bonding with polymersPrevious 2 issues largely overcome by development of effective fibre surface treatments – MAPPEmission issues – fogging and odorProcessing Temps – natural sugars caramelise between 150-205ºC must keep below this level. Limits the number of applicable matrix polymers

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Natural fibres & high impact?

(Sonntag & Barthel, 2002)

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Erfurt 2005

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“The most environmentally friendly thing that you can do for a car that burns gasoline is to make lighter

bodies”

Henry Ford

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May

200

3

Jan.

200

4

Jul.

2004

Jan.

200

5

Jul.

2005

Jan.

200

680 %100 %120 %140 %160 %

180 %

200 %220 %

Development for prices of crude oil, standard thermoplastics& natural fibres from Europe since 2003

Crude oil Standardthermoplastics

Natural fibres(Bast) from Europe

(Karus, Ortmann, Otremba, Scheurer & Müssig 2006.- adapted presentation)

Economical Aspects

Future trend: Fibres and Polymers based on renewable resources

Renewable Energy: many alternatives: available

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The increasing demand for natural and wood fibres

Source: UN 2006, AEO 2006, nova-Institut 2006

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How FPC is Viewed

++ durable++ innovative++ comfortable+ natural+ “warm“+/- elegant/exclusive- expensive

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Market Profiles

Exterior (decks, fences, siding) – natural competivinessInterior (door frames, skirting,etc…)

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Composite Families

Synthetic Vegetable Animal Mineral

aramideglasscarbonetc.

hempflaxsisalwoodramieetc.

woolmohairetc.

basaltetc.

Composite Families

Fibre Reinforced Particle reinforced/filled

Short fibre reinforced Long fibre reinforced (LFRT)

Manmade Mineral VegetableSynthetic Vegetable Animal Mineral

aramideglasscarbonetc.

hempcurauasisalwoodabacaetc.

woolmohairetc.

basaltetc.

nanotubesmetal particl.etc.

talcchalketc.

wood flouretc.

TSTP

TSTP

TSTP

TSTP

TSTP

TSTP

TSTP

TSTP

TSTP

TSTP

TSTP

Racz, 2005

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Density of NF CompositesReal Density

0

0.2

0.4

0.6

0.8

1

1.2

1.4

0 15 25 40Natural Fiber Content (% )

Rea

l Den

sity

PPBDEPPBINPPCAPPPM90PPMADPPTETPPTal

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Materials for FPC Melting Point

ABS 105°CPE 125°CPP 160°CPolystyrene 240°C Nylon-6 220°CSAN 115°CPET and PVC (personal restrictions)

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Types of Twin Screw Extruders

Co-Rotating- Parallel Screw Shafts- Fully IntermeshingCounter-Rotating- Parallel Screw Shafts- Fully Intermeshing

Counter-Rotating- Conical Screw Shafts- Fully Intermeshing

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Twin Screw Extruder

Excellent melting capability – pellets, flake, recycled resins okLower raw material costAble to recycle scrap

Flexible feeding optionsMelt resin separately from fiberIntroduce fiber downstream for optimal heat balanceHigh feed capacity for low density materials (natural fibers)

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Twin Screw ExtruderExcellent mixing capability and modular design

Screw design can be optimized for highest possible rate for a

given extruder D and formulationMaintenance cost reduced by modularity

Excellent devolatilizationRemove residual moisture

Excellent devolatilizationRemove residual moistureVacuum can be designed for very high reliabilityless scrap

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Twin Screw ExtruderFlexible processing possibilities

Direct profile extrusionPellets

Pumping capability is limited; low pumping efficiency (~10%) generates excess heatMelt pump or single-screw needed for most applications, even simple deck profilesMelt viscosity is very high –well suited for melt pump

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Single Screw ExtruderCounter-Rotating

Twin Screw ExtruderCo-Rotoating

Twin Screw Extruder

Conveying mechanism Drag flow Forced conveyingSolid flow

Drag flow(Forced flow)

Screw Speed range 60-250 rpm 25-80 rpm 100-1200 rpmViscosity range small large largeResidance time range large small smallMass and heatexchange

+ ++ ++

Mixing• Dispersing• Mixing

++

+++

+++++

Self cleaning + +++ +++Degassing + ++ +++Pressure built up ++ +++ +Flexibility + + ++

+++ very good ++ good + satisfying Source: Der Doppelschneckenextruder, VD-K

Characterization of different Plasticizing Systems

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7aS. Jornadas de plasticos en automocion

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Profile Process Configuration

1 2 3 5 6 7 8

M

M M

M

M

M

8 10 119

M

M

M

M

4Vacuum

UndriedFiber

Polymer(Pellets or powder) Additives

Conical or parallelTwin Screw Single Screw

Water Water

Melt-Mixing=Max Torque Load

Calibrator/Cooler/Puller

Coperion

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Processing Conditions

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Economic Model

Raw material costs dominate expenses (68%). Resinrepresents 60% of total raw material cost.Labor is the 2’nd largest component of expense, butdecreases in importance as extruder D increasesProfitability depends on formula cost and efficientoperation (high utilization, low scrap rate)Higher D (higher capacity) extruder is more economicalbecause of reduced laborexpense per unit of product produced. Capital cost per unit of production is also somewhat lower for higher D

