Corn Fiber
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| Image retrieved http://nickelridge.ca/ |
What is corn fiber?
Corn fiber is a PLA (PolyLactic Acid) fiber. This fiber comes from corn starch that generates a lactic acid by fermentation. Corn fiber is made from corn starch although not a natural fiber as there is a chemical transformation. It is considered a renewable fiber, as it does not come from a fossil product. (Chavin, 2001)
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| Image of Corn to Polymer and Fiber retrieved from: http://www2.dupont.com/Sorona/en_US/assets/images/Corn%20to%20clothing.jpg |
The Science that underpins Corn Fiber.
Why is Corn fiber considered so innovative?
There is a large process and high science associated with the production of corn fiber.
- The corn is harvested
- Sugar (glucose) is extracted from the corn kernal. Scientists are working towards extracting glucose from the stalk and straw to reduce the waste and cost.(Dupont,2010)
- Fermentation: The Glucose is fed down pipes into a three story vat containing genetically engineered organisms, water and some vitamins and Minerals. The machine than excretes the 2 carbon Molecule (PDO) (Dupont,2010)
- The Monomer is moved to a ploymer plant where it is mixed together with petroleum based monomer. The Polymer comes out in long strands and then is chopped into small pellets. (Dupont,2010)
- The Serona pellets are then shipped to a textile plant where they are spun into fibers. (Dupont,2010)
Corn fiber is innovative as it is using a natural, renewable source being corn starch, which is the sugar from corn. PLA fibers can be processed by extrusion, injection moulding, film and sheet casting, and spinning, providing access to a wide variety of materials. (Dugan, 2007) Through this corn fiber can mimic natural and synthetic fibers. Corn fibers are replacements for other fibers as they are turned into a range of textile fibers from its original pellet form(Dugan, 2007). The material is said to use 20-50% less petroleum based resources than polyesters, making it innovative because it is new and different from other fibers. (Glorytang,2008)
Corn Fiber is like natural fibers, its raw material is both renewable and
non-polluting. This eliminates the
often-underestimated problems associated with using a finite supply of oil as a
raw material(Gruber& O'Brian,2003). In contrast to sythentic fibers corn is grown from the suns energy, whereas synthetic fibres rely on reserves of fossill fuels that take millions of years to regenerate and are a declining source(Gruber& O'Brian,2003). Corn fibers are also considered innovative by the new and improved end uses that scientists are still improving on. This innovative PLA fiber is now being introduced to the medical field where it is being manipulated and blended with human cells to create human organs. (Farrington, 2011)
Describe how the innovation fits into the categories.Does it apply to more than one category. How and why ?
The innovation of corn fiber fits into fiber, yarns and fabrics.
The reason it complies to all is that the corn sugar is fermented and then extruded as a pellet(Dupont,2010). From that pellet the corn monomer is spun or extruded to create a fiber. From this process the corn fiber can stay in that form and then become a non woven material, these include wipes, diapers and feline hygiene pads(Dugan, 2007). The new technology is now allowing a single corn fibre be blended with human cells to create human organs (Dugan, 2007). These examples highlight how the simple fiber can be then created into a non woven material or a human organ base. The fiber can also be spun and manufactured as a yarn. This yarn can then be blended with wool, silk or cotton etc and be produced as a blended yarn to then create a fabric like Ingeo (Reena, 2009). The innovative corn fiber can be blended with a variety of other yarns to alter the properties for the intended purpose.
The main category is the overall fabric that has been created from the Fiber and yarn stage. The corn fibre can be mixed and blended to create non woven or woven fabrics that can be used fro apparel, medical industry, homewares and other end uses.
Outline a brief history of the development and use of this innovative technology.
Is this a physical, a scientific or another type of technological innovation?
Corn fiber is a technological innovation in regards to a scientific type. This is a textile chemistry based innovation because through science corn sugar can be produced to create a wide variety of end uses( Chavin, 2001). When the corn starch is extracted from the corn kernel it is then fermented by being mixed with water and living organisms(Dupont, 2010). Through the fermentation process the glucose/ corn sugar is broken down due to the mixture with the micro organisms(Dupont,2010), this than becomes a lactide acid. This acid is then polymerised to become polylactide then is extruded to then become a textile form(Glorytang, 2008).
Describe potential current/future uses and specific applications.
The main and potential use of PLA fiber is more than developing new products but the overall goal of reducing the impact of the textile industry on the environment. The result is a product that is more sustainable than comparable polymers on the market today. This Technology allows the worlds most commonly used materials to be made from a simple renewable plant source. the plant source is then turned into fivers using melt spinning equipment and processes. (Farrington, 2010)
Outline any ethical, environmental or other concerns associated with this technology.
