Cargill has broken ground on a $22-million manufacturing plant in Chicago for the production of a soy-based replacement for petroleum-based polyeurothane cushioning. Expected to be operational in November, the new plant will produce Cargill’s BiOH soybean-based polyols–an ingredient that replaces petroleum-based chemicals traditionally used in products, such as flexible foam cushioning for furniture, bedding and automotive products.
Since going commercial with BiOH polyols in 2005, Cargill has been serving customers primarily through a toll-processing capability. The biobased product’s success required expanding production capabilities at a Cargill site in Brazil in September 2007. The new manufacturing plant in Chicago will make available a much larger supply of BiOH polyols as a viable raw material option for Cargill’s growing customer base in North America and Europe.
"Only two years ago we committed to building a world-class renewable polyols business and to bring a more responsible option to the industry," said Yusuf Wazirzada, business unit leader for Cargill Biobased Polyurethanes.
Cargill’s BiOH polyols can be used as raw materials for furniture cushioning, bedding foams, automotive seats, and building insulation. A preliminary life cycle analysis indicates that manufacturing BiOH polyols results in 36% less global-warming emissions and requires 61% less non-renewable energy than traditional petroleum-based polyols. For every 1 million pounds of BiOH polyols that replace petroleum polyols, 2,200 barrels of crude oil are saved, the company said.
Businesses currently using this product in their soybean-based foam cushioning include furniture companies such as Lane, Klaussner, LEE Industries, Norwalk, Bauhaus, and Precedent. Eco Platinum Plus carpet cushion sold through Home Depot is made with BiOH polyols. In the automotive sector, BiOH materials will be in the seats of the 2009 Ford Escape.
Given that the global polyurethane market for polyols is greater than 10 billion pounds, BiOH polyols can have a significant impact on reducing crude oil consumption while using only a small percentage of global vegetable oil stocks, Cargill said.
The technology won the 2007 President’s Green Chemistry Challenge Award from the U.S. Environmental Protection Agency. The Society of Plastic’s Engineers named BiOH Polyols best Emerging Technology at its 2007 Environmental Stewardship Awards. And, BiOH polyols captured the Alliance for the Polyurethanes Industry’s 2006 Technology Innovation Award.
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