{"id":12624,"date":"2022-11-09T06:05:22","date_gmt":"2022-11-09T12:05:22","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=12624"},"modified":"2023-03-07T14:27:19","modified_gmt":"2023-03-07T20:27:19","slug":"pe-hemp-based-biocomposites-said-to-slash-carbon-emissions-offer-sustainable-alternative-to-glass-fiber","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/12624\/pe-hemp-based-biocomposites-said-to-slash-carbon-emissions-offer-sustainable-alternative-to-glass-fiber\/","title":{"rendered":"Hemp-based Composites Gaining Traction in Various Sectors"},"content":{"rendered":"

Original article date: Nov. 24, 2021
\nUpdated October 2022<\/p>\n

\"INCA
In wind-turbine applications such as this, INCA\u2019s hemp-based BioBalsa is seen as a viable alternative to balsa wood, whose supplies are dwindling and prices rising.<\/center><\/figcaption><\/figure>\n

Canadian startup INCA Renewable Technologies Inc. is continuing its push to develop and commercialize hemp-based biocomposites as a more sustainable option for applications ranging from vehicle components to boats and wind turbine blades. (UL Prospector<\/em> first reported on the company\u2019s efforts in November 2021, but much has happened since then.)<\/p>\n

Based in Kelowna, British Columbia, the firm is partnering with Toyota Motor North America Inc. on automotive prepregs for its electric vehicles and with Switzerland\u2019s Gurit on what INCA calls its BioBalsa\u2122 product \u2013\u2013 a direct replacement for balsa wood and PET. Gurit is a global manufacturer and distributor of composite solutions to the wind energy, aerospace and marine industries.<\/p>\n

As previously reported, INCA is partnering with Elkhart, Ind.-based Genesis Products Inc. and their customer, Winnebago, on recreational vehicle (RV) sidewalls manufactured from hemp fiber as a replacement for lauan plywood. INCA also has developed a hemp-based replacement for glass-fiber-reinforced polymers used in injection, compression or extrusion molded glass-reinforced plastics.<\/p>\n

\"INCA<\/p>\n

David Saltman, INCA\u2019s chairman and CEO, notes how the automotive industry uses resin-infused glass- or natural-fiber-composite (NFC) prepregs to mold interior trim components such as door panels, seat backs and package trays. He says that INCA has developed a new methodology to produce prepregs from a multi-layered mat of hemp and polypropylene fiber. The product reduces the amount of resin required, reducing weight, lowering costs and improving strength.<\/p>\n

Toyota North America has commissioned INCA Chief Technology Officer Gary Balthes to develop a recycling program for the INCA PrePregs. The aim would involve the Canadian firm taking back the end-of-life panels and reincorporating them into new products.<\/p>\n

\u201cINCA will be the first company to be able to recycle these parts back into new products on its own production line,\u201d according to Saltman.<\/p>\n

<\/h3>\n

Big potential for hemp-based prepregs<\/h3>\n
\"Husband-and-wife
Husband-and-wife team David and Camille Saltman founded INCA Renewable Technologies.<\/figcaption><\/figure>\n

INCA\u2019s methodology involves producing multilayered mats of hemp fiber, infusing these mats with foamed thermal melt resin, and consolidating the material on its twin-belt press to produce thermoformable prepregs for the automotive industry.<\/p>\n

These prepregs will be stronger, lighter, and less expensive than competitive non-woven mats and panel products, according to data from a recent life cycle assessment (LCA). They will sequester rather than generate carbon, be made of renewable resources, reduce vehicle weight, improve side impact resistance, and be formulated to be recovered and reprocessed back into future car parts once automobiles have reached the end of their useful lifecycle.<\/p>\n

Scott Oppliger, principal engineer for Toyota North America\u2019s research and development department, states: “It is my goal at TMNA R&D to lay a foundation for others to follow that envisions a more sustainable future and begin a materials development and management project that propagates itself locally and then globally.<\/p>\n

\u201cINCA has already begun to develop a vision for a master plan of vehicle life cycle management building off existing models that exist in Europe and fashioning them into INCA\u2019s vision of sustainable and smart technologies for North America and beyond. INCA understands the need to begin sustainable development of materials management that they can perfect locally and then propagate globally as it demonstrates success locally,\u201d Oppliger continued. \u201cWe must provide a path that deviates from the current end-of-life process where the interiors end up in landfill or are burned, thereby adding to greenhouse gas emissions.”<\/p>\n

A renewable balsa alternative<\/h3>\n
\"INCA
INCA has developed and patented a novel way of converting hemp hurd into BioBalsa.<\/figcaption><\/figure>\n

Low density and high strength make balsa wood an essential core material in boats and wind turbine blades, says Saltman, noting that the wind energy and marine industries use $290 million per year of the material. But this demand has led to the deforestation of Ecuadorian forests. \u201cPrices are skyrocketing, quality is falling, and balsa is in short supply,\u201d he added. \u201cThe industry is substituting fossil fuel-based PET foam but seeking sustainable, high-performance alternatives.\u201d<\/p>\n

