Progress 04/14/01 to 06/03/04
Outputs
1. What major problem or issue is being resolved and how are you resolving it (summarize project aims and objectives)? How serious is the problem? What does it matter? The U.S. is the largest per capita user of linen, but no flax is grown commercially for fiber by U.S. farmers and linen is not produced in this country. The NPS determined that research should be carried out towards the development of a U.S. flax/linen industry to supply high and consistent quality fibers to textiles and other fiber-using industries, especially those using natural fibers for reinforced composites. Two major technical problems impeding development of such industries are the lack of new retting methods to extract fiber from stems for clean and consistent quality fibers, and lack of standards to judge processing and fiber quality. To address these problems, research is being conducted on an enzymatic retting method to replace the current method of dew-retting, which depends upon
indigenous microorganisms and field conditions. For standards, research is being conducted, often with collaborators at the University of Georgia, at Clemson University, and the Cotton Quality Research Station, ARS-USDA, Clemson, SC, on fiber color, fineness, strength, length, and trash (nonfiber) content. Fundamental studies on structure and chemistry are undertaken to gain insight into problems of fiber extraction and fiber characterization. Results are then applied toward industry needs in textiles, composites, or paper/pulp industries. 2. List the milestones (indicators of progress) from your Project Plan. Milestones of project: 1. Complete Flax Pilot Plant for processing retted flax. 2. Ret new samples of fiber and seed flax. Establish recommended enzyme/chelator formulations and retting conditions. 3. Test textile and composite products with enzyme retted flax. 4. Test with specific enzymes for effectiveness of retting. 5. Analyze samples with microspectroscopic methods and
chemical analysis. 6. Report potential of specific enzyme mixtures. 7. Send color and terminology standards to subcommittee ballots. 8. Address ballot reports. Develop fineness standard. Begin work for length standard. 9. Develop length standard. Address ballot report for trash. Report standards accepted by ASTM. 10. Test on-line sensors in pilot plant. Test on-line sensors in commercial plants. 3. Milestones: A. This is a final report, so many of the milestones have been reached but a few were not; some have been modified as progress occurred. Milestones reached from Question 2 above include: # 1, 2, 3, 4, 5, 6, 7, 8 (partial),9 (partial). The milestones that were not fully reached are # 8-9 and relate to a length standard. This standard was moved in priority because of the difficulty in finding suitable methods or equipment and in the lack of priority for the potential applications. Currently, the priority is in developing a strength standard. Methods are being evaluated,
however, in conjunction with collaborators to determine the feasibility of a length method for future applications. Milestone # 10 was not met because work is continuing on developing the sensors. This topic is still a matter of interest and work is progressing with ARS collaborators in developing improved sensors. Work will continue toward use of sensors and their position on the pilot plant and commercial lines in the future. B. Work for 2004 was to address the milestones for standards development (Question 2 above, #8-9), as listed in the 2003 annual report. This work is continuing as documents, ballots, and reviews take place in conjunction with the ASTM International schedule. Specifically, in 2005, the reviews of the trash standard will be addressed. In 2005-2006, a new standard for strength will be researched and documented in collaboration with other laboratories. Related to Question 2 above, #10, in 2005-2007 new sensors using chemometrics with collaborators will be
tested for fiber characteristics toward the goal of developing additional standards. For other work proposed for 2004 in the 2003 annual report, work continues to find value-added co-products. In 2005-2006, work will focus on extracting waste products for aromatics or waxes and testing compounds for new uses. In 2005, the secondary stage for the pilot plant (for "cottonization") will be developed and implemented. In 2005-2006, work will continue to develop and test make non-woven products from flax fiber. In 2006, full integration of flax retting and cleaning should be accomplished to produce quantities of tailored flax fiber for use in various applications. In 2007, additional standards will be in place, and applications of products will be sought among various industries. 4. What were the most significant accomplishments this past year? A. Single Most Significant Accomplishment during FY 2002 year: Flax was enzyme-retted with specific formulations, cleaned through the USDA Flax
Fiber Pilot Plant, made into non-woven products, and tested for quality. This accomplishment represents the first time that flax enzyme-retted in pilot plant scale amounts has been put into a non-woven product for side- by-side testing with currently available fibers. The accomplishment is important in establishing a basis for comparing a new product (i.e., enzyme-retted flax) in one of the most important applications of natural fibers globally, namely non-woven products. Flax was grown in the southeast as a winter crop (which allows dual cropping on this region with high value summer crops), harvested with traditional farm equipment, enzyme-retted by the new method developed, tested with a series of methods/standards to identify quality factors, made into non-woven materials, and tested against similar fabrics made with dew-retted fibers. This work was done in collaboration of the Quality Assessment Research Unit of the Russell Research Center and scientists at the Cotton Quality
Research Station (ARS-USDA), Clemson University, and University of Georgia. The outcome is that distinctions could be drawn in the quality of final products by the use of various flax fibers. Further, a basis was established for comparing enzyme-retted fibers with commercial fibers, and problem areas (such as strength and cleanliness) were identified. Future work can focus on alleviating the problems in flax fibers for specific applications or on finding specific niches for these products. B. Other significant accomplishments: None C. Significant Accomplishments/Activities the Support Special Target Populations: None D. The secondary cleaning stages to "cottonize" flax fiber are being implemented through collaborative efforts with Clemson University and the Cotton Quality Research Station. Once completed, a series of fibers with various properties can be produced in sufficient quantities for testing in textiles, non-woven applications, and other products. 'Standard Test Method For
