Progress 09/01/22 to 08/31/23
Outputs
Target Audience:Global paper companies, producers of cardboard and paper packaging. Producers of paper sizing additives and coatings that improve paper barrier properties as well as producers of food packaging. Our biobased and biodegradable coatings will benefit industries that are willing to reduce the use of plastic coatings for paper and are focused on environmentally friendly alternatives Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?The project has provided training and professional development opportunity for three North Dakota students - Avery Jorgensen (BS - Mechanical Engineer at NDSU), Zane Hensel (BS - Chemistry at NDSU) and Jasmine Kostelecky (BS - Biochemistry at NDSU). During the reporting period, Jasmine had an opportunity to work on the project as a Research Scientist Intern in the summer of 2022. Jasmine carried out product development work and troubleshooting of the process issues; tested CO2 evolution for the aerobic degradation studies. She learned new product characterization techniques such asFourier-transform infrared spectroscopy, and wet chemistry methods for product quality control. How have the results been disseminated to communities of interest?The team has approached major producers of paper packaging products in the US and established a confidential relationship by signing NDA/MTA agreements. Some technical information was shared to select companies that expressed interest in soybased coatings for paper packaging. Companies were offered paper coating formulations/blends and a broad range of soy-based coating intermediates developed for their own testing and feedback. A few producers of paper packaging showed significant interest in our biobased coating products and expressed willingness to participate in scale-up and pilot trials. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
The team has successfully completed tasks 1-7 of the project. 1) Soybean oil-based copolymers and aqueous dispersions for paper coatings were produced based on vinyl monomer reactants commercially available in the US. 2) Two types of soybean oil - conventional and High Oleic Soybean Oil (HOSO) were used to produce the developmental monomers and copolymers. The monomers derived from HOSO resulted in higher copolymer yields and better polymerization kinetics compared to the monomers from conventional soybean oil. Also, paper samples coated with HOSO-based formulations showed better barrier properties compared to coating products based on conventional soybean oil. 3) Commercial soluble starch was incorporated at 20 and 30 wt.% levels to improve the rheological properties of soy polymer dispersions filled with kaolin mineral filler and cellulose nanofibers (CNFs). The optimal level of starch thickener was found to be below 20%. 4) The addition of the autoxidative drier catalyst was found to improve the barrier performance, however, impacted the viscosities of the aqueous dispersions. Although it is beneficial for the final coating, the drier catalysts dramatically reduce the shelf-life of the polymeric dispersions. Some dispersions of soy-based copolymers catalyzed with Co Hydro-Cure catalyst had a very short shelf-life. 5) The biodegradability of developmental soybean oil-based coatings was evaluated in OECD 301B ready/ultimate biodegradability testing and with Aerobic Degradation in Soil testing ASTM D5988. Based on the testing results, the polymeric materials produced showed percent biodegradation above 60%, and some of them were classified as readily degradable under 301B test conditions. The aerobic degradation testing showed that both cured and non-cured soybased coatings degrade down to carbon dioxide at rates in the range of 2-15 wt.% per month. 6) Shelf-life studies of aqueous dispersions show that most formulations lack stability, especially those produced from conventional soybean oil and loaded with autoxidative driers. 7) Drum quantities of biodegradable coating formulation were produced for pilot coating trials, and good reproducibility in performance was recorded. 8) The biodegradable soy-based coating formula was trialed at a commercial coating line to produce20,000 linear feet of paper for making prototype packaging bags. The soy-based formula was found to be applicable for paper coating using industrial coater.
