Presentation on theme: "Frontiers of Research in Sustainable Forest Products SUNY College of Environmental Science & Forestry October 25, 2006 Ron Brown MeadWestvaco Corporation."— Presentation transcript:
Frontiers of Research in Sustainable Forest Products SUNY College of Environmental Science & Forestry October 25, 2006 Ron Brown MeadWestvaco Corporation
2 Research Frontiers – Sustainable Products Scope: Sustainability of forest-based products $154 billion in 2004 – paper and paperboard products (AF&PA) $103 billion in 2004 – wood products (AF&PA) Assumes sustainable forestry Questions: What does sustainability mean in forest products? What drivers and trends are influencing our products? What current research activities address sustainable products? What research frontiers are noteworthy for sustainable products?
3 What does sustainability mean in forest products? World Business Council for Sustainable Development “We define sustainable development as forms of progress that meet the needs of the present without compromising the ability of future generations to meet their needs.” Wal-Mart Kurt Boyd, Wal-Mart, October 9, 2006, presentation at WMU Sustainability – actions that support the quality of life now and for generations to come Europe – PIRA SustainPack Conference, Dec 2005 Cyclic, solar, safe
4 What does sustainability mean in packaging? Sustainable Packaging Coalition Sustainable packaging Is beneficial, safe & healthy for individuals and communities throughout its life cycle Meets market criteria for performance and cost Is sourced, manufactured, transported, and recycled using renewable energy Maximizes the use of renewable or recycled source materials Is manufactured using clean production technologies and best practices Is made from materials healthy in all probable end of life scenarios Is physically designed to optimize materials and energy Is effectively recovered and utilized in biological and/or industrial cradle to cradle cycles
5 Sustainability and packaging – Wal-Mart Wal-Mart environmental goals for 2025 – To be supplied 100% by renewable energy To create zero waste To sell products that sustain our resources and our environment Wal-Mart is committed to Reducing solid waste from US stores and clubs by 25% in next three years Working with suppliers to create less packaging overall, increase product packaging recycling, and increase use of post-consumer material Replacing some private brand packaging with alternatives that are more sustainable and recyclable within the next two years
6 Sustainability and packaging – Wal-Mart Wal-Mart Launches 5-Year Plan to Reduce Packaging (Sept 22, 2006, News Release) Packaging scorecard – rate 60,000 worldwide suppliers on ability to reduce overall packaging by 5% Begin in – packaging scorecard with 2,000 private label suppliers Savings of $10.98 billion from 5% of 10% of global packaging industry, $3.4 billion to Wal-Mart Reducing packaging on fewer than 300 toys last year, Wal-Mart saved 3425 tons of corrugated board, 1358 barrels of oil, $3.5 million/yr in transportation costs Cost-neutral is okay - Per Kurt Boyd, a Wal-Mart buyer, WMU
7 Sustainability and printing papers – Time Inc. Time Inc. World’s largest magazine publisher – 150 titles 2005 Sustainability Report Ann S. Moore, Chairman and CEO: Sustainability for us refers to creating a durable business that provides jobs to communities and returns to shareholders for the long haul and that protects all our human and natural resources. A sustainable company will deliver at least as many benefits to future generations as it does to people alive today. Meeting economic, social and environmental goals are the three pillars of sustainability, and those goals are not in conflict.
8 Sustainability and printing papers – Time Inc. Time Inc Sustainability Report For 15 years, Time has been working with paper suppliers and printers to develop lighter grades of paper that will still hold up well on the presses and maintain the satisfying texture of the magazines. The results have been remarkable: in TIME, for example, the paper is nearly 18% lighter than it was in Life cycle analysis – greenhouse gases in magazine publishing:
9 What drivers are influencing forest products? Environmental Sustainability, renewable resources Waste minimization, recycling Economic Globalization of products and markets Marketing, brand development, mass customization Continual push for lower costs – oil prices Dominance of large retailers Growth of Third World economies Social & Political Demographics, aging population Convenience, on-the-go Product safety – contamination, counterfeiting Government rules and regulations Rapid communications Technological New developments – biomaterials, nanoscience Alternative energy supplies Supply chain – ERP, RFID
10 Products must perform while being sustainable Forest-based products need many properties Cost-effective for requirements of application Convert at expected speeds with no degradation of performance Print with acceptable image quality Survive distribution hazards Perform at conditions of use Satisfy safety, health, and regulatory requirements Designed for ease of use …. Sustainable – low mass, recyclable, biodegradable
11 Likely trends in forest products Products will change and evolve Brand and product marketing New performance features, new products Cost vs. performance as materials prices fluctuate Sustainability will grow in importance More renewable resources Less weight, less trash More biodegradable or recyclable New technologies will be adopted Biopolymers, green chemistry,.... Energy sources – biorefinery, solar, wind,.... Nanomaterials Smart packaging, active packaging,....
