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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
2
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
•3
Our presence in North America
4
• 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
5
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
8
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
10
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.
11
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
12
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
13
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.