Publications
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Progress 09/01/19 to 08/31/23
Outputs
Target Audience:Global paper companies, producers of cardboard and paper packaging. Producers of paper sizing additives and coatings that improve paper barrier properties as well as producers of food packaging. Our biobased and biodegradable coatings will benefit industries that are willing to reduce the use of plastic coatings for paper and are focused on environmentally friendly alternatives Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?The project has provided training and professional development opportunities for three North Dakota students - Avery Jorgensen (BS - Mechanical Engineer at NDSU), Zane Hensel (BS - Chemistry at NDSU) and Jasmine Kostelecky (BS - Biochemistry at NDSU). Avery Jorgensen had an opportunity to work on the project as a Research Scientist Intern in the summer 2021. Avery participated in multiple stages of technology development and product development. He performed: 1) soy-based monomer purification via WFE distillation - assembled WFE setup for continuous distillation. 2) paper coating trials and testing of barrier properties for coated paper products with TAPPI and ASTM methods. Avery learned how to use determine product quality using spectral techniques such as Nuclear Magnetic Resonance Spectroscopy. Zane Hensel had an opportunity to work on the project as a Research Scientist Intern in 2021. Zane participated in multiple stages of the new biobased product development process: 1) transformation of soy oils into reactive soy vinyl monomers, 2) polymerization of the reactive monomers into different polymers and copolymers; 3) determining the feasibility of new polymers as materials for coatings 4) troubleshooting of the polymerization process issues. 5) determining safety characteristics such as flammability, and combustibility for newly synthesized soy vinyl monomers. Zane learned techniques for scaling up small laboratory-scale processes into a pilot production of polymeric resins for coatings. Also, he was very successful in studying prior art and implementing new methods in practice. Jasmine worked onthe project as a Research Scientist Intern in the summer of 2022. Jasmine carried out product development work and troubleshooting of the process issues; tested CO2 evolution for the aerobic degradation studies. She learned new product characterization techniques such as Fourier-transform infrared spectroscopy, and wet chemistry methods for product quality control. How have the results been disseminated to communities of interest?The team has approached several major producers of paper packaging products in the US and established a confidential relationship by signing NDA/MTA agreements. Some technical information was shared to select companies that expressed interest in soy-based coatings for paper packaging. Companies were offered paper coating formulations/blends and a broad range of soy-based coating intermediates developed for their own testing and feedback. A few producers of paper packaging showed significant interest in our biobased coating products and expressed willingness to participate in scale-up and pilot trials. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
The team has successfully completed all project tasks. 1) Soybean oil-based copolymers and aqueous dispersions for paper coatings were produced based on vinyl monomer reactants commercially available in the US. 2) Two types of soybean oil - conventional and High Oleic Soybean Oil (HOSO) were used to produce the developmental monomers and copolymers. The monomers derived from HOSO resulted in higher copolymer yields and better polymerization kinetics compared to the monomers from conventional soybean oil. Also, paper samples coated with HOSO-based formulations showed better barrier properties compared to coating products based on conventional soybean oil. 3) Commercial soluble starch was incorporated at 20 and 30 wt.% levels to improve the rheological properties of soy polymer dispersions filled with kaolin mineral filler and cellulose nanofibers (CNFs). The optimal level of starch thickener was found to be below 20%. 4) The addition of the autoxidative drier catalyst was found to improve the barrier performance, however, impacted the viscosities of the aqueous dispersions. Although it is beneficial for the final coating, the drier catalysts dramatically reduce the shelf-life of the polymeric dispersions. Some dispersions of soy-based copolymers catalyzed with Co Hydro-Cure catalyst had a very short shelf-life. 5) The biodegradability of developmental soybean oil-based coatings was evaluated in OECD 301B ready/ultimate biodegradability testing and with Aerobic Degradation in Soil testing ASTM D5988. Based on the testing results, the polymeric materials produced showed percent biodegradation above 60%, and some of them were classified as readily degradable under 301B test conditions. The aerobic degradation testing showed that both cured and non-cured soy-based coatings degrade down to carbon dioxide at rates in the range of 2-15 wt.% per month. 6) Shelf-life studies of aqueous dispersions show that most formulations lack stability, especially those produced from conventional soybean oil and loaded with autoxidative driers. 7) Drum quantities of biodegradable coating formulation were produced for pilot coating trials, and good reproducibility in performance was recorded. 8) The biodegradable soy-based coating formula was trialed at a commercial coating line to produce 20,000 linear feet of paper for making prototype packaging bags. The soy-based formula was found to be applicable for paper coating using industrial coater.
