ABB Technology automates NatureWorks’ Thai bioplastics plant amid expected demand surge

17 Mar 2022 --- ABB Technology (ABB) is automating NatureWorks’ greenfield bioplastics plant in Thailand to meet the growing global demand for fossil-free material alternatives. The new site will produce 75,000 tons of Ingeo PLA (polylactic acid) biopolymer annually.

The technology company will help improve bioplastic manufacturing’s energy and production efficiency, enhancing NatureWorks’ supply chain reliability by integrating its production process from fermentation to polymerization.

European Bioplastics estimates global bioplastics production will more than triple over the next five years (2021-2026). Notably, Asia is predicted to surpass 70% market share by 2026.

“ABB’s global presence, especially in the US and Thailand, combined with its deep expertise in the chemical industry, leading automation solutions, and design optimization approach, makes them the obvious choice for a partner to help achieve meaningful progress in our new plant,” says Steven Bray, vice president of Operations and Project Program Manager at NatureWorks.

Low-carbon bioplastic
PLA is a low-carbon bioplastic made from renewable agricultural resources. NatureWorks converts sugarcane to produce the Ingeo PLA biopolymer.

Ingeo produces approximately 80% less greenhouse gas and uses 52% less non-renewable energy during manufacturing than traditional fossil-based polymers, says NatureWorks.

NatureWorks expects demand for bioplastic packaging to grow exponentially.The Thailand plant will ferment and distill plant-based sugars (in a process similar to making beer or wine), converting the sugars first to lactic acid, then lactide, before polymerizing them into Ingeo.

These three separate production processes will be fully integrated into the new site, resulting in significant energy and production efficiency improvements. In addition, the integration of the fermentation phase will secure the supply of lactic acid.

The anticipated projected startup for this greenfield facility is during the second half of 2024.

Project execution
ABB’s scope of work is a two-part order, including a FEED (front end engineering design) study followed by detailed automation project execution, with ABB acting as the Main Automation Contractor.

The technology company will deliver the hardware, software, control room design solutions, engineering, and site support to fully develop NatureWorks’ greenfield system.

ABB’s distributed control system Ability System 800xA will maximize plant efficiency and reliability through automation. Leveraging this technology will integrate inputs from all critical systems into one single user-friendly overview.

As a result, operators will be able to utilize data insights from all plant areas, delivered in real -time to drive efficiency, reduce risk and ensure production optimization.

The project will apply State Based Controls (SBC), enabling operators to take fewer interactions to start up a unit and reduce risk by having access to the right information at the right time. In addition, ABB’s automated engineering batch application tool will be implemented for this project.European Bioplastics estimates global bioplastics production will more than triple over the next five years.

Meeting rising demand
As part of NatureWorks’ global expansion plan, the plant will help meet the growing global demand for more environmentally sustainable materials. Bioplastics today represent less than 1% of all plastic produced globally, but production is expected to grow over 260% between 2020 and 2026, according to European Bioplastics.

Mariagiovanna Vetere, global public affairs director at NatureWorks, recently explained why bioplastic market demand will continue to grow despite unfavorable legislation.

Ingeo is a bio-based material used in a wide range of plastic and fiber products from compostable food packaging – coffee capsules, tea bags, food containers – to 3D printing filament, diapers, and refrigerator liners.

“Our project with NatureWorks is perfectly aligned with our 2030 Sustainability Strategy and driving more [environmentally] sustainable use of our planet’s resources through innovative solutions that help reshape industries and enable a low-carbon society,” says Brandon Spencer, ABB Energy Industries president.

NatureWorks and IMA are fast-tracking the commercialization of compostable coffee pods for distribution to coffee brands and roasters. The partners have instigated a first trial phase for the K-Cup compatible pods.

By Joshua Poole

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