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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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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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

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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)

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BWpp

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Weight Trend of A4 Tandem Engine

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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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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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