Progress 09/01/08 to 08/31/11
Outputs
OUTPUTS: Phase II began in September 2008 with securing right-scaled equipment for processing prototype recycled plastic pellets. PD rejected large, expensive, unwarrantied reconditioned granulators and pellet mills and opted instead for a smaller new Cumberland granulator and Colorado Pellet Mill 30 HP ECO-R30 mill, the latter substantially discounted for having been a lightly used floor model. Equipment shipped to Big Island from Chicago and Denver. Warehouse sublet arranged in Hilo, to serve both for production and as storage space during growth trials. Custom electrical box built by local electrician Jim Anderson. Recycled plastic feedstock (various types of post-use polyfilm and expanded polystyrene [EPS] from packaging) collected from multiple sources. Technical consultant Sergio Firpo arrived on Big Island in April 2009 to train project principals in equipment operation and recycled plastic pellet making. PD introduced to foam insulation material and decides to incorporate it into trial along with locally sourced composted mulch from OrganaGrow (OG). Primary growth trial initiated in June 2009 using four orchid genera (odontocidium [odcdm], miltoniopsis [milt.], sophrolaelaicattleya [slc], and maudiae paphiopedilum [paph]), 4 controls (New Zealand nitrogen-fixed Orchiata [NZ]; volcanic cinders; NZ+cinders; and coconut husk chips[coir]), 4 stand-alone experimental treatments (polyethylene film pellets [PEPels]; PEPels containing compost content [compels]; chopped insulation foam [IF]; and OG), and 8 50:50 mixtures (NZ+PEPels, coir+ground EPS foam [F], coir+F+F ["fluff" or ground polyfilm], cinder+EPS, cinder+compels, OG+IF, OG+PEPels, OG+EPS+F). Growth trial assessed and photodocumented at one year. Secondary trial initiated by Dr. Bill Sakai, science consultant, at University of Hawaii, Hilo, using 25 different oncidiinae clones, one control (50:50 peat moss+Perlite) and 3 experimental 50:50 treatments (NZ+PEPels, EPS+peat, IF+peat). In May 2010, tertiary trial set up with two oncidinae clones, one control (NZ) and four test mixes (NZ+EPS, NZ+IF, coir+PEPels, and coir+IF). One-year no-cost extention obtained in 08/2010 in order to assess bloom cycles in primary trial and allow tertiary trial a year to grow. Borrowed gas-powered wood chipper/ shredder used to make larger chunks than possible using granulator from block EPS and slabs of IF. It works. Field tests at project nursery ongoing. Assessments made of three trials, including photodocumentation of primary and tertiary trials. Assessment critera are as follows: number of bulbs, size of bulbs, rootedness, number of spikes, number of blooms/buds, size of new growth, and overall impression. Remarks as indicated made concerning overall vigor, color and anomalies such a leaf spotting or aborted spike. PARTICIPANTS: Dr. William Sakai, professor of tropical horticulture at University of Hawaii, Hilo, plant science consultant for project. Sergio Firpo and Clark Adams, principals in Azure Technologies, Inc, Oak Park, IL, engineers specializing in the design of plastic recycling systems. Jim Anderson, Naalehu, Hawaii, master electrician who built the electrical board for the equipment and proved adept at troubleshooting equipment vagaries. Linda Peters, Recycling Coordinator for the County of Hawaii and advocate for the project. Ken Armour, owner of the Orchidworks, Hakalau, Hawaii, who donated large quantities of EPS packing material. Elin Kalaniopio, waste diversion compliance officer for Quality Builders, Kamuela, HI, who provided post-use plastic film and foam insulation tailings. Hilo Orchid Farm, Mountain View, Hawaii, source of odcdm. and paph. trial plants. Harry Lui, Kamuela, Hawaii, who loaned his shredder/chipper for successful experimental chopping of EPS and IF. "Mr K.'s Recycling," Hilo, which set aside and transported post-use polyfilm and EPS to the production site. Dianne Tana, Temecula, CA, who approved an ad hoc but durable month-to-month warehouse sub-lease arrangement. Bob Burkey, the PD's partner, who kept the trial plants watered and fertilized despite health and occasional equipment challenges. Keely Burkey, college student, who applied her organizational skills to growth trial set-up. The project provided an opportunity for training and professional development to Dr. Sakai's Horticulture 301 class, Orchid Culture. His students set up, monitored and assessed the secondary growth trail in Hilo, thereby gaining practical experience in orchid growing as well as hands-on science. TARGET AUDIENCES: Primary target audience for efforts is commerical orchid growers, first on Hawaii Island, then in the state of Hawaii, and ultimately in areas of the U.S. mainland where production of orchids and possibly other potted ornamentals is concentrated, e.g., Salinas and Santa Barbara, California. A secondary target audience would be frustrated "greenies" in these communities