Publications
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Progress 09/01/21 to 08/31/22
Outputs
Target Audience:Global paper companies, producers of cardboard and paper packaging. Producers of paper sizing additives and coatings that improve paper barrier properties. Our biobased and biodegradable coatings will benefit industries that are willing to reduce the use of plastic coatings for paper and are focused on environmentally friendly alternatives Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?The project has provided training and professional development opportunity for three North Dakota students - Avery Jorgensen (BS - Mechanical Engineer at NDSU), Zane Hensel (BS - Chemistry at NDSU) and Jasmine Kostelecky (BS - Biochemistryat NDSU).During the reporting period, Jasmine had an opportunity to work on the project as a Research Scientist Intern in the summer of 2022. Jasmine carried out product development work and troubleshooting of the process issues; tested CO2 evolution for the aerobic degradation studies. She learned new product characterization techniques such as F spectral techniques such as Fourier-transform infrared spectroscopy, and wet chemistry methods for productquality control. How have the results been disseminated to communities of interest?The team has approached major producers of paper packaging products in the US and established a confidential relationship by signing NDA/MTA agreements. Some technical information was shared to select companies that expressed interest in soybased coatings for paper packaging. Companies were offered paper coating formulations/blends and a broad range of biobased ingredients for their own testing and feedback. A few producers of paper packaging showed significant interest in our biobased coating products and expressed willingness to participate in scale-up and pilot trials. What do you plan to do during the next reporting period to accomplish the goals?- To demonstrate the applicability of commercially viable soy-based coating products using a commercial paper coating line (Task 8). This task will involve the estimation of raw material cost, establishing logistics, and communication with potential customers regarding tolerable add-on costs for the coated products.
Impacts
What was accomplished under these goals?
The team has successfully completed tasks 1-7 of the project. 1) Soybean oil-based copolymers and aqueous dispersions for paper coatings were produced based on vinyl monomer reactants commercially available in the US. 2) Two types of soybean oil - conventional and High Oleic Soybean Oil (HOSO) were used to produce the developmental monomers and copolymers. The monomers derived from HOSO resulted in higher copolymer yields and better polymerization kinetics compared to the monomers from conventional soybean oil. Also, paper samples coated with HOSO-based formulations showed better barrier properties compared to coating products based on conventional soybean oil. 3) Commercial soluble starch was incorporated at 20 and 30 wt.% levels to improve the rheological properties of soy polymer dispersions filled with kaolin mineral filler and cellulose nanofibers (CNFs). The optimal level of starch thickener was found to be below 20%. 4) The addition of the autoxidative drier catalyst was found to improve the barrier performance, however, impacted the viscosities of the aqueous dispersions. Although it is beneficial for the final coating, the drier catalysts dramatically reduce the shelf-life of the polymeric dispersions. Some dispersions of soy-based copolymers catalyzed with Co Hydro-Cure catalyst had a very short shelf-life. 5) The biodegradability of developmental soybean oil-based coatings was evaluated in OECD 301B ready/ultimate biodegradability testing and with Aerobic Degradation in Soil testing ASTM D5988. Based on the testing results, the polymeric materials produced showed percent biodegradation above 60%, and some of them were classified as readily degradable under 301B test conditions. The aerobic degradation testing showed that both cured and non-cured soy-based coatings degrade down to carbon dioxide at rates in the range of 2-15 wt.% per month. 6)Shelf-life studiesof aqueous dispersions show thatmost formulations lack stability, especiallythose produced from conventional soybean oil andloaded with autoxidative driers. 7) Drum quantities of biodegradable coating formulation were produced for pilot coating trials, and good reproducibility in performance was recorded.
Publications
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Progress 09/01/20 to 08/31/21
Outputs
Target Audience:Global paper companies, producers of cardboard and paper packaging. Producers of paper sizing additives and coatings that improve paper barrier properties. Our biobased and biodegradable coatings will benefit industries that are willing to reduce the use of plastic coatings for paper and are focused on environmentally friendly materials. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?The project has provided training and professional development opportunity for two North Dakota students - Avery Jorgensen (BS - Mechanical Engineer at NDSU) and Zane Hensel(BS - Chemistry at NDSU). Avery Jorgensenhad an opportunity to work on the project as a Research Scientist Intern in the summer 2021. Avery participated in multiple stages of technology development and product development. He performed: 1) soy-based monomer purification via WFE distillation - assembled WFE setup for continuous distillation.2) paper coating trials and testing ofbarrier properties for coated paper products with TAPPI and ASTM methods. Avery learned how to use determine product quality using spectral techniques such as Nuclear Magnetic Resonance Spectroscopy. Zane Henselhad an opportunity to work on the project as a Research Scientist Intern in 2021. Zane participated in multiple stages of the new biobased product development process: 1) transformation of soy oils into reactive soy vinyl monomers, 2) polymerization of the reactive monomers into different polymers and copolymers; 3) determining feasibility of new polymers as materials for coatings 4) troubleshooting of the polymerization process issues. 5) determining safety characteristics such as flammability, and combustibility for newly synthesized soy vinyl monomers. Zane learned techniques for scaling up small laboratory scale processes into a pilot production of polymeric resins for coatings. Also, he was very successful in studying prior art and implementing new methods in practice. How have the results been disseminated to communities of interest?The team has approached major producers of paper packaging products in the US and established a confidential relationship by signing NDA/MTA agreements. Some technical information was shared to select companies that expressed interest in soy-based coatings for paper packaging. Companies were offered paper coating formulations/blends and a broad range of biobased ingredients for their own testing and feedback. What do you plan to do during the next reporting period to accomplish the goals?- To demonstrate the scalability and reproducibility of our production process using pilot laboratory reactors. - To produce and ship varieties of biobased coating products to potential customers for their evaluation. -To determine the applicability of the best performing soy-based paper coatings by running a pilot-scale paper coating line.