Assessing Clean Flax Fiber Fineness,' based on an airflow method used in our work for several years, was accepted as a new standard by ASTM International with the number D 7025-04. Currently, there are 3 accepted test standards for flax fiber, where there were none 3 years ago. Subordinate Projects: a. This report serves to document research conducted under a Specific Cooperative Agreement between ARS and the Department of Agricultural and Biological Engineering, Clemson University, 66124400001907S 'Optimizing Retting and Processing in Flax Fiber Pilot Plant.' Additional details of research can be found in the report for the parent CRIS 66124400001900D 'Value-Added, Bio-based Products Through Microbial Treatments'. Under this agreement, flax samples of a diverse nature were supplied for processing, and equipment was designed and put in place to make the USDA Flax Fiber Pilot Plant operational. Expertise brought to ARS through this SCA is used to operate the equipment. b. This report
serves to document research conducted under a Specific Cooperative Agreement between ARS and the Department of Textiles, Merchandising & Interiors, University of Georgia, 66124400001906S 'Textile Properties of Natural Fibers.' Additional details of research can be found in the report for the parent CRIS 66124400001900D 'Value- Added, Bio-based Products Through Microbial Treatments.' Under this SCA, flax products were tested with equipment and expertise located at the University. Specific comparisons were made between experimental and commercial fiber products. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. 1) Collaborative agreements with the University of Georgia and Clemson University to coordinate equipment and expertise related to enzymology, textiles, and engineering for development of a flax fiber industry. 2) Development, with colleagues at the University of Georgia and Clemson University, a new laboratory
procedure using pectinase-rich enzyme mixtures and chelators applied to crimped stems to ret flax. 3) Establishment of the US Flax Initiative, which was an interim consortium of state and federal scientists and administrators and industry representatives for promoting a US flax/linen industry. 4) Establishment in 1998 of the Center for American Flax Fiber (CAFF) as a not-for-profit organization to promote all aspects of a fiber flax industry in the U.S. and which helped organize four flax workshops. 5) Establishment of subcommittee D13.17 (Flax and Linen) of ASTM International to develop industry standards for judging quality of flax fibers 6) Memorandum of Understanding with Biolin Research Inc, Saskatchewan, Canada, to study spectroscopic methods to estimate fiber contents in diverse flax varieties. 7) Establishment, with collaborators, the USDA Flax Fiber Pilot Plant to integrate retting and processing using commercial-type equipment but with flexible adjustments for research
studies. 8) In the bridging research project, the accomplishments above were brought together to specifically address the development of a project to manufacture (on pilot plant scale) and test non-wovens products from a variety of types of flax fiber. RELEVANCE TO ARS NATIONAL PROGRAM ACTION PLAN. RESEARCH PROPOSED HEREIN ADDRESSES THE TWO NP 306 COMPONENTS: a. Component 1 (Quality characterization, preservation, and enhancement). The quality, preservation, and enhancement of bio-based fibers, specifically flax, are addressed through the multiple steps of this project. Methods and standards are developed for several properties, including strength, fineness, color, trash, of flax fibers from new retting methods and processing procedures. These properties are enhanced through enzyme applications for specific industrial uses. b. Component 2. (New processes, new uses, and value-added biobased- products). Enzyme-retting provides for a sustainable, environmentally friendly method to
produce consistent, high-quality fibers. These bio-based fibers may serve as a replacement for glass fibers in bio-based composites, textile blends with cotton and other fibers for value-added niche markets, and value-added pulp for specialty papers from domestically produced flax. 6. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? Test samples of enzyme-retted flax fibers have been provided to ARS laboratories for evaluation of yarn blends. Flax fiber was made available for blending with other fibers for nonwoven fabrics. Interaction with the Center for American Flax Fiber is maintained on a regular basis to provide updated research information for distribution to commercial and scientific interests. Direction is provided to the Flax and Linen
subcommittee of ASTM International for development of flax standards, which currently include ones for terminology, color, and fineness. Information on the potential use of seed flax straw residues was given to the North Dakota Council on Oilseeds, and collaborative research was established with North Dakota State University. Research results were provided to the Flax Institute at its technical meetings. A method for measuring flax fiber in plants was developed with collaborators in ARS and provided the basis for a method in Canada to test field plots for fiber yield. Technical information has been provided to universities to promote work on textiles and industrial fibers through lectures to students, collaborative projects with professors, and interaction with staff and students. Information on enzyme-retting, standards development, and establishment of a flax fiber pilot plant have been made available to university, government, and commercial personnel at several international
meetings. The major constraint is the development of a cleaning system of commercial type to interact with enzyme retting. Progress is being made on the commercial and research side of this issue, and specific recommendations on processing equipment was given to Eastern Flax-South Carolina. The technology for flax fiber production in its entirely should be available to processors and farmers within 5-7 years, with some portions available within 3-5 years.
Impacts
(N/A)
Publications
- EVANS, J.D., AKIN, D.E., MORRISON III, W.H., HIMMELSBACH, D.S., MCALISTER III, D.D., FOULK, J.A. MODIFICATION OF DEW-RETTED FLAX FIBER AND YARNS VIA SECONDARY ENZYMATIC TREATMENT. TEXTILE RESEARCH JOURNAL. 2003. v. 73(10). p. 901-906.
- AKIN, D.E. FLAX FIBER. KIRK OTHMER ENCYCLOPEDIA FOR CHEMICAL TECHNOLOGY. JOHN WILEY & SONS, INC. DOI: 10.102/0471238961.0612012401110914.a01. 2003.
- AKIN, D.E., RIGSBY, L.L., MORRISON III, W.H. OIL RED AS A HISTOCHEMICAL STAIN FOR NATURAL FIBERS AND PLANT CUTICLE. INDUSTRIAL CROPS AND PRODUCTS. VOL. 19. P. 119-124. 2004.
- AKIN, D.E., HARDIN, I.R. THE CURRENT STATE OF THE APPLICATIONS OF BIOTECHNOLOGY. American Association of Textile Chemists and Colorists Review. 2003. PP. 189-195.
- AKIN, D.E. MICROSCOPIC ANALYSIS OF PLANT BIOMASS TOWARD VALUE-ADDED USES. PROCEEDINGS OF THE UNITED STATES-JAPAN COOPERATIVE PROGRAM IN NATURAL RESOURCES, 32ND ANNUAL MEETING. 2003. PP. 440-447.