INCA has developed and patented a novel way of converting hemp hurd into BioBalsa, a direct replacement for those currently used materials. It has consistent properties and the strength required for installation in all sections of the turbine blades as well as marine applications. Those industries are actively seeking an alternative core material that can deliver the compressive and sheer strength of balsa while helping them meet aggressive sustainability goals.<\/p>\n

INCA is working directly on this project with Gurit\u2019s senior leaders responsible for innovation and circularity. Thomas Nauer, Gurit\u2019s head of sustainability, says: \u201cThe BioBalsa project fits nicely with Gurit\u2019s ambitions as a sustainability leader. The wind turbine industry is aiming at zero waste, recyclable turbine structures and is looking for ways to further reduce its greenhouse gas footprint. Therefore, a material that is both bio-based and made from recycled components is clearly a benefit and provides an answer to both sustainability and technology trends.\u201d<\/p>\n

No shortage of possible applications<\/h3>\n

Keith Netting, Gurit\u2019s director of strategic innovation projects and its technology management director, adds: \u201cThe potential for hemp-based core is of interest in the composites market for many potential applications. In wind turbine blades hemp-based core could be useful due to its lower LCA footprint and properties for use within certain areas of the turbine blade shells. Initial interest has been positive from this industry.<\/p>\n

\u201cFor the marine and industrial market, some boat manufacturers are actively developing totally recyclable boats to prevent future marine waste from building up or going to landfill. Their reaction to this type of core is that of high interest for above-water applications currently.\u201d<\/p>\n

An independent life cycle assessment conducted by GreenStep Solutions demonstrated that INCA\u2019s hemp-based BioBalsa is far more sustainable than balsa wood. One cubic meter of BioBalsa sequesters 260 kg of carbon dioxide. BioBalsa generates 107% fewer greenhouse gas emissions during the manufacturing process than cutting and milling balsa wood, reduces waste generation by 93%, and water consumption by 93%.<\/p>\n

Expanding capacity in western Canada<\/h3>\n
\"INCA
Toyota North America is partnering with INCA Renewtech on prepregs for its EVs. (All images are courtesy of INCA Renewtech)<\/figcaption><\/figure>\n

All of this promising demand is spurring INCA Renewtech to expand its production capacity in Canada. This past April the company announced plans to build a state-of-the-art, 200,000-square-foot fiber processing and composites manufacturing facility in Vegreville, Alberta. Their chosen location is adjacent to InnoTech Alberta, the government of Alberta\u2019s premier research facility for hemp composites, genomics and agronomics.<\/p>\n

INCA says it expects its factory to be operational in mid-2024 and create 70 jobs, scaling to about 100 jobs by 2026.<\/p>\n

\u201cWhen ramped to capacity, INCA\u2019s operation will purchase 54,000 tonnes of biomass per year generated from farmers growing hemp for plant-based protein,\u201d says Camille Saltman, the firm\u2019s chief marketing and sustainability officer. \u201cWe will process this renewable resource into highly refined long and short fiber and hurd, the inner core of the hemp stalk.\u201d<\/p>\n

\u201cHere in Canada,\u201d she added, \u201cthe short fiber will be manufactured into INCA BioPlastics and the hurd will be made into INCA BioBalsa. The long fiber will be sent via rail to our second factory in Bristol, Ind., where we will manufacture INCA BioPanels for the RV industry and INCA PrePregs for the automotive industry.\u201d<\/p>\n

INCA Renewtech —\u00a0 www.incarenewtech.com<\/a><\/p>\n

\n

Find the bio-polymer you need for your next project using Prospector\u2019s biomaterial filters, available with a premium account.\u00a0 Learn more.<\/a><\/h3>\n
\n","protected":false},"excerpt":{"rendered":"

Original article date: Nov. 24, 2021 Updated October 2022 Canadian startup INCA Renewable Technologies Inc. is continuing its push to develop and commercialize hemp-based biocomposites as a more sustainable option for applications ranging from vehicle components to boats and wind … 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He has broad global experience and for more than 35 years has worked as a journalist, editor-in-chief, publishing executive and key connector of like-minded parties. He has launched successful publications and C-level events on three continents. While with Crain Communications Inc., he oversaw the relaunch of the 100-year-old European Rubber Journal in London and helped to start Urethanes Technology magazine there. \u00a0In 1988 Bob returned to Akron, Ohio, to serve as founding editor of Plastics News, an award-winning, weekly business newspaper. In 2005 he oversaw the editorial launch of the bilingual (Chinese and English) PN China e-newsletter and website. For more than a decade at PN he also held the titles of associate publisher, editorial director and conference director, and most recently served as business development director. A long-time affiliate member of the Industrial Designers Society of America, Bob has organized numerous design-focused events, earned a Personal Recognition Award from IDSA in 2013, and constantly strives to help bridge the gap between the design and manufacturing communities. In 2014 he left Crain and created RC Grace LLC in Akron, Ohio, as a consultancy that aims to help companies to enhance their branding and market presence, find business partners, connect with design resources (here or in Asia), secure funding and advance their growth initiatives. 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