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To Composite Lumber Products

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Profiles in Pallets

Song, 2007

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Marine Applications

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Profile made of Sisal, Wood and Polypropylene

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Profiles made of WPC (wood, rice husk, coir, etc…

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Door Frames Profile

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Pellet Extrusion vs. Profile ExtrusionADVANTAGES

Pre-drying is not required to reach high rates for pellet processSome residual moisture is tolerable in pellet processSome decomposition of fiber is tolerable in pellet processFiber mixing is less critical than with directprofile extrusion (2'nd melt history)

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Direct Profile Extrusion: Solids, Hollows, Sheet

ADVANTAGESLower capital costLower operating costs (1 heat history, less labor)Separates primary feeding/melting/drying/mixingprocess from profile formationLess inventory of raw materials

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Direct Profile Extrusion: Solids, Hollows, Sheet

DISADVANTAGESFiber drying for highest rate –capital/operating costs offset equipmentsavingsMinimal fiber decomposition is tolerable,

especially for solid profilesComplicated process – melting, drying,

mixing and profile formation (lessthrougput)

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Pellet Extrusion vs. Profile ExtrusionDISADVANTAGES

Higher capital cost for pellet and profileequipment vs. direct profileHigher operating costs (labor, maintenance, energy, etc.)Pellets must have low initial moisture andcannot be allowed to absorb moisture from theenvironmentMore inventory in the event of quality problemin raw materials or pellets

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Natural Fiber Compounding

1 2 3

Polymer

ZSK Twin Screw

Water

To PelletCooling

4 5 86 8 97

Pelletizer

Wood orNatural Fiber

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Typical Formulations

Material Content

Natural Fibers (4- 8+%) (moisture <7%)

40-80 wt %

Polymer 20-55%

Stabilizers and Additives(secret)

1-2%

Colorants 1-2%

Powder or pellets

Foaming Agents ?

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Additives Developments

Tailor-made lubricantsNon stearate & compatibilizer packageSpecial HALS (FRT)Antimicrobials (Smelling and Odor)Blowing agents (Foamng)Anti smelling agents/treatmentsSurface hardness and impact resistanceLubricants

Rangaprasad, 2003, modified

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FPC Composition (UNESP)

Output – 70 kg/hWood Fiber. 65 and 80%PP: 33 and 28%Coupling agentUV StabiliserLubricantsFire RetardantsProcessing Agents

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Hardwood Residues Profiles Properties

Tensile – ISO 527-2: 1993Flexural – ISO 178:2005Impact Resistance (Charpy) – ISO 179-1: 2000

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Mechanical Properties SummaryProperty Unit Values

Charpy kJ/m2 2.09 – 4.56

Flexural Ef MPa 2943 – 4168

Flexural Strength MPa 18.23 – 46,31

Tensile Et MPa 2030 – 3819

Tensile Strength MPa 6.28 – 21.80

Shore D 72 – 78

Density g/cm3 0.906 – 1.020

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E-LFT

Gravimetric feeder

MEGAcompounder ZSK 58

DevolatilizationSisalRovings

1 2 3

MM

4 5 6 7

Polishing roll stack with roller conveyer

Belt-type take-off

Polymer

Backing film

LFRT –Long Fiber Reinforced Thermoplastics

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The Future in Brazil Partnership between

Fiber Plastics Composites

FIBERTECH ™ 50, 60 and 70

FLEXWOOD ™

diretoria@ plastitech.com.br

(xx14) 3814 5200

Caixa Postal 69 – Botucatu, SP

Plastitech Suzano Petroquímica

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PlastitechCompounder company(Coperion machinery)FPC as masterbatchNatural fibers as reinforcementagentsMatrix: PP, HDPE, PS and ABSAdditives: Fire retardant; compatibilizers, UV filters

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Important Reminders

Operational excellence is a necessity because of raw material costs and inelasticity of product priceFind low-cost formulations that work well beforetightening building codes make changes difficultand expensiveDetermine what the consumers want and sell itWood competition in Brazil is very hardInvestment in machinery (twin screw vs singlescrew)

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The Future

The future of the materials based on FPC depend on many factors, such as:

1. Identification of new products;2. Quality of the products;3. Consumers perception;4. Performance of the products; and5. Identification with innovation

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“There is no Substitute for Quality”

Our Principles

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Curauá Fabrics Fashion Show at ISNAPol 2000

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Life is pretty simple:You do some stuff. Most Fails. Some Works. You do more what works. If it works big, others quickly copy it.Then you do

something else. The trick is the doing something else

Leonardo da Vinci

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ACKNOWLEDGMENTSCNPq – National Council for Research – BrazilFAPESP – São Paulo Research Support AgencyPlastitech Indústria e Comércio Ltda –www.plastitech.com.br