- MORVAN, C., ONZIGHI, A.C., HIMMELSBACH, D.S., DRIOUICH, A., AKIN, D.E. BUILDING FLAX FIBRES: MORE THAN ONE BRICK IN THE WALLS. PLANT PHYSIOLOGY AND BIOCHEMISTRY. 2003. VOL. 41. PP. 935-944.
- Akin, D.E., and Hardin, I.R. Recent research on biotechnology in textiles. Colourage 7 (Annual 2004): 55-60. 2004.
- AKIN, D.E., MORRISON III, W.H., ANDERSON, W.F. LIGNOCELLULOSE OF GRASSES: POTENTIAL FOR BIOGENERY AND CO-PRODUCTS. 227TH AMERICAN CHEMICAL SOCIETY NATIONAL MEETING, MARCH 28-APRIL 1, 2004, ANAHEIM, CA. 2004. ABSTRACT #144.
- Anderson, W.F., Peterson, J., Akin, D.E., Morrison Iii, W.H. 2004. Enzyme- pretreatment of grass lignocellulose for potential high-value co-products and an improved fermentable substrate. Biotechnology for Fuels and Chemicals Symposium Proceedings, Chattanooga, TN, May 9-12, 2004. (Abst).
- Akin, D.E., Foulk, J.A., Dodd, R.B., Epps, H.H. 2004. Properties of enzyme- retted, mechanically processed flax fibers. International Conference on Textile Biotechnology. June 13-16, Graz, Austria. Abstract #16.
- Akin, D.E. 2004. Update on standards for flax fiber. Proceedings of the 60th Flax Institute of the United States. p. 44-50.
- Akin, D.E. 2004. Summary of usda research on flax fiber in the united states: recent events. Proceedings of the 60th Flax Institute of the United States. p. 51-55.
- Foulk, J.A., Akin, D.E., Dodd, R.B., Frederick, J.R. Optimizing flax production in the south atlantic region of the United States. Journal of the Science of Food and Agriculture. 2004. 84:870-876.
- Foulk, J.A., Akin, D.E., McAlister III, D.D. Fiber crops: cotton and cottonized flax. Proceedings of 27th International Cotton Conference, Faserinstitute Bremen Cotton Exchange Meetings, 2004. p. 102-116.
- Foulk, J.A., Chao, W., Akin, D.E., Dodd, R., Layton, P.A. Enzyme-retted flax fiber and recycled polyethylene composites. Bio Environmental Polymer Society. 2003. Page 25. Available from: www.beps.org.
- Foulk, J.A., Chao, W.Y., Akin, D.E., Dodd, R.B., Layton, P.A. Enzyme- retted flax fiber and recycled polyethylene composites. Polymers and the Environment. 2004. v.12(3), p. 165-171.
- Foulk, J.A., Akin, D.E., McAlister III, D.D., Dodd, R.B. USDA flax fiber pilot plant. 60th Flax Institute Proceedings. 2004. p. 56-63.
- McAlister III, D.D., Foulk, J.A., Akin, D.E., Annis, P. 2004. Cotton fibers: properties and interaction with flax fibers in blends (focus on rotor spun yarn). Faserinstitute Bremen Cotton Exchange Meetings.
- AKIN, D.E., HIMMELSBACH, D.S. MICROSCOPY TO EVALUATE RETTING OF FLAX AND FLAX FIBERS. MICROSCOPY AND MICROANALYSIS. 2003. 9 (SUPPL. 2). P. 1296- 1297.
- AKIN, D.E., RIGSBY, L.L. THE SOUTHEASTERN MICROSCOPY SOCIETY - A HISTORY FROM 1964 TO 2003. PROCEEDINGS OF THE SOUTHEASTERN MICROSCOPY SOCIETY. 2003. ABSTRACT #14. P. 16.
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Progress 10/01/02 to 09/30/03
Outputs
1. What major problem or issue is being resolved and how are you resolving it? The U.S. is the largest per capita user of linen, but no flax is grown commercially for fiber by U.S. farmers and linen is not produced in this country. The NPS determined that research should be carried out towards the development of a U.S. flax/linen industry to supply high and consistent quality fibers to textiles and other fiber-using industries, especially those using natural fibers for reinforced composites. Two major technical problems impeding development of such industries are lack of new retting methods to extract fiber from stems for clean and consistent quality fibers, and lack of standards to judge processing and fiber quality. To address these problems, research is being conducted on an enzymatic retting method to replace the current method of dew-retting, which depends upon indigenous microorganisms and field conditions. For standards, research is being conducted, often
with collaborators at the University of Georgia, at Clemson University, and the Cotton Quality Research Station, ARS-USDA, Clemson, SC, on fiber color, fineness, strength, length, and trash (nonfiber) content. Fundamental studies on structure and chemistry are undertaken to gain insight into problems of fiber extraction and fiber characterization. Results are then applied toward industry needs in textiles, composites, or paper/pulp industries. 2. How serious is the problem? Why does it matter? The U.S. imports an estimated $150 million worth of flax fiber annually to satisfy performance requirements and consumer preferences in textiles, nonwoven, and wet-laid nonwoven, composite, and fiberboard products. Much of this import is short fibers (i.e., tow) rather than the traditional long line linen fiber for blending primarily with cotton in the textile mills of the southeast. The U.S. has no industry for producing this fiber but instead imports the material. The quality of imported
flax is extremely variable, creating considerable problems for the fiber-using industries. Flax fiber, unlike many other potential new crops, has ready markets for textiles, composites, and paper/pulp. The opportunities, therefore, are not realized for growing fiber flax as an additional cash crop to help U.S. farmers and rural economies, for creating new jobs in flax processing plants, and for supplying a domestic source of clean, high, and consistent quality flax fibers. 3. How does it relate to the National Program(s) and National Program Component(s) to which it has been assigned? National Program 306 -- Quality and Utilization of Agricultural Products. The CRIS Project and related research objectives relate to priorities of ARS as follows: enhancing marketability of agricultural products, developing environmentally friendly and efficient processing concepts, expanding domestic and global market opportunities of value-added nonfood products, and meeting consumer needs. These
goals are addressed through development of an enzyme-retting method to produce short staple flax fibers for blending with cotton and other fibers in textiles, for non- woven textiles, for composites, and for specialty papers. Further, development of standards for judging fiber quality will promote this product for domestic and global marketing. Work will support an emerging flax industry where flax will be grown as a winter crop in the southeastern USA to complement traditional summer crops and enhance rural economies through production of flax and the establishment of associated industries. 4. What were the most significant accomplishments this past year? A. Single Most Significant Accomplishment during FY 2002 year: Research is needed on use of enzymes to improve retting of flax and then to integrate retting methods with processing systems to produce clean fiber of specific properties. In collaboration with the ARS-USDA Cotton Quality Research Station and Clemson University, both
in Clemson, SC, flax retted with commercial enzyme and chelator, with the enzyme and chelator both varied to give 12 treatments in duplicate, were processed through newly installed modules in the USDA Flax Fiber Pilot Plant. The accomplishment is that specific properties of flax fibers were determined after enzyme-retting and processing through systems representing typical flax fiber cleaning equipment in Europe. The impact of the research is that methods of retting, processing, and characterizing flax fibers are becoming defined to promote a flax fiber industry in the US. B. Other Significant Accomplishments: 1. Research is required to develop standards to judge flax fiber properties for development of a flax fiber industry. Research was undertaken to method to objectively determine the shive (non-fiber contaminants) content in processed flax fibers using near infrared spectroscopy with Dr. Woody Barton, Quality Assessment Research Unit, ARS- USDA, Athens, GA. The accomplishment
