1.
Bioplastic Container Cropping Systems
Project Background
James Schrader - Iowa State University

2.
Sustainability in Industry
The continuous development and implementation
of products and practices that reduce waste,
minimize environmental impacts, and ensure our
ability to meet the world's needs today without
compromising the ability to meet the needs of
tomorrow.

3.
Container Cropping Systems
Petroleum Plastic Containers
Efficient
Productive
Profitable
Sustainable ?
Environmentally Responsible ?

4.
Petroleum Plastic Containers
• Over 4 Billion used per year
• ~ 832,000 tons
• Less than 2% are recycled or re-used
Petroleum Plastic Containers
• Over 4 Billion used per year
• ~ 832,000 tons
• Less than 2% are recycled or re-used

5.
5-Year Project
“Bioplastic Container Cropping Systems:
Green Technology for the Green Industry”
• USDA - Specialty Crop Research Initiative
• Multi-disciplinary : Multi-institutional
• Systems based approach
• Research and Extension
• Collaboration with Industry

6.
Principal Investigator: William Graves
Department of Horticulture,
Iowa State University
graves@iastate.edu
Co-Principal Investigators:
David Grewell Barrett Kirwan
Agricultural and Biosystems Engineering Agricultural & Consumer Economics
Iowa State University University of Illinois, Urbana
dgrewell@iastate.edu bkirwan@illinois.edu
Heidi Kratsch Chris Currey
Extension Horticulture Specialist Department of Horticulture
University of Nevada, Reno Iowa State University
kratschh@unce.unr.edu ccurrey@iastate.edu
James Schrader
Department of Horticulture
Iowa State University
jschrade@iastate.edu

7.
To create a bioplastic container that functions as well
as (or better than) petroleum-based containers during
plant production and sale, but then can be broken to
smaller pieces, installed with the plant, and provide a
fertilizer or soil-conditioning effect as the bioplastic
biodegrades.
Our Original Target

8.
All Biorenewable Material
Additional Categories for Consideration
1. Containers biodegradable in soil (within a timeline of 1 to 2 years)
2. Containers not degradable in soil, but degradable by
composting
3. Exceptional or durable containers that can be recycled
- or will be carbon-negative if landfilled
- carbon neutral if incinerated

9.
Containers Biodegradable in Soil
Example: PHA + DDGS (80/20)

10.
Example: PLA + BioRes™ (80/20)
Containers Not Biodegradable in Soil
but Degradable in Compost

11.
Containers with no change in
cultural practices
Example: PLA + Lignin (80/20)

12.
Containers with Additional Function
Example: PLA + Soy (50/50) - Fertilizer effect
- Root improvement

13.
First Research on Fertilizer Effect of Soy Plastics
Schrader et al.,
2013

14.
First Research on Fertilizer Effect of Soy Plastics
Schrader et al.,
2013

15.
@ 6 weeks
200 mL / week
150 ppm N
Fertilizer Effect ~ Root Improvement

16.
Three Rounds of Development and Evaluation
Round 1: Screen numerous potential bioplastics and
biocomposites
Round 2: Improve and evaluate the best 15 types from
round 1
Round 3: Manufacturer and Grower collaborations
with the best six container materials

17.
Project Components and Timeline

18.
12 Injection molded
10 Coated fiber
4 Uncoated fiber for comparison
12 Injection molded
10 Coated fiber
4 Uncoated fiber for comparison
22 Prototypes of
Bioplastics and Biocomposites
Round 1

19.
Soy-Protein
Based
SP
SP.A
SP - PLA
SP.A - PLA
SP and SP.A = Soy Protein Isolate
PLA = Polylactic Acid

20.
Mirel™ PHA from Metabolix
PHA = Polyhydroxyalkanoate
Produced by bacteria, such as Bacillus subtilis
P 1003 P 1004 P 1008
10% starch
P 4010
30% starch
P 1003
+ DDGS
P 1004
+ DDGS

21.
PLA PLA
+ DDGS
PLA
+ Stover
PLA
+ Clay
Ingeo™ PLA from NatureWorks
PLA = Polylactic Acid
Lactic acid produced by microbes, such as Lactobacillus
NatureWorks
Blair, Nebraska

22.
Dried Distillers Grains with Solubles
- DDGS

23.
Corn Stover

24.
Dip-coated Fiber Containers
Bioplastic
Coatings
• Polyurethane
from castor oil
• PLA
• Tung Oil
• Polyamide
from pine oil

25.
18 Prototypes of
Bioplastics and Biocomposites
Round 2

26.
Blend ratio Container size
Bioplastic or biocomposite material by weight 4.5 in. Gallon
Injection molded
PLA Blends and Composites
PLA + Soy 50/50 X
PLA + Soy 67/33 X
PLA + Soy + DDGS 60/30/10 X
PLA + Soy + Lignin 60/30/10 X X
PLA + DDGS 80/20 X
PLA + Lignin 80/20 X
PLA - Protein Compound (Aspen Research) - X
Recycled PLA # 1 (Aspen Research) 100% X
Recycled PLA # 2 (Aspen Research) 100% X
PHA Blends and Composites
PHA + Soy 67/33 X
PHA + DDGS 80/20 X
PHA + Lignin 80/20 X
PHA + Starch (Mirel P1008) 90/10 X X
PHA + Cellulose (Aspen Research) - X
PolyAmide Blends and Composites
PolyAmide + DDGS 70/30 X
PolyAmide + PLA 70/30 X
Petroleum plastic controls
Polypropylene 100% X
High density polyethylene (HDPE) 100% X
Fiber containers
Paper-fiber (uncoated control) - X X
Paper-fiber (one coat polyurethane) - X X
Paper-fiber (two coats polyurethane) - X X
Round 2
16 Injection molded
2 Coated fiber
1 Uncoated fiber
for comparison

27.
Results summarized in
Schrader et al. 2015. Development and evaluation of bioplastic containers for
sustainable greenhouse and nursery production. Acta Hort. (In press).
Round 2

28.
7 Injection-molded
4.5 inch
1 Injection-molded
gallon
1 Coated fiber 4.5 in.
1 Coated fiber gallon
10 Commercial-grade
Biocontainers
Round 3

29.
Collaborations for
4.5-inch Injection-molded Containers
VistaTek, Stillwater, MN Aspen Research, Maple Grove, MN
Laurel Biocomposite, Laurel, NE

30.
Molding at VistaTek - October 2014

31.
Molding at VistaTek - October 2014
7 Bioplastic Formulations
1500 Containers Each
10,500 Containers Total
1) PLA - BioResTM
(80/20)
2) PLA - Lignin (90/10)
3) PLA - Soy - BioResTM
(50/30/20)
4) PLA - Soy (60/40)
5) PHA - DDGS (80/20)
6) PLA - Soy - BioResTM
(55/35/10)
7) Recycled PLA
4.5-inch Containers

32.
Collaboration with
Laurel Biocomposite LLC and Nursery Supplies, Inc
1,500 Injection-molded Gallon Containers
PLA - BioResTM
(80/20)

33.
Polyurethane-coated Paper Fiber
4.5 inch Gallon

34.
Questions ?Questions ?Questions ?Questions ?