12 What current research activities address sustainable forest-based products? Agenda 2020 Technology Alliance Forest biorefinery, breakthrough manufacturing, wood products Nano in FPI European Union 6 th and 7 th Framework Programs Forest-Based Sector Technology Platform (FTP) SustainPack US government Forest Products Lab, National labs, NREL DOE Industries of the Future National Nanotechnology Initiative Universities & research institutes Institutes – STFI, Paprican, YKI Pulp & paper – SUNY ESF, WMU, NCSU, Miami,.... Packaging – MSU, Clemson Industry & supplier R&D
13 SustainPack – Sustainable Packaging Objective: To establish breakthroughs in fiber-based packaging value chain 4-year program: June 2004 – May partners, 13 countries in Europe 36 million Euro budget (19 million from EU 6 th Framework) Coordinated by STFI-Packforsk
14 Nano in FPI – Agenda 2020 Nanotechnology in Forest Products Industry Task group in Agenda 2020 Technology Alliance Establishing links with National Nanotechnology Initiative and other industries Industry CBAN being formed Links with chemical industry nano programs Research priorities Breakthroughs in performance/weight ratio for paper and paperboard Control of water interactions with wood and paper products Wood-derived fuels, chemicals, biopolymers Improvements in manufacturing efficiency Control of optical interactions with paper and paperboard
15 What themes are promising frontiers for research? Reduce Reuse Recycle Remove Renewable Right-sized Biodegradable Compostable Safe Environmentally- friendly Energy-efficient Effective Revenue New Moisture-resistant Strong and stiff Flexible Inexpensive ….
16 Get weight out! Reduce weight of paper, paperboard, and wood products cost-effectively while maintaining performance properties Opportunity exists for breakthrough approaches Specific modulus (E/ ) of wood matches steel Paper, paperboard, and wood composites are not as strong as wood
17 Get weight out! – SustainPack Reduce weight of paper and paperboard cost-effectively while maintaining performance properties SustainPack – Target reduction of 30% in paperboard Concept for 30% weight out of 3-ply structure presented at SustainPack Conference in Dec 2005 Apply breakthrough innovations using new nano-structuring technologies Kraft pulp 40 gsm CTMP 120 gsm Kraft pulp 40 gsm CTMP 62 gsm Kraft pulp 40 gsm
18 Get weight out! Reduce weight of paper and paperboard cost-effectively while maintaining performance properties Agenda 2020 Breakthrough Manufacturing – 15-20% Nano in FPI – Stretch goal of 40%, or 45 lb = 60 lb Research – technical approaches Stiffness and strength improvement Fiber engineering, sheet structure Surface treatments Nanoscience – e.g., LbL by Lvov showed 50% tensile gain Biomimicry Strength – imitate natural structures Opacity – especially in lightweight printing papers Fiber bonding fundamentals Non-fiber materials
19 Get oil out! Use renewable resources instead of oil-based materials Make paperboard and wood products that reduce the demand for plastics Fiber/polymer composites Nanostructures, biomimicry Develop biopolymers and biomaterials from wood to replace oil-based polymers and chemicals Forest biorefinery feedstocks Polyhydroxyalkanoates (PHAs) and other polymers Green chemistry – e.g. lignin-based phenolics Use renewable materials and renewable energy in manufacture of paper, paperboard, and wood products
20 Control effect of moisture! Develop new approaches to control the interactions of water and moisture with paper, paperboard, and wood products Control hygroexpansivity of paper and paperboard Understand nanoscale structures in fibers and how water affects them Turn wettability off and on Develop barriers and mechanisms for controlling water transport within wood and paper products Increase rate of removing water from wood and paper products
21 Add new features! Introduce new performance features to paper, paperboard, and wood products Helpful for long-term growth and sustainability of forest products industry Optical features achieved through nanoscience, photonics, and biomimicry Abalone shells, pearlescent appearance Color and shade without dyes and pigments Brightness without optical brighteners Printed electronics and sensors Super-high strength products Flexible, formable, shapeable
22 Use new processes! New manufacturing processes can make our operations more sustainable and efficient 61-77% of greenhouse gas emissions in magazine publishing are from pulp & paper mills – Time Inc study Renewable energy, less oil and natural gas for energy Efficiency and sustainability – pulping, bleaching, recovery, papermaking Application of nanoscience in operations – mixing, refining, sheet forming, fiber bonding, drying,.... New pulping, bleaching, chemical recovery processes Cost-effective use of waste and recycled materials
23 Create new technologies! Be creative and innovative. Imagine.... Carbohydrate industry rather than wood and fiber Manufacture fibril/fiber structure from sugars synthetically Synthetic photosynthesis – carbon dioxide to sugars Transparent paperboard....
24 What research frontiers are noteworthy for sustainable products? Get weight out – less weight at equal performance Get oil out – renewable resources Control effect of moisture Add new features Use new processes Create new technologies