PROJECT MANAGEMENT AND MONITORING

Green Footprint Project Update – March 2012 The chart below provides an overview of scheduled activities (blue). Progress is indicated for each activi...
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Green Footprint Project Update – March 2012 The chart below provides an overview of scheduled activities (blue). Progress is indicated for each activity (green).

PROJECT MANAGEMENT AND MONITORING 01-PM.D.1 - Project Management and reporting to the EC by DOW Italia 02-PM.D.2 - Project Monitoring by DOW Italia (with DIDC) 03-PM.M.3 - Project Management by MONDIALSUOLE Project management is in place and covers all the project lifetime. Main activities/achievements since last update have been: Internal meetings for work planning, issues addressing and solving have been held on purpose Confirmation of the project feasibility thanks to the alternative feedstock defined by the project team. Several external validation at customer plants achieved using the new renewable polyol. Industrial trial on the customer production line consuming 4 MT of PU system and producing more than 8.000 pairs of soles. LCA analysis completed assessing precisely the benefit to the environment delivered by the new green solution. The new material not only reaches the project target but widely outperform the former renewable material considered at the beginning of the project. Product brochures for an effective dissemination are under preparation and almost completed.

PREPARATORY ACTIONS 04-PA.D.1 - Preparation of the Demonstration by DOW This activities performed by Dow in collaboration with Mondial Suole, has been done following the timeframe planned in the work plan. In particular:  A specific plan has been defined for the final design of the prototyping machine, fundamental for the development of the upcoming demonstration phase.  The required mechanical properties of the material containing renewable raw materials have been defined: hardness, specific gravity, tensile and tear strength, elongation and abrasion resistance  Preliminary agreement on test samples has been taken to guarantee highest efficiency of testing.  Outsole, midsole and foot bed specifications have been defined as reported on the Deliverable 4-PA.D.1 The action was reopened to check the applicability of the above mentioned set of specification in case of the new solution found to continue the project. The steering committee has decided that the projects will continue not changing the set of specification of the new product. Laboratory tests on the new material have been done to support this decision.

IMPLEMENTATION PHASE 05-IA.D.1 - Upgrade of the PU prototyping machine This action was revisited during kick-off meeting and inserted into a project amendment in the first months of the project. Lately, during the project progress and after doing evaluations about pros and cons of the upgrade of the PU machine, the consortium decided to modify the technical execution of the action but assuring the achievement of the planned results. In fact, the GREEN FOOTPRINT steering commettee considered the option to adjust to the project request the current PU machine of Dow laboratories instead of complete the upgrade and finally integrate the pre-existing machine with new pieces. Following this option, molds prototypes have been purchased and installed (see picture); the adjustments about adapting the machine to work properly with the new molds have been provided. With the PU machine adjusted to the requirement of GREEN FOOTPRINT project, it was possible to use the molds accordingly to a fully integrated production cycle in a semiautomatic mode, instead fully automatic as originally planned in the project.