who wish to but are unable to recycle post-use EPS packing material and polyfilm. The idea behind the concept is to keep the collecting and processing of Recycled Plastic Media (RPM) as regional as possible. PROJECT MODIFICATIONS: The Phase II proposal budgeted for developing a device that would slice polyfilm into strips. The PD was ultimately convinced this concept wasn't feasible and the funds were spent instead on equipment -- a blower, ducts, and a cyclone separator -- that allowed granulator and pellet mill to be connected into a unified system. This proved to be a significant efficiency. A second major change was prompted by the desire to discover a locally sourced organic substrate and to develop an all-local, patentable hybrid pellet containing plastic and buffering organic material. Thus the PD elected to trial composted mulch from the local greenwaste processor, OganaGrow. Though it looked ideal -- combining right-sized chunks and fibers -- this material took down a disproportionate number of trial plants, possibly because it harbored residual herbicides. Unfortunately, OG was used in five sample treatments in the growth trials and was a constituent in the compels, which in most cases underperformed, the exception being Slcs which thrived in them. Some OG+synthetic mixtures worked well over time, but downside risks are too great to pursue this material. This disappointment partially compelled the tertiary trial. Another major change was felicitious. This was the incorporation of IF into the growth trials. This material was unknown to the PD until shortly before the growth trials began. It was suggested by a post-use polyfilm supplier, Elin Kalaniopio, who, as compliance officer on a platinum-LEEDS construction project, was charged with diverting as much construction material as possible from the landfill. Tailings of the IF turned out to be superabundant and a very appealing and promising non-degradable material.
Impacts
Extensive trial and error involved in making solid yet fluffy pellets from mixed types of post-use PE film, but good results finally achieved when baselines for die rotation rate, feed rate and die temperature are determined. Attempt to incorporate peat moss into pellets fails when moss proves too absorbent and pellets break apart in water. Less absorbent organic fibers tried next in combination with ground PE film and "hybrid" compels are born. Attempts to add ground EPS to pellets fail when plastic "meltdown" occurs in die. Growth trials see high attrition among milts and paphs which become stressed when shading trees on neighboring property are felled, creating hotter, brighter conditions. But some survive in certain mixes, producing commercially significant results for some experimental treatments. Odontocidiums and Slcs fared much better overall, with several experimental treatments appearing to promote superior rooting and overall performance equal to or better than controls. Two controls, coir and cinders, are especially prone to uneven results. But the least effective stand-alone medium is OG, which kills all milts and paphs and more odcdms and slcs than do other treatments. However, mixed with certain synthetics, OG becomes a viable, even superior, substrate constituent with odcdm and slc. The U.H. Hilo trial gets equivalent favorable results with control (which also proves most lethal) and peat with EPS. NZ+PEPellets underperforms, producing worse results than did the same combination at the project nursery trial. In the tertiary trial, the signal finding is near-universal lethality with the NZ control. Certain mixtures produce above average blooming, and one variety exhibitd branched spikes when normally its spikes are unbranched -- a very encouraging result. Trial outcomes point to near-term commercialization of one recycled plastic form, and ways to effectively refine others. Lab analysis of leaf tissue and certain synthetic+organic combinations will be conducted. Overall, outcome of project achieved goal of showing that a cost-cutting, clean, durable plastic growth media amendment can be produced locally, thereby keeping grower dollars in the local community, providing employment opportunities, productively diverting trash from the landfill, reducing risk of environmental harm by waste plastics, and shrinking the carbon footprint made by growth media options imported from the U.S. mainland and distant foreign countries.
Publications
- "Plastic Ocean: How a Sea Captain's Chance Discovery Launched a Determined Quest to Save the Oceans," Charles Moore with Cassandra Phillips (PD), Avery/Penguin, October 2011. This is a "popular science" book that resulted from a connection made at a project-related Zero Waste meeting. It supports the intentions of the project by advocating, among other things, responsible, productive re-use of waste plastics. Moore is a well-known researcher and activist who discovered the Great Pacific Garbage Patch.
