Mark Herrema didn’t all the time hate plastic forks. It took years for him to develop this disdain. But mounting proof ultimately satisfied him that plastic—in all its numerous shapes and kinds—was one of many world’s best environmental threats. Herrema wished to rid the world of plastic, one planet-choking fork at a time.
The catalyst for his anti-plastic offensive got here from an unlikely supply—a cow named Lucy. After studying an article citing the particular quantity of methane emitted per cow per yr (round 600 air-contaminating liters), Herrema had an concept.
“If we could find a way to turn carbon that would otherwise be in the air into useful products,” Herrema says, “we would have a pathway to reducing the amount of carbon in the air.”
This concept has turn out to be a significant tenet of what’s referred to as “carbon-negative manufacturing,” which is simply what it feels like: making merchandise with out contributing to the rising international environmental disaster. Herrema wished to not solely create one thing that will fight plastic, but additionally pull it off with out doing extra hurt than good.
But two main questions remained: How to do it, and methods to do it to scale? Finding a solution would take almost 17 years. But now his firm’s innovations are prepared for the world.
Reinventing Nature to Save Nature
While rainforests stands out as the lungs of the world, oceans are additionally an important carbon sink, soaking up 25 percent of all carbon emissions.
To discover his plastic alternative, Herrema and his good friend Kenton Kimmel, who was a biomedical pupil on the time, pored over scientific publications and found that some microorganisms within the ocean eat methane and carbon dioxide. Most considerably, these organisms then use that carbon to develop.
“When they grow, one of the things they make inside their cells is this material called PHB,” says Herrema. “It’s made in almost all known living things, including the human body. But because it’s meltable, you can use it to replace plastic.”
In 2003, Herrema and Kimmel based Newlight, a Southern California firm with a mission to capitalize on PHB. That’s when the actual work started: They wanted to determine a system to coax lots of tiny micro organism to eat a greenhouse-gas weight loss program, after which corral the ensuing pure polymers. For greater than a decade, and after a lot trial and error, Newlight arrange a system that will mimic this oceanic conversion on land.
The course of includes filling 50-foot metal tanks with a saltwater answer. Ocean-derived microorganisms are added, after which methane and air are combined into the answer so the microorganisms can feast on a greenhouse lunch. The creatures make the PHB materials, after which the organisms are collected and run via a high-pressure filtration course of. That course of separates the microorganisms from the PHB materials. The result’s what Newlight calls “AirCarbon.”
The materials is dried right into a effective white powder that’s heated in an extruder, the place it turns right into a molten strand. The cooled strand is minimize into pellets that may be processed via a spread of apparatus, identical to commonplace plastic. With injection molding, for instance, the pellets can be utilized to make quite a lot of objects, together with faux-plastic forks.
Herrema feels that probably the most important facet of Newlight’s expertise is that it helps folks transition from damaging artificial supplies to pure supplies. Which is nice for people and the setting.
We know in regards to the seen plastic particles floating in our oceans: Fishing nets, plastic luggage, bottles, straws, and cigarette-butt filters are an issue. But scientific analysis shows that microplastics—the particles derived from the breakdown of that particles—are even worse.
There’s no sensible solution to clear up microplastics, and analysis suggests that the majority plastic within the ocean will by no means absolutely degrade. Enter AirCarbon: The massive advantage of this materials is that it’s absolutely marine degradable. The ocean lastly will get a break.
Joseph Greene of California State University has graded Newlight’s homework. Greene is a professor of engineering who has been researching biodegradable plastics since 2005. “I’m helping companies understand what the behavior of their plastic material is in the marine environment,” says Greene.
Greene says PHA is a household of easy plastics, with very small molecules, simply digestible by tiny animals within the ocean. Newlight’s materials, PHB, is the most well-liked kind as a result of its rubberlike qualities make it extra helpful. “The question is, what happens to this plastic material? It has to first fall apart in very small pieces,” he says. “Second, those pieces have to be a food source for the bacteria in the ocean.”
Greene says that Newlight’s PHB has met the standards for marine biodegradability and that the material will even break down, though slowly, in a home composter. “I’ve tested these materials in a backyard composter and it actually biodegraded. Not rapidly, but it was better than other biodegradable plastics that did nothing.”