06-IA.D.2 - Demonstration of pilot scale production Original solution materials were produced in the Market Development Plant of Dow Correggio’s lab and used to formulate PU systems. Formulations of NOP containing systems, targeting the specifications set in 4.PA.D.1 have been produced at pilot scale and molded in Correggio Application lab facility. Fine tuning of the NOP formulations has been done to achieve the above mentioned specification set. The fine tuning activity in the lab has delivered polyurethane systems, containing up to 25% NOPs, suitable to be used in the footwear industry, as materials for outsole, unit soles, and footbed. The action was reopened in order to get the same results using the different material chosen. With our facilities (polyester reactor) and formulation machine, the new solution has been prepared and foamed to make shoe soles in the Correggio’s Application lab. The subsequent fine tuning has got to the demonstration of a suitable polyurethane system containing up to 35% or renewable raw material, so far exceeding the project target. Depending on the final application and on the cost of the formulation, this solution will be implemented at intermediate percentages of renewable raw material, all ranging from 25 and 35%. Action closed. 07-IA.M.3 - Testing of pilot scale production Under the responsibility of Mondial Suole, tests on sample have been realized to verify the required quality standards and suitable use of material in existing process/equipments. In particular, selected polyurethane materials have used to produce small series of shoes at Mondial Suole plant to be tested for wear. This activity started on July 9th 2009 on the old solutions and results are in line with the requirements. Also this action was reopened to check in Mondial Suole production plant the new material produced in Correggio Market Development Plant at suitable quantities. Almost 8000 pair of shoe soles have been produced fulfilling the specifications set. Wear test on finite shoes are ongoing. So far no issues are reported from final users. 08-IA.D.4 - Demonstration of pre-industrial scale production This activity started in the first phase of the project with the old technical solution. A small scale blender at Dow premises was used as pre-industrial plant for polyurethane formulation production. The material was tested in Mondial Suole plant with good results. For what concerns the new material developed, after the purchasing of the required renewable feedstock, 3 MT of polyol were produced at our premises in Parona Lomellina (PV). The industrial quantity of the novel polyester was produced successfully and delivered to our partner. Action closed

09-IA.M.5 - Mould prototypes In order to have first feedback about characteristics of the product, it was decided to run preliminary tests using general purpose molds and then design specific models for the project, taking in consideration the feedback and results of the first tests. New molds have been designed, ordered, produced and delivered to Mondial Suole . Molds have been tested with the new raw material developed within the project finding no processing issues. Action is closed

10-IA.M.8 - Market introduction by MONDIALSUOLE Mondial Suole started to contact potential customer in the footwear industry in light of understand their interest in accessing soling materials made from renewable resources, the potential fields of application, and market size. Interest of Mondial Suole potential customer is confirmed. Samples were judged of good aspect and properties. Some of them noticed some difficulty in painting the shoe soles; this issue has been already solved by adjusting processing conditions at the plant. A detailed report was issued by Mondial Suole on October 2010. EVALUATION PHASE 11-EA.D.1 - Evaluation of demonstration – –

The action started on September 2011. The considerable amount of data gathered during the industrial trial and pre industrial scale production highlighted the quality and the performance of the novel renewable polyol we have defined. Preliminary LCA data will be combined with the performance features of the material

12-EA.D.2 - Life Cycle Analysis (LCA) Action started on October 2010 seeking to involve Dow Chemical Department in USA in charge of LCA analysis. Life Cycle Assessment (LCA) is a useful methodology for examining the total environmental impact of a product or service. Rather than focusing on a single process, LCA takes a holistic view, examining environmental impacts over the complete “cradle to grave” product life cycle. A life cycle perspective helps to ensure that environmental burdens are not unintentionally transferred from one life cycle phase to another during process improvement, and thus helps to prevent unintended environmental consequences. This cradle-to-gate LCA study compares a partially bio-based polyester polyurethane made from renewable feedstock with a fossil-based polyester polyurethane made from adipic acid for use in shoe soles. Dow operations data and literature sources were used to develop the life cycle inventories. Global warming, total energy demand, fossil energy demand, acidification, eutrophication, photo-oxidant creation, ozone depletion, land occupation, and water demand were examined as life cycle impact categories. Of these categories, global warming and fossil energy use were the categories of chief interest, due to these being stated publicly as expected benefits for the use of the bio-based materials. This study showed that the novel bio-based materials do have reduced potential environmental impacts compared to the fossil based materials on a functionally-equivalent, per kilogram basis for all metrics considered except water use. The bio-based material has 54% lower global warming potential (4.4 kg CO2-eq/kg bio-based polyurethane with credit for biogenic carbon; 5.2 kg CO2-eq/kg without), 22% lower cumulative energy demand, and 25% lower cumulative fossil energy demand. Project targets are then fully met obtaining much better results in comparison with the first chemistry considered at the beginning of the project. Action is closed.