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Progress 09/01/09 to 08/31/10
Outputs
OUTPUTS: Outputs during the period between August 2009 and August 2010 were as follows: Fall 2009: Provided the following materials to Dr. William Sakai for a secondary growth trial to be conducted by an advanced tropical horticulture class at U.H. Hilo: 3 cu.ft. each of recycled mixed-source polyethylene film, pelletized (PEPels); granulated post-use expanded polystyrene packing material (EPS); and tailings of soy-based foam insulation(soy). December 2009: Assessed growth trial at six months. Results entered into Excel spreadsheet. Winter: re-upped lease agreement with Hilo warehouse manager and checked on equipment and supplies stored there. May 2010: Set up tertiary trial with a Orchiata (NZ)control and four new 50:50 organic/plastic mixtures: NZ + soy, NZ + granulated EPS, coir + soy, and coir + PEPels, using (16 each) Oda. Nettie Valentine and Odontonia Bravura. July 2010: Performed one-year assesesment of growth trial using five point grading system. Results entered into Excel spread sheet. Photo-documented each plant. Determined that a one year no cost extension warranted to allow for assessment of bloom cycle. Developed book proposal about plastic pollution -- the fate of waste plastics when they're not properly managed -- with Charles Moore, a noted plastics researcher who attended the local Zero Waste meeting in September 2008. PARTICIPANTS: Dr. William Sakai, professor of tropical horticulture at University of Hawaii, Hilo, and students in his Hort. 360 class, Orchid Culture. They ran a secondary growth trial at sea level conditions to determine if organic:synthetic combinations perform differently in a climate warmer than that at the project nursery, located at 2700 feet. Robert Burkey, horticultural associate and co-owner of project nursery, Kamuela Greenhouse/Specialty Orchids LLC. Charles Moore, plastics researcher, advocate for responsible handling of post-use plastics, co-author of book with PD that came about as a result of PD's project-related activities. TARGET AUDIENCES: Dr. Sakai's horticulture students, who were learning to conduct scientific growth trials with the project's sample media amendments. Commercial orchid grower colleagues who visited the nursery to observe progress of the growth trials. There has been keen interest in the project among local orchid producers. PROJECT MODIFICATIONS: The tertiary trial that was set up in May 2010 came about as a result of underperformance of a key element of the primary trial: OrganaGrow composted chips and fibers. An objective of the PD was to develop an all local organic:synthetic growth medium for orchids that would reduce the need to import materials from the U.S. mainland and foreign countries. Very mixed results (some impressive and encouraging, but too many disappointing) led to the decision to test new combinations of organics and synthetics (noted above) that were not part of the primary trial. The concept was to try mixtures that the typical commercial orchid grower would readily adopt and that would be likely to cut growing costs and produce cultivation results equal to or better than those obtained with standard imported media.
Impacts
Determined that with planning and coordination, there will be sufficient EPS feedstock to supply projected demand for granulated EPS as a 50:50 orchid growth media amendment. Determined that locally sourced composted OganaGrow chunks and fibers, the basis of several primary growth trial treatments, was not effective enough to form the basis of an all local organic:synthetic orchid growth medium. In light of this determination, initiated tertiary trial with new organic:syntehtic combinations noted above. Observed that PEPels appear to enhance root growth but in some cases reduce the size of vegetative growth. Observed that a combination of PE film flakes and granulated EPS with coir produces a superior miltoniopsis plant. Indeed, in a genus that displayed high attrition in the growth trial, these plants grew and bloomed vigorously. Noted that paphiopedilums struggled in most media, but grew best in those with a plastic additive. Observed a seeming synergistic effect between two treatments that underperformed as stand-alones, soy and OG, when they were combined. Together they produced among the best results in two genera, odontocidium and sophrolaeliacattleya (mini-catt.). Book proposal bought by Avery, a Penguin imprint, in August 2009.