is that a model was developed and tested towards developing a standard for determining trash in flax. The impact of this work, with subsequent development of a trash standard, would allow the characterization of flax fibers to promote a flax fiber industry in the US. C. Significant Accomplishments/Activities the Support Special Target Populations: No progress addressed specifically small farms or under-served producers. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. A series of steps has been followed to initiate and develop a program on flax fiber related to improved processing, establishment of standards, through collaborative arrangements with specific departments of several universities, private organizations, and international laboratories. Specific milestones include the following: Established the validity of enzymatic retting of flax stems using pectinase-rich, commercial enzymes. Established collaborative
agreements with the University of Georgia and Clemson University to coordinate equipment and expertise related to enzymology, textiles, and engineering that was required for the project but unavailable at RRC. Developed, with colleagues at the University of Georgia and Clemson University, a laboratory procedure using pectinase- rich enzyme mixtures with the addition of chelators applied to crimped stems to more efficiently ret flax. Served as co-chair of the U.S. Flax Initiative, which was a consortium of state and federal scientists and administrators and industry representatives for promoting a flax/linen industry. Assisted with other Flax Initiative members in establishing in 1998 the Center for American Flax Fiber (CAFF) as a not-for-profit organization to promote all aspects of a fiber flax industry in the U.S. Assisted in establishing the subcommittee Flax and Linen (D13.17) of ASTM International and therein established working task groups to develop industry standards in the
areas of trash (non-fiber) content, strength, length, fineness, and color. Began serving as Chair of the Flax subcommittee in ASTM in 2001, leading in promoting documents for balloting for terminology, color, fineness, and trash to become full standards. Continued to serve as Technical Advisor to CAFF and provided information on flax fiber for a US industry as part of the CRADA. Worked to support the Memorandum of Understanding with Biolin Research Inc, Saskatchewan, Canada, to study spectroscopic methods to estimate fiber contents in diverse flax varieties. With colleagues, developed the first stage of a flax fiber pilot plant to integrate retting and processing using commercial-type equipment but with flexible adjustments for research studies. These accomplishments are a basis for developing a flax/linen industry in the U.S. to provide fiber for textile, composite and paper/pulp applications. Initiated research at the University of Rouen, France, and at the Faserinstitute,
Bremen, Germany to address problems in structure and fineness determinations, respectively. Initiated work on agronomic practices related to fiber yield and quality through a Headquarters-sponsored Research Associate in Plant Physiology. Technically, accomplishments address two major problems related to establishing an improved and environmentally friendly retting system (i.e. , enzymatic retting) and development of industry standards for judging fiber properties. In total, accomplishments address research to develop an enzyme retting system and then to process the flax in ways for specific properties using to various industries. Research addresses priorities of ARS for U.S. agriculture in improving rural economies, developing new and value added agricultural crops, products and industries, and improving global competitiveness. The development of fiber flax in northern states offers an additional cash crop for rotation with traditional crops as well as providing a value added
product from seed flax straw, a byproduct of the linseed industry. In the southern states, flax grown as winter crop could provide economic assistance by double cropping with summer crops. 6. What do you expect to accomplish, year by year, over the next 3 years? During FY 2004, analysis will continue on substantial amounts of data obtained from microwave measurements on grain sorghum, sunflower, safflower, canola, and peanuts, in addition to wheat, corn, oats, and soybeans, to develop improved density independent moisture determination techniques and to further test the universal moisture calibration function for granular materials over wide ranges of frequency, temperature, and bulk density. The use of small inexpensive antennas for on line sensing of physical properties of granular materials will be further investigated. During FY2005, the moisture sensing techniques will be refined and the range for unified calibration functions studied for possible extension to other materials
for which moisture monitoring is important. CRADA partners will be sought to speed the development of practical moisture sensing instrumentation for on line use in harvesting and processing equipment. Work is expected to continue on development of microstrip antennas and microwave circuits for sensing moisture content and density for application in practical microwave moisture meters. Work is also expected to begin on developing broad frequency range dielectric spectroscopy systems for use in efficiently characterizing dielectric behavior of agricultural products. During FY2006, extension of the moisture sensing and calibration techniques to other commodities and products is anticipated, with further efforts toward implementation of the technology for practical use. More effort will be shifted to the development of broadband dielectric spectroscopy systems for potential measurement of composition and quality of agricultural products. Dielectric characterization of biofuels may be
explored for detection of important qualities. Dielectric spectroscopy studies are expected to open entirely new avenues for the nondestructive instantaneous sensing of product composition and quality factors, which will eventually be useful in automating processes that produce superior products and provide competitive advantages for American agriculture in the global economy. 7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? Specifically, the following information/technology has been transferred. Test samples of enzyme-retted flax fibers have been provided to ARS laboratories for evaluation of yarn blends. Interaction with the Center for American Flax Fiber is maintained on a regular basis to provide updated research information for distribution to
commercial and scientific interests. As Chair of the Flax and Linen subcommittee of ASTM, promotion and support have been given for documents related to Terminology and Color. 'Standard Terminology Relating to Flax and Linen' has been approved for publication in the Annual Book of Standards with designation D 6798-02. 'Standard Test Method for Color Measurement of Flax Fiber' has been re-submitted for full committee balloting. Information and technical assistance was given to scientists at the University of Georgia to continue test plots of varieties of flax. Information on the potential for use of seed flax straw residues was given to the North Dakota Council on Oilseeds and collaborative research was established with North Dakota State University and the Flax Institute was provided at its technical meeting. Technical information is provided to universities to promote work on textiles and industrial fibers through lectures to students, collaborative projects with professors, and
interaction with staff and students. The major constraint is the development of a cleaning system of commercial type to interact with enzyme-retting. Progress is being made on the commercial and research side of this issue, and specific recommendations on processing equipment was given to Eastern Flax-South Carolina. Advice has been given to NPS and other ARS locations in initial workshops and seminars on structural and chemical factors influencing biodegradation of lignocellulose for proposals on lignocellulose to ethanol projects. The technology for flax fiber production in its entirety should be available to processors and farmers within 5-7 years, with some portions available within 3-5 years.