13-EA.D.3 -Evaluation of replication potential and environmental impact after LCA The objective is to evaluate the market acceptance of sustainable materials, effectiveness of the market introduction strategy and propose improvements to the strategy and or the products. The aim is to establish knowledge regarding the potential for continued growth of PU in the market, even if (partly) substituted by Natural Oil Polyols based materials.

Various potential application sectors have been mentioned. To detail such applications here are reported examples of final application uses: polyurethane (PU) Foams For Flexible polyurethane foams we intend all the applications where a flex polyurethane is obtained by molding with a blowing agent to obtain a stable “flexible foam” with the desired shape. Examples are: pillows, mattrasses, foam sheets to be cut or preformed for various coating applications, chairs, seats, automotive seats and equipments (armrest, headrest, etc..) , armchairs and generally furniture goods.

Polyurethanes adhesives & sealants generally have applications in industry, but also in the retailers, for solving adhesion of different materials, form plastics to metal, wood, fabrics, concrete, stones, etc.. Main application field is in goods packaging, also with reference to the food industry. Sealants are generally applied in gqsketing applications, for solving problems of potential liquid or gas leakages in joints, piping, reservoirs, as well as windows glass bonding.

PU elastomers are materials very similar to footwear materials in terms of applied density, microcellular characteristics, and chemical resistance. They may have requirements for higher thermal resistance than footwear. Main applications are in the automotive industry, as “under the hood” gasketing or sound/vibration dampening, automotive parts for suspensions, filter gasketing and other minor. Some applications are starting having interests in the industry like shock absorbing material for sportswear, motorbike wear, etc.

Coatings represent a wide application area for polyurethane materials, main application field is relative to varnishes, or coating layers for liquid barrier between layers of different materials,; they require heat resistance, compatibility with materials, liquid (solvent and or water) resistance, etc.

Usually the most known polyamide product is nylon 66, the synthetic fiber used mainly in textiles for wear. Using Azelaic acid instead of Adipic acid one can obtain a different fiber, named nylon 69 or polyamide 69, with somewhat similar characteristics with respect to nylon 66. It is expected that this product can be a “green” substitution of Azelaic acid also in this worldwide common product. The first four areas are all polyesters, where azelaic acid should function chemically much as adipic acid. Polyamde 69 (PA 69) is already made for special nylon fibers applications where specific properties are necessary, such as in monofilaments fibers. This is a large potential market, but would require low-cost azelaic acid. PA 69 is about the 1 % of the total global nylon production. A 25years scenario has been developed finalizing the following table in terms of potential opportunities of introduction of the Azelaic acid into the different sectors analyzed.

The scenario has been evaluated in terms of environmental benefits achievable in the next 25 years, as depicted in the figure below. This means very attractive and important savings in CO2 emissions. The estimated benefit on the global warming potential in the future 25 years could reach up to 6 million tons CO2 reduction, i.e. 600 times the current expected benefits coming from only the shoe sole application.

Action is completed

14-MI.M.1 Market Introduction Evaluation Customer feedback and wear test The interest of Mondial Suole potential customers is confirmed. Samples provided to the customers were judged of good aspect and properties. Some of them noticed some difficulty in painting the shoe soles and this issue was addressed by use of selected additives for improving surface quality. Reports from Mondialsuole were issued throughout the timeframe of the project and are attached, together with showcasing activities done at footwear fairs/events. In conclusion, Mondialsuole noticed a really good interest of this product in the footwear industry and the innovation of the technical characteristics of this new material is certainly following the new market trends which always ask a greater attention to sustainable products. Finally a wear test was conducted on a set of 35 pair of complete shoes taken from the set of 70 manufactured with the shoe soles coming from the industrial plant. The results have been very positive, with appreciation of lightness, grip and normal abrasion. Market acceptance, effectiveness and improvements of the strategy for market introduction. It is difficult to have a clear picture regarding market acceptance as during the timeframe of the project only sampling of shoe soles and of shoes has been done, but no sales have been realized. There is a good potential for a good acceptance as in terms of material properties all the expectations of technical targets have been achieved. As said, customers like the idea of a “green” product for shoe soling, at acceptable cost. The current economic situation, where also the footwear market is suffering difficult times, does not facilitate the introduction into the market of novel solution. Effectiveness and improvements in the market introduction strategy cannot be evaluated nor suggested within the time frame of the project. Nevertheless, after the conclusion of the project timeframe, Dow has started contacting selected customers producing soles and finite shoes that agreed testing the material and starting business. This is a good sign and we expect starting business with other customers too.

