Creating markets for bio-plastics Value drivers and targeted applications Marc Verbruggen Bangkok – October 2014
1 Topics
• NatureWorks • Value drivers for bio-plastics • Targeted applications
© 2014 NatureWorks 2 Who we are
• World’s leading bio-polymer player − 150,000 ton plant in Blair, NE − Significant manufacturing know-how and an extensive IP position • Jointly owned by Cargill and PTTGC • Proprietary portfolio of Ingeo bio- polymers & intermediates • Ingeo - competitive on a cost and performance basis with traditional plastics (PS, PET) • Superior environmental characteristics − Lower carbon footprint , low fossil energy − Additional end-of-life options • Established global market channels − Over 100,000 ton in annual sales volume − Commercial partnerships with global brands
© 2014 NatureWorks 3 General Ingeo/PLA Property Comparison
Ingeo GPPS PET PP Tensile Strength Mpa 53 45.5 58.6 35.9
Elongation at break % 6 1.4 5.5 350 (%) Tensile Modulus Gpa 3.6 3.03 3.45 1.31 Izod Impact J/m 16 21.4 26.7 48.1 Tg C 55-60 102 74 -20 Melting Point C 125- None 270 165 180 Density g/cc 1.24 1.05 1.35 0.9
* Properties measured on 3.2 mm thick injection molded tensile bars. Specific properties pertain to Ingeo 2003D
© 2014 NatureWorks 4 Ingeo Technology Platforms
8-series Foam
7-series Blow Molding
6-series Fibers/Non-woven
4-series Film
3-series Injection Molding
2-series Thermoforming
Lactide Monomer
© 2014 NatureWorks 5 Bulk Truck
Bulk Railcar
1 MT Super Sack 750 kg Box
© 2014 NatureWorks 6 6 Where is Ingeo in the Market ? Rigids Food Serviceware Films
Nonwovens / Fibers Durables Lactides Incubator
© 2014 NatureWorks 7 Supported by a broad & growing Ingeo distribution network
Europe, Middle East, Africa Asia Pacific Americas • Resinex (EU 27 countries) • PTT Polymer Marketing (Thailand) • Nexeo (USA & Canada) • Resinex BMY (Turkey) • BP Consulting (Japan) • Jamplast (USA) • Protea (South Africa) • Unic (China) • Promoplast (Mexico) • Jolybar (Israel) • First In Colours (Philippines) • Cromex (Brazil) • Seeplas (Australia) • Oxiquim (Chile & Peru) • Poynter Agency (New Zealand) • Quimicoplasticos (Colombia) • Cosalco (Costa Rica)
© 2014 NatureWorks 8 Tangible Commitment to the A/P Region
New Asia Pacific Regional Headquarters Blair, NE USA
Rayong Province Thailand
• Bangkok, February, 2013. NatureWorks 1st Asia Pacific regional headquarters established – Warehousing and logistics capabilities, customer service, finance staff, • Engineering Underway for plant II in the region
Investments reinforce NatureWorks' commitment to the region and its support of accelerating Asian market growth
© 2014 NatureWorks 9 Markets for bio-plastics: A decade in the market – Some take-aways:
• Most (all) bio-plastics compete against commodity plastics – Developed & optimized over the last 50 years – Large & global asset base, established converter network
• Except for legislated applications, carbon footprint reduction has failed to gain much traction as a value driver (no “green premium”) – Consumers are confused and/or don’t see value (packaging) – Brands have largely not succeeded positioning “carbon footprint” as a brand differentiator.
• Bio-plastics are increasingly recognized as “just” plastics – Compete on price/performance – AND THAT WORKS FINE FOR A BIO-PLASTIC SUCH AS PLA
© 2014 NatureWorks 10 Three Era’s of Bioplastics
Norming & Forming Storming Performing “Bioplastics “Bioplastics “Bioplastics are for sequester = Biodegrading” Carbon” Plastics”
• Biobased = exception • Carbon footprint • Biobased = expectation • Litter focused focus • Performance is king • “biodegradable” where it’s the highest good
1990’s 2000’s 2010’s
© 2014 NatureWorks 11 Plastics Consumption (%) Total Addressable Market (Bn lbs.)