Impacts
(N/A)
Publications
- Morrison, W.H. III, Himmelsbach, D.S., Akin, D.E., Evans, J.D. Chemical and spectroscopic analysis of lignin in isolated flax fibers. Journal of Agricultural and Food Chemistry. 2003. v. 51. p. 2565-2568.
- Liu, Z., Erhan, S.V., Akin, D.E. Preparation of soy based composites with flax fibers. 2002. Abstracts of the 224th American Chemical Society National Meeting, Division of Industrial and Engineering Chemistry. Abstract No. 134.
- Khalili, S., Akin, D.E., Pettersson, B., Henriksson, G. Fibernodes in flax and other bast fibers. Journal of Applied Botany. 2002. v. 76. p. 133-138.
- Zhang, J., Pettersson, B., Akin, D.E., Foulk, J.A., Johansson, G., Henriksson, G. Effects of acidic media pre-incubation on flax enzyme retting efficiency. Textile Research Journal. 2003. v. 73. p. 263-267.
- Akin, D.E., Morrison, W.H. III, Rigsby, L.L., Evans, J.D., Foulk, J.A. Influence of water pre-soak on enzyme-retting of flax. Industrial Crops and Products. 2003. v. 17. p. 149-159.
- Foulk, J.A., Akin, D.E., Dodd, R.B., Frederick, J.R. Cultural practices of flax in the Southeastern United States. Proceedings of the 59th Flax Institute of the United States. 2002. p. 124-137.
- Foulk, J.A. Akin, D.E., Dodd, R.B., McAlister, D.D. III. Flax fiber harvesting, separation, and textile processing in the USDA. International Conference on Production, Processing, and Use of Natural Fibers. 2002. CD ROM. Potsdam University, Germany, Chapter 8.
- Liu, Z., Erhan, S.Z., Akin, D.E., Barton, F.E. II. Preparation of soybean oil-based composites reinforced with flax fiber. Proceedings of the 31st United States-Japan Cooperative Program in Natural Resources-Protein Resources Panel. 2002. p. NN 1-8.
- Foulk, J.A., Akin, D.E. Dodd, R.B. Fiber flax farming practices in the southeastern United States. Crop Management (on line). 2003. doi:10. 1094/CM-2003-0214-01-RS.
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Progress 10/01/01 to 09/30/02
Outputs
1. What major problem or issue is being resolved and how are you resolving it? The U.S. is the largest per capita user of linen, but no flax is grown commercially for fiber by U.S. farmers and linen is not produced in this country. The NPS determined that research should be carried out towards the development of a U.S. flax/linen industry to supply high and consistent quality fibers to textiles and other fiber-using industries, especially those using natural fibers for reinforced composites. Two major technical problems impeding development of such industries are lack of new retting methods to extract fiber from stems for clean and consistent quality fibers, and lack of standards to judge processing and fiber quality. To address these problems, research is being conducted on an enzymatic retting method to replace the current method of dew-retting, which depends upon indigenous microorganisms and field conditions. For standards, research is being conducted, often
with collaborators at the University of Georgia, at Clemson University, and the Cotton Quality Research Station, ARS-USDA, Clemson, SC, on fiber color, fineness, strength, length, and trash (nonfiber) content. Fundamental studies on structure and chemistry are undertaken to gain insight into problems of fiber extraction and fiber characterization. Results are then applied toward industry needs in textiles, composites, or paper/pulp industries. 2. How serious is the problem? Why does it matter? The U.S. imports an estimated $150 million worth of flax fiber annually to satisfy performance requirements and consumer preferences in textiles, nonwoven, and wet-laid nonwoven, composite, and fiberboard products. Much of this import is short fibers (i.e., tow) rather than the traditional long line linen fiber for blending primarily with cotton in the textile mills of the southeast. The U.S. has no industry for producing this fiber but instead imports the material. The quality of imported
flax is extremely variable, creating considerable problems for the fiber-using industries. Flax fiber, unlike many other potential new crops, has ready markets for textiles, composites, and paper/pulp. The opportunities, therefore, are not realized for growing fiber flax as an additional cash crop to help U.S. farmers and rural economies, for creating new jobs in flax processing plants, and for supplying a domestic source of clean, high, and consistent quality flax fibers. 3. How does it relate to the national Program(s) and National Program Component(s) to which it has been assigned? National Program 306 -- Quality and Utilization of Agricultural Products. The CRIS Project and related research objectives relate to priorities of ARS as follows: enhancing marketability of agricultural products, developing environmentally friendly and efficient processing concepts, expanding domestic and global market opportunities of value-added nonfood products, and meeting consumer needs. These
goals are addressed through development of an enzyme-retting method to produce short staple flax fibers for blending with cotton and other fibers in textiles, for non- woven textiles, for composites, and for specialty papers. Further, development of standards for judging fiber quality will promote this product for domestic and global marketing. Work will support an emerging flax industry where flax will be grown as a winter crop in the southeastern USA to complement traditional summer crops and enhance rural economies through production of flax and the establishment of associated industries. 4. What was your most significant accomplishment this past year? A. Single Most Significant Accomplishment during FY 2002 year: Fundamental studies are required on fiber-enzyme interactions that occur during enzyme-retting to determine ways to overcome loss of fiber strength resulting from enzyme retting. A series of studies were undertaken where enzyme levels were varied, time of incubation was
