Japan’s Polyplastics has developed a cellulose-reinforced polypropylene LFT compound featuring reduced weight and higher rigidity, while Canada’s INCA Renewtech has received funding to develop and trial hemp-based bio-composites at Toyota and automotive Tier 1 suppliers.

Efforts to develop and commercialize composite materials reinforced with natural fibers are accelerating as automakers target reduced carbon footprints for their onroad offerings. Engineering plastics supplier Polyplastics has debuted an eco-friendly composite of polypropylene (PP) resin and long cellulose fiber, which delivers low density, high specific rigidity, high impact strength, and optimized damping for a range of applications, including electric vehicle (EV) motor components and head-up displays.

Furthermore, Canada’s INCA Renewable Technologies announced that it has been approved for a $202,534 grant from the Alberta Innovates Agri-food and Bioindustrial Innovation Program to complete development of its novel hemp-based bio-composites and conduct line trials at Toyota and automotive Tier 1 part makers.

Reduced cost and recyclability

According to David Saltman, chairman and CEO of INCA Renewtech, the grant enables production and trialing of several thousand pounds of INCA’s BioPlastics. Further, “by replacing glass-reinforced plastics with natural fiber composites we will enable our industrial partners to produce stronger and lighter products. Our customers will also be able to reduce costs by recycling trim waste and produce recyclable end products.”

Converters can manufacture products using Inca BioPlastics pellets on existing injection molding equipment with no modification, enjoying 59% less water consumption and 64% less waste production, according to an independent life cycle analysis by GreenStep Solutions. Image courtesy of Inca Renewable Technologies.

INCA’s proposed operation in Vegreville, AB, will purchase hemp biomass from farmers growing the cultivar for plant-based protein, refine this renewable resource, and produce advanced composites for the automotive and other industries. This secondary income for farmers will help make hemp one of the most profitable cash crops in the Canadian prairie and expand utilization of the hemp cultivar.

According to Scott Oppliger, principal engineer at Toyota Motor Manufacturing and Engineering: “The shift toward environmentally friendly materials is crucial in our efforts to reduce our carbon footprints and mitigate climate change. Inca’s injection- and extrusion-grade pellets not only promise enhanced physical properties in finished products but also significantly improve CO₂-equivalent emissions.”

Lower carbon footprint

Polyplastics’ Plastron LFT (long-fiber-reinforced thermoplastic) RA627P incorporating 30% regenerated continuous unidirectional cellulose fiber achieves a roughly 30% lower carbon footprint than 30% short-glass fiber-reinforced PP resin. The regenerated cellulose fiber exhibits high strength and elasticity thanks to unique spinning conditions and polymerization of the raw cellulose materials.

In addition, Plastron RA627P delivers roughly 10% lower density than 30% short-glass-fiber-reinforced PP resin, while maintaining roughly the same flexural modulus. The material’s specific rigidity is higher than 30% short-glass-fiber-reinforced PP resin, together with a large loss coefficient.

Polyplastics is developing other new grades made from recycled PP resin that can further mitigate carbon footprint levels while expanding its portfolio of Plastron LFT products to meet growing market needs.

Originally published at Plastics Today