100 60 Our End Applications 58Bn lbs/$50Bn LLDPE 11
Films / Cards Cards Films HDPE 50 14.5 80 17
1 PC 3 Nylon 40 Apparel Home Textiles 4 ABS 5 PS Fibers / 60 14.0 Non-wovens 7 PET
30 Non-Wovens 9 LDPE
40 13.6 Durables PVC 18 20 Durable Goods Folder Cartons
Food 20 5.9 Serviceware PP 10 Food Packaging Serviceware 25 Fresh Food 5.9 Packaging
3.6 Beverage 0 0 Bottles
12 © 2014 NatureWorks 12 The value drivers for each bio-plastic (and plastic) must be clearly defined
“The 3 P’s for Ingeo PLA”
Properties Price Preferences
• Broad and Sugars vs oil Lower carbon adjustable physical footprint and energy property set Favorable yields, usage
Economies of scale Health Concerns BPA free Feedstock hedging Phthalates free capabilities Acrylonitrile free Styrene free Cradle to cradle economics
© 2014 NatureWorks 13 Properties: Over the last 10 years, NatureWorks has optimized Ingeo grades towards specific applications
Nonwovens / Fibers Rigids Durables Food Serviceware Films
Key Properties Key Properties Key Properties Key Properties Key Properties
Range of melting Stiffness Stiffness Stiffness Stiffness points/crystallinity Gloss, transparency Miscibility Compostability High gloss and levels transparency Printability Improved flow High versatility for Tunable hydrolysis injection, extrusion Dead fold / twist Weight reduction (vs. Chemical resistance Hydrophilic / moisture and coating retention PET) wicking processes Grease, oil and aroma
Inherent odor barriers resistance Chemical resistance UV resistance High throughput Low bonding temp
© 2014 NatureWorks 14 Ingeo Innovations in Fibers/Nonwovens
© 2014 NatureWorks 15 Ingeo Innovations in Flexible Films
© 2014 NatureWorks 16 Shrink Films
© 2014 NatureWorks 17 Ingeo Innovations in Food Serviceware
© 2014 NatureWorks 18 In Food Service, Ingeo provides a tool for organics diversion
© 2014 NatureWorks 19 And what about colleges, high schools, airports, hospitals, …. And if it works in the North America, what about the rest of the world?
© 2014 NatureWorks 20 3D Printing: Ingeo Performance in a (rapidly) emerging market
• Low polymer thermal shrinkage means high resolution printing of the most complex parts • Strong Ingeo fusing performance means it’s easy to use and performs well on most prints • Low Ingeo melt point means safer, lower temperature printing. • Very low emissions with Ingeo means no unpleasant odors
© 2014 NatureWorks 21 Improved Stiffness for Heat Resistant Ingeo Parts
Improved Stiffness with Crystalline Ingeo for Practical Temperature Range of Hot Foods 100
~40% increase ) 80 in stiffness
Mpa 60 High Productivity Grade 40
20 Incumbent Modulus ( Modulus 0 60 70 80 90 100 110 120 Temperature, °C
© 2014 NatureWorks 22 With related reduction in the manufacturing time required to produce the heat resistance part …
Existing Ingeo Grades
New High Productivity Ingeo Grades: ~ 70% shorter cycle times
Temperature
© 2014 NatureWorks 23 Price: Ingeo can compete with rigid plastics (PS, PET) since: 1: Sugar-to-polymer yields allow for feedstock cost competition with oil 2: Plant yields, CAPEX, OPEX are comparable with PS/PET
Polymer Technology Overall Kg sugar for Process Yield 1 kg polymer Bio PLA (Ingeo) Sugar to PLA via lactic 80% 1.25 acid and lactides Bio PP Sugar to ethanol to 47% 2.14 propylene to PP Bio PET Bio MEG + Bio PTA from 36% 2.77 sugar Bio PE Sugar to ethanol to 31% 3.22 ethylene to PE
© 2014 NatureWorks 24 PET/PS/Ingeo Feedstock Cost Comparison
$250 PET $200
Above lines, Ingeo wins $150 PS $100 Material Indifference Curve $50 Cost of Oil ($/bbl) Oil of Cost Below lines, PET/PS wins $0 $0.00 $0.10 $0.20 $0.30 $0.40 $0.50 $0.60 Cost of sugar (c/lb)
PET Analysis from McKinsey margin models, CMAI, February 2006
© 2014 NatureWorks 25 PET/PS/Ingeo Feedstock Cost Comparison
$250 For Example • When sugar cost ~$.17/lb, the cost $200 of feedstock per lb of Ingeo is the
Above lines, same as the cost of feedstock per Ingeo wins lb of PS when oil is ~$50/barrel $150 • OPEX and CAPEX arePS similar. • The rest is scale… $100
$50 Cost of Oil ($/bbl) Oil of Cost Below lines, PS wins $0 $0.00 $0.10 $0.20 $0.30 $0.40 $0.50 $0.60 Cost of sugar (c/lb) Cellulosic sugars Gen 3 sugars PET Analysis from McKinsey margin models, CMAI, February 2006
© 2014 NatureWorks 26 We are committed to feedstock diversification: Performance materials made by transforming whatever are the right, abundant, local resources
Investment in innovation and R&D collaboration to grow our Ingeo feedstock portfolio.