varied, non-cellulase-containing mixtures were tested and fiber strength measured. The accomplishment is that, partially through a Headquarters Research Associate, specific enzyme levels, incubation times, and enzyme types were identified that produce flax fiber with high strength. The impact of the research is that specific conditions are defined to optimize enzyme retting and control strength loss of fibers during processing. B. Other Significant Accomplishments: 1. The role of growth conditions and specific chemical applications to plant growth and flax fiber yield and quality are unknown and must be researched to develop a flax fiber industry in the southeast. Partially through a second Headquarters Research Associate and collaboration with Roy Dodd, Clemson University and Phil Bauer, ARS-USDA, Florence, SC, research was initiated on irrigation, subsoil tillage, herbicide application, and maturity to determine their effect on flax fiber yield and quality. The accomplishment
is that initial results showed that tillage systems profoundly influenced plant yield, and herbicide application dried the plant more quickly and uniformly allowing improved dew-retting. The impact of this research is that agronomic practices can have a large influence on fiber yield and quality and improve cost efficiency of a flax fiber industry in the US. 2. Research is required to develop standards to judge flax fiber properties for development of a flax fiber industry. Research was undertaken to develop a fineness standard with Jonn Foulk, CQRS, ARS-USDA, Clemson, and Roy Dodd, Clemson University, based on cotton micronaire and one on trash with Woody Barton and Herb Morrison, QARU, ARS-USDA, Athens. The accomplishment is that a standard method document for fineness based on air-flow methods has been prepared, revised and re- submitted through ASTM International and research has shown that Near Infrared Spectroscopy (NIRS) can be used to assess trash in flax fibers. These
results are important milestones in a long-term goal for developing a set of standards for judging and trading flax fibers. C. Significant Accomplishments/Activities the Support Special Target Populations: No progress addressed specifically small farms or under-served producers. 5. Describe your major accomplishments over the life of the project, including their predicted or actual impact? A series of steps has been followed to initiate and develop a program on flax fiber related to improved processing, establishment of standards, through collaborative arrangements with specific departments of several universities, private organizations, and international laboratories. Specific milestones include the following: Established the validity of enzymatic retting of flax stems using pectinase-rich, commercial enzymes. Established collaborative agreements with the University of Georgia and Clemson University to coordinate equipment and expertise related to enzymology, textiles, and
engineering that was required for the project but unavailable at RRC. Developed, with colleagues at the University of Georgia and Clemson University, a laboratory procedure using pectinase- rich enzyme mixtures with the addition of chelators applied to crimped stems to more efficiently ret flax. Served as co-chair of the U.S. Flax Initiative, which was a consortium of state and federal scientists and administrators and industry representatives for promoting a flax/linen industry. Assisted with other Flax Initiative members in establishing in 1998 the Center for American Flax Fiber (CAFF) as a not-for-profit organization to promote all aspects of a fiber flax industry in the U.S. Assisted in establishing the subcommittee Flax and Linen (D13.17) of ASTM International and therein established working task groups to develop Industry standards in the areas of trash (non-fiber) content, strength, length, fineness, and color. Began serving as Chair of the Flax subcommittee in ASTM in
2001, leading in promoting documents for balloting for terminology, color, fineness, and trash to become full standards. Continued to serve as Technical Advisor to CAFF and provided information on flax fiber for a US industry as part of the CRADA. Worked to support the Memorandum of Understanding with Biolin Research Inc, Saskatchewan, Canada, to study spectroscopic methods to estimate fiber contents in diverse flax varieties. These accomplishments are a basis for developing a flax/linen industry in the U.S. to provide fiber for textile, composite and paper/pulp applications. Initiated research at the University of Rouen, France, and at the Faserinstitute, Bremen, Germany to address problems in structure and fineness determinations, respectively. Initiated work on agronomic practices related to fiber yield and quality through a Headquarters-sponsored Research Associate in Plant Physiology. Technically, accomplishments address two major problems related to establishing an
improved and environmentally friendly retting system (i.e., enzymatic retting) and development of industry standards for judging fiber properties. In total, accomplishments bring progress towards addressing priorities of ARS for U.S. agriculture in improving rural economies, developing new and value added agricultural crops, products and industries, and improving global competitiveness. The development of fiber flax in northern states offers an additional cash crop for rotation with traditional crops as well as providing a value added product from seed flax straw, a byproduct of the linseed industry. In the southern states, flax grown as winter crop could provide economic assistance by double cropping with summer crops. 6. What do you expect to accomplish, year by year, over the next 3 years? In FY 2003, work will continue to integrate and test the enzyme-retting pilot plant system, with various levels of enzymes and chelators to further optimize fiber for industrial applications.
