Innovative applications of

biopolymersbiopolymers

Dirk De Saedeleir

Chief R&D Officer

Alain Goossens

Fibre Unit Manager

♦Sustainable entrepreneurship:

family owned companies have an embedded long term vision

♦ Social importance with following keystones:

Mutual respect

Flat structure

Real improvements through teamwork

a family owned company

DS GROUP

Good foundation for R&D

Real improvements through teamwork

Customer minded structure

♦ Focus on three product groups:

Fibres &Yarns

Technical non woven

Carpets

♦ DS Fibres is market leader in dope

dyed polyester fibre

♦ Sommer needlepunch is market leader

in event carpets

a niche player

DS GROUP

in event carpets

♦ Work force of 350 people

♦ Turnover of +80 million euros

♦ Located in Dendermonde(B) and Baisieux(F)

Challenges for innovative fibre producers

♦ Ensure a continuing economic growth

♦ Wealth creation for an increasing group of people

♦ Alternatives, replacing the limited Fossil energy sources ♦ Alternatives, replacing the limited Fossil energy sources

♦ Environmental responsibility: controled waste management, energy savings, CO2 emissions (Kyoto)

♦ Increasing awareness of consumer and industry. Change of attitude.

Different depletion scenarios

source: www.trendlines.ca

What is future bringing us?

Mutual long term goal

waste

2000

1950

Oil

Oil

No oil

No waste

No waste2007

2000

Biocolor PLA

Biocolor

DS OFFERS SOLUTIONS

Biopolymers

♦ An answer for the environmental issues

♦ Reducing waste through :

BIOCOLOR®

(Polyolefins)

100% recycable carpet

BIOCOLOR ® PLA (patent pending)

(Poly Lactic Acid)

99% Biodegradable carpet (EN 13432)

Overview of biopolymers

♦Starch Polymers

♦♦♦♦ Polylactic acid (PLA)

♦♦♦♦ Polytrimethyleneterephtalate

(PTT)(PTT)

♦♦♦♦ Polybutyleneterephtalate

(PBT)

♦♦♦♦ Polybutylene succinate (PBS)

♦♦♦♦ Polyhydroxyalkanoates

(PHA’s)

What is PLA ?

A polymer made from lactic acid

- Lactic acid is a natural product which is found in the body,yogurt

and many foods

Lactic acid Is made from fermentable sugars

- sugars are found in plants - sugars are found in plants

Sugars are made from CO2

via Photosynthesis

- Photosynthesis involves carbon

Where it comes from

sugar fermentation

monomerproduction

lactic acid

lactide

polymerproduction

lactide

PLApolymer

conversion

Resin

Fibres

Reducing energy consumption :

Fossil Energy use (FEU) From cradle to pellet [MJ/kg polymer]

142

120 117

92 9387100

120

140

160Source : Natureworks PLA

8781 79 77 77

54

7

0

20

40

60

80

100

Nylon 66 Nylon 6 PC HIPS Cel lophane GPPS LDPE PET SSP PP PET AM PLA 1 PLA Bio/ WP

Reducing CO2-emmisions

Global warmingCradle to pellets [kg CO2 eq./ kg polymer]

PLA versus Traditional Polymers (APME)

7.68.1

6.4

8.0

10.0Source : Natureworks PLA

5.3

2.9

6.4

2.72.1

3.3

2.0

3.2

1.8

-1.7-2.0

0.0

2.0

4.0

6.0

Nylon 66 Nylon 6 PC HIPS Cel lophane* GPPS LDPE PET SSP PP PET AM PLA PLA B/ WP

Fibre Characteristics

PA 6 PET PP PLASpecific

Gravity

(g/cm3)

1.14 1.39 0.91 1.25

Tm (C°) 220 265 - 275 165 - 175 120 – 175*

Tenacity

(cN/dtex)

4.10 – 7.90 2.50 – 5.40 2.00 – 5.50 2.00 – 3.20

(cN/dtex)

Elongation

(%)

45 - 85 40 - 80 100 - 200 40 - 80

LOI 20 -24 20 - 22 18 -19 26+

UV resistance Poor Fair Poor Excellent

Moisture

regain

1.9 – 9.5 0.10 – 0.50 0 0.4 – 0.6

Life cycle

Biodegradability

Under ground PLA yarn

(55dtex/124)

2

years

50% tenacity loss

Weather-o-meter PLA staple fibre

PET staple fibre

500h 5% tenacity loss

40% tenacity loss

Aerobe PLA fleece 45 79% biodegradationAerobe

composting

PLA fleece

(25g/cm2)

45

days

79% biodegradation

Anaerobe

composting

PLA fleece

(25g/m2)

45

days

92% biodegradation

Further tests will be performed.

Source : ITA Fiber tables

Next steps

♦ Re-styling of colorants is needed ?

♦ End of life by recycling (break down to chemical structure)?

Composting ?

♦ Waste management for PLA products is to be developed

♦ Policies & measures needed for sustainable growth

End uses

♦(Event) carpets

♦ Entrance mats

♦ Artificial grass

♦ Fibrefill♦ Fibrefill

♦ Agro & Geo-textiles

♦ Automotive

♦ Matrass Ticking

♦ ….

Broad textile applications

Carpets…….

Automotive

Technical

ApparelFibres

Hygiene

Household

Conclusion

♦ Biopolymers are sustainable and give a future to our textile

industry

♦ Alliances are needed with complementary economic sectors.

♦ Biopolymers meets the increased awareness of citizens to

guarantee future for our children.

♦ Interaction with governemental bodies for regulations and

policies

FOTO MARKETINGFOTO MARKETING

Soon …under your feet!