Corn fiber has a lot of positive effects on the environment and is also considered an ethical product. This PLA fiber is made from a natural and renewable source which is using 20-40% less fossil fuels then a synthetic fibre(Chavin, 2001). Also this innovative fibre is less envronmentally costly than other biodegradable fibers because the whole entire mass can be eventually recreated into a new PLA basis material (Gruber& O'Brian,2003).
PLA is not perfectly sustainable polymer since some energy is used my processing the converted corn polymer into fibres and fabrics. But even through this processsing it is has less of an overall impact on the environment because it is started from a natural source which is renewable. (Gruber& O'Brian,2003)
Corn fiber is also biodegradble which allows the fibre, yarn or fabric to be broken down and decomposed in the environement without causing harm and landfil. (Gruber& O'Brian,2003)
Describe specific uses and applications
Corn fiber can mimic synthetic and natural fibers, spun or filament fiber allowing a wide variety of end uses (Chavin, 2001). PLA fibers falls into more than one sub field of textiles, being clothing, medical and also the packaging industry. Because corn fiber can be spun or extruded to have different properties, its properties and applications are endless. The corn fiber can become a non woven material, these include wipes, diapers and feline hygiene pads.(Gruber& O'Brian,2003).
Corn fiber balances strength and reilience with softness and comfort (Reena, 2009). Unlike normal synthetic fibres PLA fibers do not absorb light. This allows for low strength loss compared to petroleum based UV light. The fiber can also be spun and manufactured as a yarn (Dugan, 2007).This yarn can then be blended with wool, silk or cotton etc and be produced as a blended yarn to then create a fabric like Iactron(Gruber& O'Brian,2003).
The innovation of corn fiber fits into fiber, yarns and fabrics.
The reason it complies to all is that the corn sugar is fermented and then extruded as a pellet(Dupont,2010). From that pellet the corn monomer is spun or extruded to create a fiber. From this process the corn fiber can stay in that form and then become a non woven material, these include wipes, diapers and feline hygiene pads(Dugan, 2007). The new technology is now allowing a single corn fibre be blended with human cells to create human organs (Dugan, 2007). These examples highlight how the simple fiber can be then created into a non woven material or a human organ base. The fiber can also be spun and manufactured as a yarn. This yarn can then be blended with wool, silk or cotton etc and be produced as a blended yarn to then create a fabric like Ingeo (Reena, 2009). The innovative corn fiber can be blended with a variety of other yarns to alter the properties for the intended purpose.
The main category is the overall fabric that has been created from the Fiber and yarn stage. The corn fibre can be mixed and blended to create non woven or woven fabrics that can be used fro apparel, medical industry, homewares and other end uses.
Outline a brief history of the development and use of this innovative technology.
PLA has been investigated and tested for over a century. In 1845 the first experiment was done by Pelouze. He condensed lactic
acid by distillation of water to form low
molecular-weight. This was unsuccessful but about 50 years later it was tested again. The experiment comprised of preparing PLA from lactide. This was also unsuccessful. In
1932 another group was able to
polymerise lactide to PLA but the method was unsuitable for practical use. Even though PLA had be known for over a century its usefullness had not been practical. In 1986, PLA was
described as having potential as a plastic . In 1988, Cargill began an
investigation into lactic acid, lactide, and
PLA and concluded that although PLA was
an interesting material, it was not practical
with the then-known technology. Cargill knew the technology wouldnt allow it to be produced so he began to address the manufacturing processes. In
1997, Cargill and The Dow Chemical Company formed Cargill Dow LLC in order to
develop and bring to full commercialisation
the PLA technology and products. (Gruber& O'Brian,2003)
Is this a physical, a scientific or another type of technological innovation?
Corn fiber is a technological innovation in regards to a scientific type. This is a textile chemistry based innovation because through science corn sugar can be produced to create a wide variety of end uses( Chavin, 2001). When the corn starch is extracted from the corn kernel it is then fermented by being mixed with water and living organisms(Dupont, 2010). Through the fermentation process the glucose/ corn sugar is broken down due to the mixture with the micro organisms(Dupont,2010), this than becomes a lactide acid. This acid is then polymerised to become polylactide then is extruded to then become a textile form(Glorytang, 2008).
Describe potential current/future uses and specific applications.
The main and potential use of PLA fiber is more than developing new products but the overall goal of reducing the impact of the textile industry on the environment. The result is a product that is more sustainable than comparable polymers on the market today. This Technology allows the worlds most commonly used materials to be made from a simple renewable plant source. the plant source is then turned into fivers using melt spinning equipment and processes. (Farrington, 2010)
Outline any ethical, environmental or other concerns associated with this technology.