Various flax types will be tested, and parameters modified to optimize fiber quality from specific sources (e.g., seed flax straw). Enzyme formulations will be tailored to produce fibers, and to modify properties of dew-retted flax, for specific properties for use in various applications. A commercial processing facility could be operational in the southeast for enzymatically retting and cleaning fibers for industrial applications. Improved and controlled dew-retting practices will be evaluated with an emphasis for on-farm technologies to improve farm economies. Work will be initiated along similar lines of the Flax Pilot Plant to determine recalcitrance of plant lignocellulose for use as sources of bioethanol. In FY 2004, sensors, based on industry adapted standards, will be introduced to discriminate fibers for use in high value (textiles), moderate value (composites), or lower value (paper/pulp) applications from a variety of sources, including crops exclusively grown for fiber
or as value added products from seed flax residues. Enzyme-retted fiber of high and consistent quality should be available for large-scale testing in fabrics with cotton and other fibers and for testing in composites. Work will continue on the lignocellulose-to-ethanol process, with research aimed at mitigating the barriers to bioconversion of plant carbohydrates. In 2005, full integration of flax retting and processing will be accomplished, with optimal conditions for high quality fiber under the optimal cost efficiencies. Research to improve conversion of lignocellulose to ethanol will focus on pilot plant systems to modify and use various lignocellulosic resources. 7. What technologies have been transferred and to whom? When is the technology likely to become available to the end user (industry, farmer other scientist)? What are the constraints, if known, to the adoption durability of the technology? Specifically, the following information/technology has been transferred. Test
samples of enzyme retted flax fibers have been provided to ARS laboratories for evaluation of yarn blends. Interaction with the Center for American Flax Fiber is maintained on a regular basis to provide updated research information for distribution to commercial and scientific interests. As Chair of the Flax and Linen subcommittee of ASTM, promotion and support have been given for documents related to Terminology and Color, which are in final balloting for standards and direction and guidance have been given for preparation of documents on fineness and trash for subcommittee review. Information and technical assistance was given to scientists at the University of Georgia to continue test plots of varieties of flax. Information on the potential for use of seed flax straw residues was given to the North Dakota Council on Oilseeds and collaborative research was established with North Dakota State University and the Flax Institute was provided at its technical meeting. Technical
information is provided to universities to promote work on textiles and industrial fibers through lectures to students, collaborative projects with professors, and interaction with staff and students. The major constraint is the development of a cleaning system of commercial type to interact with enzyme retting. Progress is being made on the commercial and research side of this issue, and specific recommendations on processing equipment was given to Eastern Flax-South Carolina. Advice has been given to NPS and other ARS locations in initial workshops and seminars on structural and chemical factors influencing biodegradation of grass lignocellulose for proposals on lignocellulose to ethanol projects. The technology for flax fiber production in its entirely should be available to processors and farmers within 5-7 years, with some portions available within 3-5 years.
Impacts
(N/A)
Publications
- Akin, D.E., Slomczynski, D., Rigsby, L.L., Eriksson, K.-E.L. Retting of flax by endopolygalacturonase from Rhizopus oryzae. Textile Research Journal. 2002. v. 72. p. 27-34.
- Akin, D.E., Himmelsbach, D.S., Morrison, W.H. III. Bio-based fiber production: enzyme retting for flax/linen fibers. Journal of Polymers and the Environment. 2002. v. 8. p. 103-109.
- Adamsen, A.P., Akin, D.E., Rigsby, L.L. Chelating agents and enzyme retting of flax. Textile Research Journal. 2002. v. 72. p. 296-302.
- Akin, D.E., Foulk, J.A., Dodd, R.B. Influence on flax fiber of components in enzyme-retting formulations. Textile Research Journal. 2002. v. 72. p. 510-514.
- Akin, D.E., McAlister, D.D. III, Foulk, J.A., Evans, J.D. Cotton fibers: properties and interaction with flax fibers in blends. Proceedings of the 26th International Cotton Conference Bremen. 2002. p. 189-196.
- Annis, P.A., Etter, J.N., Sarkar, A.K., Akin, D.E. Influence of flax/cotton blend ratio on dyebath exhaustion and color yield of C.I. direct blue 1 and C.I. direct red 80. American Association for Textile Chemists and Colorists Review. 2002. v. 2 p. 26-28.
- Akin, D.E. Standards for flax fiber. Proceedings of the 59th Flax Institute of the United States. 2002. p. 92-101.
- Evans, J.D, Akin, D.,E., Foulk, J.A. Flax-retting by polygalacturonase- containing enzyme mixtures and effects on fiber properties. Journal of Biotechnology. 2002. v. 97. p. 223-231.
- Akin, D.E., Dodd, R.B., Foulk, J.A., McAlister, D.D. III. Flax fiber: potential for a new crop in the southeast. 5th National Symposium New Crops and New Uses: Strength in Diversity. 2001. Abstract p. 65.
- Evans, J.D., Akin, D.E. Processing of flax fibers using enzyme formulations. The Second International Symposium on Biotechnology in Textiles. 2002. Abstract p. 6.
- Akin, D.E. Microscopy to assess quality in agricultural crops. Southeastern Microscopy Society. 2002. Abstract p. 14.
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Progress 10/01/00 to 09/30/01
Outputs
1. What major problem or issue is being resolved and how are you resolving it?
The U.S. is the largest per capita user of linen, but no flax is grown commercially for fiber by U.S. farmers and linen is not produced in this country. The NPS determined that research should be carried out towards the development of a U.S. flax/linen industry to supply high and consistent quality fibers to textiles and other fiber-using industries, especially those using natural fibers for reinforced composites. Two major technical problems impeding development of such industries are lack of new retting methods to extract fiber from stems for clean and consistent quality fibers, and lack of standards to judge processing and fiber quality. To address these problems, research is being conducted on an enzymatic retting method to replace the current method of dew-retting, which depends upon indigenous microorganisms and field conditions. For standards, research is being conducted, often with collaborators at the University of Georgia, at Clemson University, and the Cotton Quality
Research Station, ARS-USDA, Clemson, SC, on fiber color, fineness, strength, length, and trash (nonfiber) content. Fundamental studies on structure and chemistry are undertaken to gain insight into problems of fiber extraction and fiber characterization. Results are then applied toward industry needs in textiles, composites, or paper/pulp industries.