GENERATION I: 1st step GENERATION I: 2nd step GENERATION II GENERATION NEXT
Where we are today Where we are going now Next 3-5 years And next?
Dextrose from corn starch Sucrose from locally Lignocellulosics: Sugars CO2 to lactic acid abundant materials such as from bagasse, wood chips, technology? “Bridging Crops” sugar cane switch grass or straw. CH4 to lactic acid technology?
© 2014 NatureWorks 27 Ingeo Innovations in Rigids
© 2014 NatureWorks 28 Plastics by Preference: The Brandowner View
• In non-legislated markets/applications, “carbon footprint” does not create a “green premium”
• Health & safety perceptions with some plastics increasingly drive materials substitution – “BPA free – “Phthalates free – “Acrylonitrile free – “Styrene free … Greenpeace’s “Pyramid of Plastics”
© 2014 NatureWorks 29 Ingeo Innovations in Durables
© 2014 NatureWorks 30 Danone’s Stonyfield - in their own words:
“IMPACT OF INGEO CONVERSION” • Carbon savings Environmental • 75% reduction in CO2 emissions
• Equivalent to 1,320 MT CO2/year savings
• Ingeo out performs polystyrene • Stronger/less breakage Performance • Better lid adherence • Lower temperature filling (less energy use) • Maintained line speed and shelf life
• Addresses consumer concerns • Well received by key opinion leaders Consumer • Reduction in human toxicity • Did NOT increase our retail price & Cost
Stonyfield CEO Gary_Hirschberg, Innovation Takes Root Conference Keynote: “Inventing a WIN-•WIN-•WIN-•WIN-WIN FUTURE”, February 21, 2012
© 2014 NatureWorks 31 Market Presence
2005 – 2013 Footprint in the market
6 X
1 Billion lb Milestone
aggregate volume in the market as of 2013
© 2014 NatureWorks 32 MarketMarket Presence Presence – in the bigger picture
2005 – 2013 Footprint in the marketToday
Poised for 6 X Strong Operations Growth Startup & Established 1 Billion lbMarket Seeding Technology & MilestoneIntellectual Property Established aggregate volume in the market 1990-2001 2002-2005 2006-2013as of 20132014 - forward 4k -8k mt 2002 -140k mt 2006 - 24/7 Blair Expanding pilot plant facility @ Blair. operations at Blair customer & 2003 -largest 2013 – 150k ton product base. lactic acid plant expansion Plant 2
© 2014 NatureWorks 33 Ingeo Commercialized Applications throughout Asia China South Korea
• Mulch film • Shopping bags Rigids Films
3D Printing Nonwovens Durable Taiwan Japan
Food Service Rigids
Fibers Durable
Thailand Australia / New Zealand
1-in- 5 coffee cups is made of Ingeo Rigids Food Service
Food Service Foam
© 2014 NatureWorks 34 Dairy Home’s Yoghurt Cup
Avitez’s Bottle
Doi Chaang’s Cup Chaho’s Cup
© 2014 NatureWorks 35 Naturally advanced materials made from locally abundant and sustainable natural resources Thank you
Marc Verbruggen
NatureWorks LLC www.natureworksllc.com
@natureworks
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© 2014 NatureWorks 36