FLAX PRODUCTS- BUILDING THE 21ST CENTURY logos, et/Flax Straw... · Flax Fiber and Shive Products =...
Transcript of FLAX PRODUCTS- BUILDING THE 21ST CENTURY logos, et/Flax Straw... · Flax Fiber and Shive Products =...
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Flax Fiber and Shive Products =
Path Making in the 21ST Century Presented to
Sask Industry & Resources
Sask Environment
Sask Ag & Food
by
Sask Flax Development
Commission, May 9-05
Linda Braun
Richard Marleau
Alvin Ulrich
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Flax in Saskatchewan
• Approximately
800,000 to
1,000,000
acres of flax
are grown in
Saskatchewan
every year
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Flax in Saskatchewan
• Most seed is exported and
crushed to make linseed
oil for linoleum, paints,
stains, ink, form release
agents
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Flax in Saskatchewan
• BUT more
and more
seed is
being
ground
for animal
and human
nutrition
and health
market
products
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Flax in Saskatchewan
• For every
acre of
flax
grown,
0.5 to 2.0
tonnes of
straw is
produced
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Traditional Uses for Flax Straw
• Specialty paper (e.g., cigarettes)
• Bale Shelters
• Fuel for straw stoves
• Duck Nesting Sites
• Lining Ditches
• Flax Straw Mulch
• Livestock Bedding
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Traditional Flax Straw R&D has
focused on:
• Collecting, processing and uses of straw
SALVAGED from the back of a combine
• low value end uses that can use low quality
straw (e.g., specialty paper, low end plastic
composites)
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Lack of Profitable End Uses = “The Straw Problem”
At present 15%-20% of flax straw used;
Remainder chopped and spread or burnt
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Flax Straw Composition
• Fiber, Shive and Dust
• Fiber content in flax straw is variable
– Range 2% to 30%
– Normal 13% to 18%
• Shive 60% to 75%
• Remainder is Dust
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BUT flax can be a four letter
“f-word” for environmental
sustainability. It is:
• Renewable
• Biodegradable
• Energy
Efficient
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What can we do to capture the
potential?
• Find new ways to:
– manage straw in the field
– grade and value different types of straw
– process different straws in different ways
– use flax fiber and shive
– improve cost-effectiveness of the above
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What Higher Value Processors
Don’t Want
Weeds
or
Plastic
Mixed
With
Unretted
Straw
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13 Weedy Fields
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Lodged
Crop
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….What Higher Value
Processors Don’t Want
Badly Broken,
Unretted Straw
With Seed
Holders
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Seed Holders
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...What Higher Value Processors
Don’t Want
“the come
and take
my
garbage
away
attitude”
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How can we manage it
differently to make it profitable?
Use
Stripper
Header
or
Straight
Cut as
high as
possible
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Disc Bine standing straw or….
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20 ….Land Roll the standing straw
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Rake up the straw after it is retted
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22 Bale the retted straw
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Fiber Yield
• Fiber Yield = Straw Yield x Fiber Content
– Straw Yield
• Traditional baling after combine
– average 1.2 to 1.5 t/ha
– range 0 to 2.5 t/ha
• New methods may double these “salvaged” yields
– Fiber Content – average 13 to 18%
– range 2 to 30%
• Agronomic research has found ways to cost-
effectively increase fiber content
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Fiber Content and Processing
Cost Example Showing how Fiber Content in Flax Straw Greatly Affects Profitability of
Processing the Straw for Fiber
Fiber Content of Straw 5% 15% 25%
Average payment to farmers $/tonne <8> <8> <8>
Average total cost for baling, hauling,
Stacking, unstacking from field to factory $/tonne <42> <42> <42>
Cost to process 1 tonne of straw $/tonne <25> <25> <25>
Total cost of Straw + Processing $/tonne <75> <75> <75>
Straw needed to give 1 tonne of fiber tonnes 20 6.7 4
= Cost of I tonne of fiber (Straw + Processing) $/tonne <1,500> <500> <300>
Average value of fiber fob Sask factory $/tonne 600 600 600
Gross Margin (before fixed costs) $/tonne <900> 100 300
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Fiber Production
• Influenced by the interaction of several
Agronomic and Non Agronomic factors • growing season weather
• variety sown
• fertility
• seeding rate
• seeding date
• type of soil
• harvest management
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Managed flax straw will allow
us to profitably supply fiber for:
• Building products
• filtration industries
• geotextile products
• absorbency products
• textile spinning industry
• higher end plastic composites
• specialty and pulp sweeteners
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Managed flax straw will allow
us to profitably supply shives for:
• High end horse bedding
• pet bedding
• horticultural uses
• absorbency products
• building products
• biofuel
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Crop Fibers Canada
• Initially a pilot plant in Saskatoon
– will utilize different types of straw
– use different processing methods
– produce fiber and shive with various
characteristics
– develop proto-type grading systems
– secondary processing -needle punch, card, etc.