Impacts
What was accomplished under these goals?
The team has successfully completed tasks 1 through5 of the project.1) Soybean oil-based copolymers and aqueous dispersions for paper coatings were produced based on vinyl monomer reactants commercially available in the US. 2) Two types of soybean oil - conventional and High Oleic Soybean Oil (HOSO) were used to produce the developmental monomers and copolymers. The monomers derived from HOSOresulted in higher copolymer yields and better polymerization kinetics compared to the monomers from conventional soybean oil. Also, paper samples coated with HOSO-based formulations showed better barrier properties compared to coating products based on conventional soybean oil. 3) Commercial soluble starch was incorporated at 20 and 30 wt.% levels to improve the rheological properties of soy polymer dispersions filled with kaolin mineral filler and cellulose nanofibers (CNFs). The optimal level of starch thickener was found to be below 20%. 4)The addition of the autoxidative drier catalyst was found to improvethe barrier performance, however, impacted the viscosities of the aqueous dispersions. Although it is beneficial for the final coating, the drier catalysts dramatically reducethe shelf-life of the polymeric dispersions. Some dispersions of soy-based copolymers catalyzed with Co Hydro-Cure catalyst had a very short shelf-life. 5) The biodegradability of developmental soybean oil-based coatings was evaluated in OECD 301B ready/ultimate biodegradability testing and with Aerobic Degradation in Soil testing ASTM D5988. Based on the testing results, the polymeric materials produced showed percent biodegradation above 60%, and some of them were classified as readily degradable under 301B test conditions. The aerobic degradation testing showed that both cured and non-cured soy-based coatings degrade down to carbon dioxide at rates in the range of 2-15 wt.% per month. Tasks 6 through 8 are still in progress.
Publications
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Progress 09/01/19 to 08/31/20
Outputs
Target Audience:Global paper companies, producers of cardboard and paper packaging. Producers of paper sizing additives and coatingsthat improve paper barrier properties. Our developmental biobased and biodegradable coatings will benefit industries that are willing to reduce the use of plastic coatings for paper and are focused on environmentally friendly alternatives. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?
Nothing Reported
How have the results been disseminated to communities of interest?
Nothing Reported
What do you plan to do during the next reporting period to accomplish the goals?- To evaluate the effect of added auto-oxidative driers and hydrophobic soy polyester additives on thecuring and the barrier properties of the dispersion coatings based on the newsoy oil copolymers. - To determine stability (shelf-life) of aqueous dispersions at different copolymer concentrations and pH. - To demonstrate the scalability and reproducibility of the new process using a 10L pilot reactor. - To determine the applicability of aqueous dispersions based on soy copolymers by running a pilot-scale paper coating line using a pilot coater
Impacts
What was accomplished under these goals?
The team has successfully completed task 1,2,3 and 5 of the project. 1) Soybean oil-based copolymers and aqueous dispersions for paper coatings were produced based on vinyl monomer reactants commercially available in the US. 2) Two types of soybean oil - conventional and High Oleic Soybean Oil (HOSO) were used to produce the developmental monomers and copolymers. The monomers derived from HOSO oil resulted in higher copolymer yields and better polymerization kinetics compared to the monomers from conventional soybean oil. Also, paper samplescoated with HOSO-based formulations showed better barrier properties compared to coating products based on conventional soybean oil. 3) Commercial soluble starch was utilized at 20 and 30% levels to improve the rheological properties of soy polymer dispersions filled with kaolin mineral fillerand cellulose nanofibers (CNFs). The optimal level of starch thickener was found to be below 20%. 5) The biodegradability of developmental soybean oil-based polymers was evaluated in OECD 301B ready/ultimate biodegradability testing. Based on the testing results, the polymeric materials produced showed percent biodegradation above 60% and some of them were classified as readily degradable. Tasks 4, 6, 7, and 8 are still in progress.
Publications
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