Progress 07/01/01 to 06/30/07
Outputs
No accomplishments since 2006 report due to retirement of principal investigator.
Impacts
No accomplishments since 2006 report due to retirement of principal investigator.
Publications
- No publications reported this period
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Progress 01/01/06 to 12/31/06
Outputs
A pilot plant for processing flax straw into fibers was established and tested using a diverse set of samples. The USDA Flax Fiber Pilot Plant (Flax-PP), which is the only research facility of this type in the US, was designed according to the commercial Unified Line (Czech Flax Machinery) but smaller and in four individual modules. The modules and order for processing were as follows: 9-roller calender, top shaker, scutching wheel, top shaker, 5-roller calender, and top shaker. The enzyme retting portion of the pilot plant consist of two chambers. The first is temperature and humidity controlled by steam injection. The second chamber is a electrically heated for drying the finished product. Flax straw has been processed through all parts on the pilot plant. Unretted Neche linseed flax, dew-retted Natasja, and enzyme-retted Jordan fiber flax were processed, and the cumulative weight loss of material at successive processing steps was determined to judge the
effectiveness of cleaning. Fiber strength, fineness, and elongation were determined for the retted samples after cleaning through all steps in the Flax-PP. Enzyme retted fibers compare very well to the industry standard of dew retting. Current research will determine the economics of enzyme retting.
Impacts
The pilot plant has been used by two companies to determine fiber quality and yield. Based upon these results one company is exploring the possibility of starting a new venture into fiber production for composites.
Publications
- No publications reported this period
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Progress 01/01/05 to 12/31/05
Outputs
Specific progress for this time period is as follows: 1. the secondary cleaning stage of the pilot plant was initiated, with placement of blenders and cards and connection of duct work and electrical hook-up, 2. controlled environmental chambers were outfitted with a spraying system for pilot plant enzyme-retted (work continues on this part, 3. drying apparatus was developed for small sized samples for testing multiple formulations. 4. assistance was provided in obtaining linseed straw for tests. With the development of the USDA Flax Fiber Pilot Plant, the secondary stage for cottonizing flax fibers is being researched and put in place. Cottonizing of flax is needed to refine and shorten fibers for blending with cotton in staple spinning systems or to supply high-quality fibers for selective non-woven and composite products. The implementation of this stage will provide for a diverse range of fibers for applications in all fiber-requiring industries. Specifically,
equipment has been acquired that will refine fiber that is first cleaned by the four modules that mimic a commercial scutching system. Work is on-going to integrate both cleaning systems. Further, the expertise at Clemson University has been used to grow flax, harvest, and store flax under specific conditions to relate cultural and agronomic conditions to fiber quality and use.
Impacts
Development of flax fiber as a replacement for glass fiber in composites has a tremendous future. Not only would it be a new crop for growers and a new revenue source, it is good for the environment. When standards are established, marketing of the flax fiber will be based upon science. Trading can be accomplished with a high level of confidence in the fiber quality.
Publications
- No publications reported this period
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Progress 01/01/04 to 12/31/04
Outputs
A pilot scale enzyme retting system has been installed. The system will allow for processing of 1 kg samples of straw. The system consist of spray chamber, environmental chamber and drying chamber. Scale-up from laboratory size samples 1 kg samples to confirm the effects of enzyme type, concentration, retting time and retting temperature will be possible. A line of textile equipment has been added to cottonize the material for textile applications. The modules in the line include a opener/blender, cleaning section, even feeding section, long fiber capable card. The line can produce a matt for non-woven application or a sliver for spinning purposes. Approximately one hectare of flax was planted at the Pee Dee Research and Education Center to have material to process at the flax pilot plant. Three varieties, Hermes, Omega and York were used in equal size plots. Work continues with ASTM on developing flax fiber standards. A standard for terminology, color and fineness
are listed in ASTM publications. A standard for trash(shive) content has been approved and will be listed soon.
Impacts
Development of flax fiber as a replacement for glass fiber in composites has a tremendous future. Not only would it be a new crop for growers and a new revenue source, it is good for the environment. When standards are established, marketing of the flax fiber will be based upon science. Trading can be accomplished with a high level of confidence in the fiber quality.
Publications
- Akin, D. E. et al, 2004, Progress in Enzyme-Retting of Flax, Journal of Natural Fibers, Vol. 1(1) 2004, pp21-47
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Progress 01/01/03 to 12/31/03
Outputs
The flax pilot plant continues to take shape. Four modules have been installed in the straw processing line. The four modules consist of a nine roller crushing set, a top shaker, a five-roller calendar assembly and a scutching heel. All are equipped with variable speed drive for research purpose. This equipment will take straw, which is approximately 30% fiber, and produce a product that is more than 90% fiber. This material will be further clean into for specialized end uses. Material from this line and the flax facility in Kingstree, SC are currently in testing for composites application in both the United States and Europe. To gain acceptance of natural fiber, Clemson and USDA is working with ASTM to develop standards for measuring fiber properties. Standard Terminology Relating to Flax and Linen, ASTM International designation D- 6798-02 and Standard Test Method for Color Measurement of Flax Fiber (D- 6961-03) have been accepted and are listed as official
standards.