2. How serious is the problem? Why does it matter?
The U.S. imports an estimated $150 million worth of flax fiber annually to satisfy performance requirements and consumer preferences in textiles, nonwoven, and wet-laid nonwoven, composite, and fiberboard products. Much of this import is short fibers (i.e., tow) rather than the traditional long line linen fiber for blending primarily with cotton in the textile mills of the southeast. The U.S. has no industry for producing this fiber but instead imports the material. The quality of imported flax is extremely variable, creating considerable problems for the fiber-using industries. Flax fiber, unlike many other potential new crops, has ready markets for textiles, composites, and paper/pulp. The opportunities, therefore, are not realized for growing fiber flax as an additional cash crop to help U.S. farmers and rural economies, for creating new jobs in flax processing plants, and for supplying a domestic source of clean, high, and consistent quality flax fibers.
3. How does it relate to the National Program(s) and National Component(s)?
National Program 306 - Quality and Utilization of Agricultural Products. The CRIS Project and related research objectives relate to priorities of ARS as follows: enhancing marketability of agricultural products, developing environmentally friendly and efficient processing concepts, expanding domestic and global market opportunities of value-added nonfood products, and meeting consumer needs. These goals are addressed through development of an enzyme-retting method to produce short staple flax fibers for blending with cotton and other fibers in textiles, for non-woven textiles, for composites, and for specialty papers. Further, development of standards for judging fiber quality will promote this product for domestic and global marketing. Work will support an emerging flax industry where flax will be grown as a winter crop in the southeastern USA to complement traditional summer crops and enhance rural economies through production of flax and the establishment of associated
industries.
4. What were the most significant accomplishments this past year?
A. Single Most Significant Accomplishment during FY 2000 year: This is a bridging project for 6612-44000-015-00D and accomplishments are under the CRIS project.
5. Describe the major accomplishments over the life of the project including their predicted or actual impact.
A series of steps has been followed to initiate and develop a program on flax fiber related to improved processing, establishment of standards, initiating collaborative arrangements with specific departments of several universities, private organizations, and international laboratories. Specific milestones include the following: Established the validity of enzymatic retting of flax stems using pectinase-rich, commercial enzymes. Established collaborative agreements with the University of Georgia and Clemson University to coordinate equipment and expertise related to enzymology, textiles, and engineering that was required for the project but unavailable at RRC. Developed, with colleagues at the University of Georgia and Clemson University, a laboratory procedure using pectinase-rich enzyme mixtures with the addition of chelators applied to crimped stems to more efficiently (less enzyme required) ret flax. This accomplishment overcame a major barrier in other work where amounts (and
costs) of enzymes were prohibitive for the process. Served as co-chair of the U.S. Flax Initiative, which was a consortium of state and federal scientists and administrators and industry representatives for promoting a flax/linen industry. As acting coordinator, communication and interest was maintained, resulting in four annual workshops and establishment of a formalized organization to promote fiber flax. Assisted with other Initiative members in establishing in 1998 the Center for American Flax Fiber (CAFF) as a not-for-profit organization to promote all aspects of a fiber flax industry in the U.S. Assisted, through efforts of colleagues in CAFF, in establishing the subcommittee Flax (Linen Content) Products (D13.17) of ASTM and therein established working task groups to develop Industry standards in the areas of trash (non-fiber) content, strength, length, fineness, and color. Began serving as Chair of the Flax subcommittee in ASTM in 2001. Continued to serve as Technical
Advisor to CAFF and provided information on flax fiber for a US industry as part of the CRADA. Worked to support the Memorandum of Understanding with Biolin Research Inc, Saskatchewan, Canada, to study spectroscopic methods to estimate fiber contents in diverse flax varieties. These accomplishments are a basis for developing a flax/linen industry in the U.S. to provide fiber for textile, composite and paper/pulp applications. Initiated research at the University of Rouen, France, and at the Faserinstitute, Bremen, Germany to address problems in structure and fineness determinations, respectively. Technically, accomplishments address two major problems related to establishing an improved and environmentally friendly retting system (i.e., enzymatic retting) and development of industry standards for judging fiber properties. In total, accomplishments bring progress towards addressing priorities of ARS for U.S. agriculture in improving rural economies, developing new and value-added
agricultural crops, products and industries, and improving global competitiveness. The development of fiber flax in northern states offers an additional cash crop for rotation with traditional crops as well as providing a value-added product from seed flax straw, a byproduct of the linseed industry. In the southern states, flax grown as winter crop could provide economic assistance by double-cropping with summer crops.
6. What do you expect to accomplish, year by year, over the next 3 years?
In FY 2002, a new CRIS project will be written. The optimized retting formulations will be tested in the Flax Pilot Plant using processing equipment based on commercial designs but with flexibility to vary parameters and optimize flax production based on fiber quality and costs. Support of the emerging flax industry in Kingstree, SC, will be provided through coordinated research plans. In FY 2003, work will continue to test the enzyme-retting pilot plant system, with new enzymes and chelators to further optimize fiber for industrial applications. Various flax types will be tested, and parameters modified to optimize fiber quality from specific sources (e.g., seed flax straw). Enzyme formulations will be tailored to produce fibers, and to modify properties of dew-retted flax, for specific properties for use in various applications. A commercial processing facility could be operational in the southeast for enzymatically retting and cleaning fibers for industrial applications. In
FY 2004, sensors, based on industry adapted standards, will be introduced to discriminate fibers for use in high-value (textiles), moderate value (composites), or lower value (paper/pulp) applications from a variety of sources, including crops exclusively grown for fiber or as value-added products from seed flax residues. Enzyme-retted fiber of high and consistent quality should be available for large-scale testing in fabrics with cotton and other fibers and for testing in composites.
7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end user (industry, farmer, other scientists)? What are the constraints if known, to the adoption & durability of the technology product?
Technology transfer activities are listed under the closeout project 6612-44000-015-00D.
8. List your most important publications in the popular press (no abstracts) and presentations to non-scientific organizations and articles written about your work (NOTE: this does not replace your peer-reviewed publications which are listed below)
Impacts
(N/A)
Publications
- Publications are listed under the closeout project 6612-44000-015-00D.
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