Advancements in Starch Derived Biomaterials and Chemicals Keenan.pdf · Advancements in Starch...

Innovative Processes to High Value Biobased Products

Advancements in Starch Derived

Biomaterials and Chemicals

Greg Keenan, Director North American BioMaterial Solutions- Ingredion

JULY 20, 2015

High value biobased products from starch

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Value = Benefit - Cost

One of the world’s leading ingredient solutions

companies

• Focused on providing critical ingredients to the food,

beverage, industrial and personal care industries

• A global network of manufacturing facilities, Ingredion

Idea Labs™ innovation centers and sales offices

• Over 11,000 talented and experienced employees

• $5.7 billion net sales in 2014

• One of the World’s Most Admired Companies as

named by FORTUNE magazine for six consecutive

years - 2015-2010

• Headquartered in Westchester, Illinois

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Our presence in North America

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• Operations in Canada, Mexico

and the United States

• 19 plants producing a range of

sweeteners and starches

• 13 U.S. facilities providing a full

line of starches, sweeteners and

specialty starches

• Global headquarters for

Ingredion Idea Labs™

innovation centers in

Bridgewater, NJ

• Only corn refiner with plants

located in Canada

ProductionFacility

Global headquarters Ingredion Idea Labs™ Innovation Centers

Ingredion Idea Labs™ Innovation Center

NORTH AMERICA

55% 2014 net sales

Biomaterial Solutions- high performance ingredients that leverage

core technologies and product capabilities

• Construction: Delivering specialty

ingredients for nonwovens, adhesives and

building materials

• Home care: Producing more effective

softeners and detergent products

• Personal care: Enabling personal care

products to deliver the sensorial

performance consumers desire

• Packaging: Creating high-performance,

functional packaging

• Oil & Gas: Improving the performance

and environmental impact of oil and gas

drilling operations

Home

Care

Cons-

truction

Personal

Care

Food

Packaging

Oil &

Gas

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Corn Biorefinery: Feed, Food, Fuel & Biomaterials

Dent

Waxy

High Amylose

Food Ingredients

Industrial Ingredients

Starch Conversion

and Modification

Physical

Chemical

Enzymatic

Wet Milling and

Starch Separation

• Starch: 60 - 70%

• Protein: 10%

• Fiber: 10%

• Oil: 4%

Feed Fiber/Protein

Corn

Oil

Starch

Modifications create

higher value

molecules and

functionalities:

rheology, charge,

thickening, tack,

hydrophobicity, film

forming, texture,

hydrophilicity, texture,

etc.

Upgrading Starch: Unmodified, Modified and Feedstock

Native Starch

Starch backbone is retained but is

modified physically, enzymatically or

chemically to enhance functionality, ie.

etherification, cationization, cross-

linking, oxidation, etc.

Hydrolyzed (Feedstock)

Native Starch (Unmodified)

Biopolymer (Modified Starch) Plant Source Size (Microns) Average

(Microns) Dent Corn 5-30 25 Waxy Corn 5-25 15 Potato 15-150 100 Rice 1-5 2 Tapioca 5-35 20

Starch is hydrolyzed to its glucose

monomer for conversion into other

chemicals, ie. succinic acid, 1,3-PDO,

lactic acid, etc.

Unmodified starch in granular form

providing limited function.

Cost, Processing,

Function, Value

Amylose

Amylopectin

Feedstock choice and process technologies

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Feedstock

StarchCorn

Potato Tapioca

Rice

Natural Gums

CoproductsProtein Fiber

Base Modification

EsterificationAnionic

EtherificationCationic, Nonionic

UnmodifiedDry, Slurry

Proprietary Processing

PenFlex™ Aqueous

PenPoly™Polymerization

PenSolv™Solvent

PenCap™Encapsulation

Delivery

Powder Spray Dry

Fluidized Bed Roll Dry

Liquid Dispersion

Slurry

ExtrusionPellets

Penford has the broadest line of feedstock and modification technologies in the industry.

Technology Platforms

• Performance Biopolymers

– Tailored charged products

– Personal care polymers, water treatment, oil field

applications

• Biobased Latex

– Film forming / coating products

– Coatings, adhesives

• Natural / Synthetic Composites

– Hybrid products for functionality

– Oil & gas, adhesives, barrier coatings, bioplastics

• Encapsulation

– Encapsulation of actives for delivery and release

– Oil & gas, adhesives, agriculture, household & personal

care

Bioproducts for Packaging

PEN-COTE™ D is in 43%

of coated recycled board

tons

and 55% of carton

carrier tons

ECOPLASTIC™

• Biocontent 80%

• Improved oxygen barrier

• Reduce food waste

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http://www.tetrapak.com/us/Documents/Millennials and Food Packaging Final.pdf

Innovation from Seed to Film

• Plantic is a leader in bioplastic materials.

– Patented technology uses modified high amylose starch as a key building block

– Products contain up to 85% biopolymers derived from starch

– Materials exhibit high gas barrier properties and are biodegradable & compostable

• Ingredion is a strategic feedstock partner

– Developed proprietary non-GMO corn hybrids optimized for Plantic’s products

– Support feedstock supply chain from seed to starch extraction and modification.

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Etherification

Extrusion

Sheet Production

& Lamination

Superior performance, sustainably

New eco Plastic™ builds on high gas barrier functionality to deliver superior

packaging materials that exceed performance and sustainability attributes of

existing products.

– Extends shelf life

– Outstanding gas barrier performance

– Consumes 50% less energy in its life cycle

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Material Thickness OTR* Yield Sealing Temp.

Eco Plastic™ 450 micron 0.07 cc/m2 1.76 m2/kg 120 – 130oC

PET/EVOH/PE 450 micron 0.80 cc/m2 1.73 m2/kg 135 – 175oC

*cm3/m2/24hr.atm @ 10oC, 90/50% RH (Mocon test data)

Naturally derived ingredients that perform

Personal Care Deposition and Conditioning is a $1 Billion Global Market; Less

than 10% of US market is biobased

Mintel Hair Treatments & Colorants, April 2015

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Penford Launches PenCare DP

INCI Name: Starch

Hydroxypropyltrimonium Chloride

Applications:

Rinse off: Shampoos, conditioners, body

washes

Leave on: Lotions, styling products,

conditioners

Resonates with Consumers

Non-GMO

Not ethoxylated

Boron free

Not animal tested

No preservatives

PenCare DP represents a new family of naturally-based deposition ingredients

that are built on a novel, patent pending, cationic biopolymer.

O

O

CH2 OH

OH

OH

O

O

CH2 OH

O

OH

O

O

CH2 OH

OH

OH

N

CH3CH3

H3C

HO

Cl

m n

1

23

4

5

6

Structure

BASF: Polymers and active ingredients suitable for the development of

shampoo formulations, 2003

Performance Attributes

Superior Performance and Naturally Based. PenCare DP shows superior

performance over traditional deposition polymers while maintaining high

biobased content.

For more information

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visit www.ingredion.com