Practice What You Preach
Creating this pure plastic alternative was tough sufficient. Doing so whereas additionally remaining a carbon-negative firm required nearly as a lot ingenious engineering. The firm spent severe time researching probably the most environment friendly methods to acquire methane and put it to the simplest use.
Newlight didn’t create extra methane for its greenhouse ingredient—as an alternative, it sourced biogas from dairy farms, meals waste digesters, landfills, and deserted coal mines.
Saving Oceans With…Blockchain?
The solely solution to perceive the carbon influence of an merchandise is to trace it all through its complete manufacturing course of, and that may get sophisticated.
“We…also wanted to give consumers the ability to understand our process, its various steps and its carbon impact,” says Herrema. “We called up IBM three years ago and said, ‘Hey, we’d love to apply blockchain technology to our process and our products.’”
Blockchain is a digital ledger, a file of transactions. The system works by linking particular person information, referred to as blocks, in a single checklist, dubbed a series. Those chain databases are related in a community via peer-to-peer nodes. Blockchains are used for recording transactions made with cryptocurrencies, equivalent to Bitcoin, and different purposes, equivalent to with Newlight’s public, clear product monitoring.
Newlight and IBM arrange a blockchain so that every one the inputs and outputs of their system have been registered. The blockchain knowledge creates traceable, trackable numbers for every part the corporate does. When they’ve a completed product, they’ve recorded all of the steps it went via.
“Using that individual unique blockchain number, customers can see all the major steps in the production process and the time and date associated with those,” says Herrema, “and then also the specific carbon impact associated with the product.”
Any buyer can plug in a product quantity and discover dynamic knowledge related to the merchandise. “The blockchain is always running and each new product has its own number,” says Herrema. “Every single number is different, and every single number shows its own unique times and dates associated with the various steps in the process.”
“We work with a company that’s come in and basically set up a gas capture system that captures the methane emissions and purifies out the non-methane gases like nitrogen, carbon dioxide, and other things. Then they inject that into the natural gas grid,” says Herrema.
The firm pays further for the renewable energy and renewable fuel, and the fuel is piped into Newlight’s manufacturing unit. The firm says it has a carbon discount influence of 45,000 tons of CO2 a yr, a declare that’s backed up by SCS Global and Carbon Trust, two impartial third-party carbon accounting companies. And all steps within the manufacturing course of, from packaging to transportation, are accounted for.
Some of the world’s largest firms are going inexperienced. Apple has declared its intention to be carbon impartial by 2030 and has instituted six major initiatives towards that effort. Large firms like Disney, Starbucks, and Nike have additionally said their deep commitment to environmental protection, although what that appears like stays to be seen.
Newlight’s carbon-negative sport plan is barely now coming into sharper focus. Herrema and Kimmel initially meant to make the AirCarbon materials accessible straight, and so they proceed to discover that possibility. But first, they grew to become its preliminary largest buyer by beginning two manufacturers, Restore and Covalent.
Restore makes reusable marine-biodegradable straws and utensils, and Covalent makes high-end sun shades and purses—a testomony that PHB might be each utilitarian and fashion-forward.
“We want to see the end of the plastic fork that never goes away replaced with a natural material, AirCarbon, that nature understands,” Herrema says.
Even when a Covalent purse or pair of sun shades turns into unusable, it received’t languish in a landfill. Instead, Newlight encourages clients to return worn-out or broken merchandise, as a result of the PHB materials might be melted down and re-formed.
“The primary intended pathway is for products to be remelted and then re-formed into new products,” says Herrema, citing a Covalent purse for example. “We would probably turn it into an alternative leather-type product, but theoretically you have the ability to form it into lots of different parts and pieces.”
Newlight is increasing its personal footprint (whereas shrinking the carbon one) by beginning the design and preparation to construct a second manufacturing unit, Eagle 4, and the brand new merchandise that’ll be constructed—or grown—inside its partitions.
And the growth is warranted as a result of AirCarbon is now prepared for the lots. This spring, Newlight partnered with Shake Shack places in New York, Miami Beach, and California to make use of Restore for buyer orders. On a bigger scale, Target shops nationwide will begin carrying Restore foodware.
After almost 20 years of labor, Herrema’s ideas on the “plastic” fork have modified. “I did have an awkward moment when I think I fell in love with one of our straws, and then I fell in love with a fork as well,” Herrema says.
Hopefully, the world may have comparable emotions.