– work towards commercialization
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Consider the case of flax fiber
and shive for building products...
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Traditional Uses of Flax Fiber in
Building Products
• Mixed with Stucco
• Linen Wallpaper, Drapes and Blinds
• Linen Upholstery
• Flax Carpets
• Geotextiles
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Traditional Uses of Flax Shive in
Building Products
• “Loose Fill” Flax for insulation
• Mulch
• Shive Board (like particle board)
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New Uses for Flax Fiber and
Shive in Building Products
• Plastic Composites- Shelving, Garbage
Cans, Chairs, Desks
• Flax Insulation-Batting
• Acoustical Panels
• Filtration Products
• Concrete Reinforcement (with proper
chemical treatment)
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Flax Shive in Rotationally
Molded Plastic Composites
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Flax Fiber in plastic composites
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Reasons Behind Increasing the
Use of Flax Fiber in Building
Products
• Environmental Movement In Europe
– Stronger Regulations
– Financial Incentives/Disincentives
• Search for a Replacement for Glass Fiber
• Research into Plastic Composites
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Types of Flax Batt Insulation
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Flax Insulation
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The Building Insulation Case:
• “Carding” process for making flax insulation batting was 2 to 3 x price compared to glass fiber
• New “air laid” technology leads to flax insulation 1 to 2x price compared to glass fiber
• More flax insulation would be used but Europe is short of suitable flax fiber
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Saskatchewan’s Blue Prints for
Flax Fiber and Shive Based
Products…...
• A significant amount of R&D has been conducted
by Biolin Research Inc. and the SaskFlax
Development Commission on:
– Agronomy
– Quality Traits
– Processing
– Human Capital
– Industry Contacts
– Budgets and Markets
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…..Saskatchewan’s Blue Prints
for Flax Fiber and Shive Based
Products…...
• Agronomic Research:
– Fiber Content
– Straw Yield
– Fiber Yield
– Fiber Quality-Retting
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…..Saskatchewan’s Blue Prints
for Flax Fiber and Shive Based
Products…...
• Quality
– Development of Standards and Grading
– ASTM
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…..Saskatchewan’s Blue Prints
for Flax Fiber and Shive Based
Products…...
• Utilize the services of the Crop Fibers
Canada Pilot Processing Plant
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…..Saskatchewan’s Blue Prints
for Flax Fiber and Shive Based
Products…...
• Use existing Human Capital
– World-Recognized North American Flax Fiber
Expert
– Biolin Research Inc. staff
– Plant Breeders and Farm Researchers
– Dept. of Agriculture and BioResource
Engineering at University of Saskatchewan
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…..Saskatchewan’s Blue Prints for Flax Fiber and Shive Based
Products…...
• Develop Industrial Contacts in
• insulation
• non wovens
• textiles
• plastic composites
• horticulture
• concrete products
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“Map” for Flax Fiber/Shive
Products in the 21st Century • Start small
• Learn Advantages and Disadvantages of flax products compared to competition
• Understand market potential and costs of production
• Work towards consistency of quality and quantity
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Flax Insulation Challenges
• 4 -7 M$ Investment for Plant and Market Development
• Sufficient quantity and quality of flax straw
• Human Capital
• Products must meet building code requirements
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Flax Batt Insulation
• Can be an environmentally friendly solution to an existing environmental problem
• Can decrease health problems (asthma, sick buildings)
• Can lead to new industries in rural areas
• Can generate higher incomes for farmers, processors and governments
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Need a Holistic Approach to
build a New Industry…..
• All stakeholders involved
• A common vision (expectations)
• Funds to quantify/qualify what is possible
• Supporting policies
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Flax Canada 2015
• A Federal/Provincial/Industry Initiative
• Focus and stimulate funding to remove
constraints and capture potential of flax
• Some new money but most funding
expected to come from existing funding
sources
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• Do our goals and our potential help
meet your Department’s needs?
• What can we do to help meet your
Department’s goals and needs?
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• Next Steps??
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Flax Straw Products
Path Making in the 21ST Century Contact Alvin Ulrich or
Richard Marleau Crop Fibers Canada 161 Jessop Avenue Saskatoon S7N 1S4
Tel: 306.668.0130 Fax: 306.668.0131 [email protected] [email protected]