Publications
- No publications reported this period
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Progress 09/01/08 to 08/31/09
Outputs
OUTPUTS: In consultation with Sergio Firpo of Azure Technologies, Oak Park, IL, equipment with which to fabricate experimental pellets was ordered from Cumberland Industries (plastics granulator) and Colorado Pellet Mill (a pellet mill)in Fall 2008. A sublease arrangement was made for warehouse space in Hilo. Equipment arrived from the mainland in February 2009. A local electrician installed and created a control system for the equipment. In April, Firpo flew to the Big Island to train Kamuela Greenhouse personnel on the equipment and assist with experimental pellet fabrication. After much trial and error, we successfully made pellets from ground recycled polyfilm from various sources, and also made pellets incorporating organic material--local compost. Several hundred pounds of pellets were produced using different proportions of pallet wrap, recycled shopping bags, and greenhouse film. We granulated Styrofoam. The samples were brought back to the project's home nursery and growth trials commenced using four "shifter"-size groups of commonly cultivated commercial orchid varieties: Colmanara, Miltoniopsis, Paphiopedilum, and Miniature Cattleya. One objective of the project has been to create a product whose ingredients are all locally sourced. Prior to making the pellets, the PD contacted a local green waste composter with the intention of learning if his product would be compatible with orchids and the pellets. Some had characteristics -- small chunks and fibers -- that seemed suitable. Also, a local contractor had been engaged to make a "green" science building for a nearby school and used a soy-based foam to insulate. There wound up being much excess of this material, which resembles horticultural Oasis, so we took it to shred and include in the trials, hoping the soy content might prove estrogenic, ergo growth-promoting. Indeed, the serendipitous finding from Phase I was that some plastic types enhance orchid growth while others stunt. The growth trial includes 12 blocks containing 14 substrate options for each orchid variety, including four controls: Orchidata fixed nitrogen bark from NZ, medium coir chunks from Sri Lanka, local volcanic cinder, and half-half NZ bark and cinder, an increasingly popular combination among commercial growers. The experimental substrates are.... stand-alone: PE pellets, (PE + compost) pellets, locally sourced compost, soy foam chunks (topped with cinder)AND 50-50 combinations of the following: cinder + ground Styrofoam, coir + ground Styro, NZ bark + PE pellets, coir + ground PE + ground Styro, local compost + ground PE + ground Styro, cinder + (PE+compost)pellets, and, finally, soy foam + local compost. A parallel trial in Hilo, with a different set of oncidiinae orchids in a warmer climate, is a class project initiated by our science adviser, Dr. William Sakai. They're testing PE pellets, ground Styro and soy foam with 20% cinder, NZ bark and coir. The combinations are a focus because growers are unlikely to risk straight plastic substrate with their commercial crops. Indeed, growing protocols do have to change with stand-alone plastics, especially as regards fertilization. PARTICIPANTS: Sergio Firpo and Clark Adams of Azure Technologies provided indispensable consulting services regarding equipment acquisition, installation, and operation. James Anderson, a local electrician, proved a great asset by building the electrical control box and installing the equipment, and trouble-shooting in the early days of operating the system. A number of entitiies have set aside post-use plastic film and other usable recycled plastic materials: Mr. K's Recycling in Hilo, The Orchidworks, Quality Builders, and DHS Trucking. Keely Burkey, a college student, assisted ably with documentation of the trial plants and will be helping later with assessments. This could be considered training. The project's horticultural associate, Bob Burkey, has irrigated and fertilized the growth trial plants. Dr. William Sakai, a University of Hawaii, Hilo, horticulture professor, assisted with the trial protocol and is also heading up the Hilo trials. His 20 students are learning methodology from setting up and conducting the trial. Patty Moore of Moore Recycling in Sonoma, Calif., a plastics recycling activist, is tracking the progress of the project, as is staff in the Hawaii County Environmental Management Department. A number of local orchid growers are eager to try the new product, and several mainland growers have also expressed interest. TARGET AUDIENCES: As noted above, a number of commercial orchid growers await the results of the trials and are eager to try the new product, which is designed to cut planting media costs and boost performance. And the research and recycling communities are also engaged. PROJECT MODIFICATIONS: With the goal of testing a variety of locally sourced alternatives to expensive, organic imported planting media, we have included the soy-based insulation foam (an organic polyurethane) and local compost in the growth trials. These were not part of the proposal's work plan.
Impacts
Growth trials, initiated in June/July 2009, at this point have only yielded preliminary results. Thus it is too early to say what the outcome/impact will be.
Publications
- No publications reported this period
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