Impacts
Development of flax fiber as a replacement for glass fiber in composites has a tremendous future. Not only would it be a new crop for growers and a new revenue source, it is good for the environment. When standards are established, marketing of the flax fiber will be based upon science. Trading can be accomplished with a high level of confidence in the fiber quality.
Publications
- Foulk, J., Akin, D., Dodd, R. 2003. Fiber flax farming practices in the southeastern United States. Online. Crop Management doi:10.1094/CM-2003-0124-01-MG. 2003
- Akin D., Henriksson G., Evans J., Adamsen A., Foulk J., Dodd R. 2004. Progress in Enzyme-Retting of Flax. Journal of Natural Fibers,1(1). (Accepted 6/9/2003). 2003.
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Progress 01/01/02 to 12/31/02
Outputs
The equipment for the pilot line at Clemson was delivered and installed. The equipment was manufactured by the same company that made the commercial processing equipment at Eastern Flax, Inc. in Kingstree, South Carolina. The pilot plant has separate modules, a nine-calendar roller assembly, five-grooved rollers assembly, a scutching wheel and upper shaker. The modules are arranged such that material can be feed through each module separately. The fiber is kept separate from the trash at each module, which allows for precise calculations of cleaning efficiencies. If desired, the process can be repeated or the material moved to the next module. Addition of these components will allow work to go forward in establishing specific levels of components for enzyme retting toward development of a commercial method and also support an emerging flax processing plant in Kingstree, SC. Since the equipment is same, only smaller in width, the results from the pilot plant should
correlate well to material processed on the commercial line. The pilot plant can be used to optimize the machine setting for the commercial operations. In addition the pilot plant will be helpful in the establishment of quality standards for flax fiber. With the pilot plant, controlled lots for fineness and trash can be established and measured. Samples processed through the pilot line have been processed and the fiber is waiting to be tested for fiber quality. Harvesting of the 2002-2003 crop was accomplished with little difficulty. No seed harvest was attempted because of poor crop conditions due to dry weather. A small acreage was planted in December of 2002 to investigate extending the planting time in the fall. The results are encouraging at this point. The facility at Kingstree is operational, but production has not become as contracts for the fiber are still in negotiation.
Impacts
Flax fiber has the potential to replace glass fibers in a wide number of applications. The automotive industry in Europe has taken the lead in using natural fibers such as flax and kenaf to manufacture automotive components such as door liners and interior trim. The advantages have been weight saving, better crash safety and lower life cycle cost. The major disadvantage of natural fibers has been inconsistent quality. With enzyme retting, this problem will be eliminated. The pilot plant at Clemson is a very important part of optimizing the enzyme retting process and making enzyme retting a commercial viable process. A domestic production of high quality flax fiber will be a boost to both the agricultural and manufacturing sectors. For southern agriculture, it will be new winter crop, which will increase the profitability for the agribusiness. With the rapidly developing automotive industry in the southeastern US, it will mean a supply of high quality natural fiber
close to the manufacturing sites. For the US textile industry, the new fiber production will supply it with a fiber for niche manufacturing that is not available anywhere else in the world. All of this means start-up of new companies and additional jobs in both the rural and urban areas.
Publications
- No publications reported this period
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Progress 01/01/01 to 12/31/01
Outputs
Based upon the years of research and outreach at Clemson University, Eastern Flax SC, LLC is installing a flax processing facility at Kingstree, SC. The processing line has been installed and preliminary operation has begun. The output from the plant will be short staple fiber for use in the textile, composites and paper industry. Value-added uses such animal bedding is being investigated for the flax shive. The equipment for the pilot scale line at Clemson was delivered from the Czech Republic. Installation will begin soon. This line has the same type of equipment as the facility at Kingstree. The pilot equipment is smaller in width. The pilot line will first be used to determine the optimum formulation for the enzyme mixture for retting. Since the final quality of the finished fiber is a combination of retting and mechanical processing, a commercial type processing equipment must be used. Approximately 300 acres were planted in the fall of 2002 for a spring 2003
harvest. It is anticipated that approximately 1500 acres will be planted in the fall of 2003. Four varieties were planted in the fall of 2002 at the Pee Dee Research and Education Center. The parameters to be studied are yield, cold weather tolerance and disease resistance.
Impacts
The flax processing facility locating in Kingstree, Sc will have very positive effect on the area. It will mean new jobs in a rural area that has high unemployment. The growers in the area will have a new winter crop in their rotation. It will add jobs in the infrastructure of such as mechanical/electrical contractors, freight haulers and personnel services. The pilot plant will allow enzyme mixtures to be evaluate. This will assist the biotechnology effort to formulate the optimum enzyme mixture and produce it on an economical scale.
Publications
- No publications reported this period
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