Corn fiber has a lot of positive effects on the environment and is also considered an ethical product. This PLA fiber is made from a natural and renewable source which is using 20-40% less fossil fuels then a synthetic fibre(Chavin, 2001). Also this innovative fibre is less envronmentally costly than other biodegradable fibers because the whole entire mass can be eventually recreated into a new PLA basis material (Gruber& O'Brian,2003).
PLA is not perfectly sustainable polymer since some energy is used my processing the converted corn polymer into fibres and fabrics. But even through this processsing it is has less of an overall impact on the environment because it is started from a natural source which is renewable. (Gruber& O'Brian,2003)
Corn fiber is also biodegradble which allows the fibre, yarn or fabric to be broken down and decomposed in the environement without causing harm and landfil. (Gruber& O'Brian,2003)
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| biodegradable corn startch image retrieved from: rbchavan.yolasite.com/resources/Lactron.doc |
Describe specific uses and applications
Corn fiber can mimic synthetic and natural fibers, spun or filament fiber allowing a wide variety of end uses (Chavin, 2001). PLA fibers falls into more than one sub field of textiles, being clothing, medical and also the packaging industry. Because corn fiber can be spun or extruded to have different properties, its properties and applications are endless. The corn fiber can become a non woven material, these include wipes, diapers and feline hygiene pads.(Gruber& O'Brian,2003).
Corn fiber balances strength and reilience with softness and comfort (Reena, 2009). Unlike normal synthetic fibres PLA fibers do not absorb light. This allows for low strength loss compared to petroleum based UV light. The fiber can also be spun and manufactured as a yarn (Dugan, 2007).This yarn can then be blended with wool, silk or cotton etc and be produced as a blended yarn to then create a fabric like Iactron(Gruber& O'Brian,2003).
SMART CARPET
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| Image received of SmartStrand Carpet : http://www.owencarpet.com/smartstrand-carpet-fiber.htm |
Smart carpet is a major end use of corn fiber. It is called Dupont Sorona which is an extruded yarn of corn fiber (Dupont, 2010). When the fermented polymer is extruded the serona is constructed with a unique kink that allows for outstanding properties. SmartStrand Carpet is manufactured using Sorona Fibers because it uses 30% less energy and reduces greenhouse gases by 63%(Dupont, 2010). Smart Strand carpets have everlasting properties engineered into the fiber so it will never wear or wash off. The stain and soil resistant property is embedded inside the fiber so it is not only prevented from soil and stains it is also UV protected(Dupont, 2010). 37% of Smart Carpet is made from a renewable source. (Dupont, 2010)
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| Serona structure retrieved from: http://www2.dupont.com/Sorona/en_US/home/science_of_sorona.html |
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| Sorona compared to nylon in green house gas emmisions retrieved from: http://www2.dupont.com/Sorona/en_US/home/science_of_sorona.html |
The diagram above highlights the positive impact on the environment as it is limiting greenhouse gas affects on the environment compared to the standard carpet being nylon.
Recycling:
Dupont is looking into the recyclability of SmartStrand carpets because if the sorona fiber carpet is removed from its backing then it is fully recyclable. The problem is today that recycling plants do not accept PLA fibers as of yet.(Dupont, 2010)
Interesting:
- SmartStrand carpet resisted up to 50% more soil than normal nylon carpets
- using the same cleaning products smartStrand carpet comes up 42% cleaner.
- Resists UV light so colour fastness lasts.
- Pet Urine wont even stain the carpet.
Drawbacks:
- Even though it is recyclable in carpet form, recyclable plants do not recycle it yet.
References:
Chavin,
R.B. (2001). Ecofriendly synthetic fiber from corn, 16(1) 26-36.
Retrieved fromhttp://www.slideshare.net/nega2002/biodegradable-synthetic-fibre-from-corn
Reena , A. (2009, November 13). Corn fiber: a new fiber on
horizon. Retrieved from http://www.fibre2fashion.com/industry-article/23/2216/corn-fiber-a-new-fiber-on-horizon1.asp
GloryTang
(2008). PLA Fiber, Retrieved fromhttp://www.glorytang.com/html/zh/product/Man-made%20Fiber/PLA_fiber.html
Mohork
Industries (2010). SmartStrand [Smartstrand0 Mohork]. Retrieved from http://www.mohawkflooring.com/flooring/carpet/smartstrand.aspx
Dugan, J. (2007). Novel Properties of PLA
Fibers, 1(1) 1-10. Retrieved from www.fitfibers.com/files/PLA%20Fibers.doc
Gruber, P, O’Brian, M. (2003).
Polylactides PLA Natureworks, 8, 235-239. Retrieved from http://www.wiley-vch.de/books/biopoly/pdf_v04/bpol4008_235_239.pdf
Dupont, 2012. Sorona. Retrieved from http://www2.dupont.com/Sorona/en_US/home/science_of_sorona.html