DISSEMINATION OF RESULTS 15-DA.D.1 - Dissemination activities by DOW (with DIDC) 16-DA.M.2 -Dissemination activities by MONDIALSUOLE Promotion of the new polyurethane to shoe-manufacturers Fairs visits 08/03/2011 16-19/03/2011 17/06/2011 20/06/2011 07-09/09/2011 20/09/2011

Micam; Dusseldorf; Pitti; Garda; Dusseldorf; Micam;

Customers visits Tuscany: Jan-Dec 2011 Soldini S.p.A. Tuscany: Jan-Oct 2011 Calzaturificio San Giorgio Srl, Designed by Angelo e Ugo Srl, Club shoes Srl , Italian Shoe Makers Srl, Mario Micheli Srl, London: 02-04/11/2011 Marks & Spencer Uk Germany: 30/03/2011-02/04/2011; 03-07/10/2011 Josef Seibel kft DOW project web site The Dow web site hosted the public project Website Furthermore, references to the project have been inserted into Dow Intranet Web site as “EU Funded Projects” Association meetings, exhibitions, and technical conferences Desma Open House, Achim, Bremen (D) “New voralast R sustainable soling material”), September 2010 LCA XI , Chicago USA, “The impact of bio-feedstock choice on the LCA of renewable shoe soles” October 2011 E-MRS 2012 FALL MEETING at Warsaw University of Technology on section “Materials Fabrication, Characterization and Applications”, part B: “Renewable Polymers as multifunctional materials: properties, processing and applications” September 2012 Life Cycle Assessment of polyurethanes for shoe soles with at least 20% renewable (bio-based) content: The Green Footprint Project Authors : Dr. Rich Helling (1) Dr. Renato Paludetto Dr. Andrea Benvenuti Mr Giuseppe Lista (2)

Workshops A small workshop event have been held on November 11, 2011within the Inauguration Day Ceremony of the new laboratories of Dow Correggio R&D. Footwear customers were also invited to attend presentations of technologies and projects for footwear application. Scientific and Technical articles Preference has been done on technical/application papers rather than scientific, as the demonstration of the technology was the main goal of the project Here is the list of technical magazines/bulletins where articles on new technology appeared Satra Bulletin (April 2009) The Newsbundle (May 2009) Chemie magazine (May 2009) REInvent 2010 Ambiente (“Dow Italia e i suoi progetti” May 2011) Ars Sutoria (“Una nuova generazione di sistemi poliuretanici per la sostenibilita’ e le prestazioni nell’industria calzaturiera” Federchimica (“Una nuova generazione di sistemi poliuretanici per la sostenibilita’ e le prestazioni nell’industria calzaturiera”

Chemie magazine Satra Bulletin (“Dow develops renewable polyurethane for footwear industry” February 2012) Internet Web site of Chimica 2011 (“Una nuova generazione di sistemi poliuretanici per la sostenibilita’ e le prestazioni nell’industria calzaturiera”) Footwearbiz.com (“Generations Forward for Sustainability & Performance in the Footwear Industry“) Layman’s Report The Report has been printed in 50 copies after the completion of the timeframe of the project and distributed to potential customers. Plan is to present the Report to next fairs and exhibitions . See dedicated section in the web page. After Life Communication Plan A plan was issued and is in place. Post Project commercialization activities with Voralast*R (GreenFootprint product family) Activity started in 2012 as expected