Flax Fiber Transformed into Green Dinnerware

By EduTransfer Design Associates and Haywire Creative

November 10, 2009

Saskatchewan collaboration develops biodegradable flax fiber dinner plates.

A recent collaboration between the University of Regina and a Swift Current manufacturing firm has designed green disposable dinnerware. Using locally produced flax fiber, Dr. Denise Stilling, associate professor of the Faculty of Engineering and Applied Science at the University of Regina has found a way to turn flax straw into molded biodegradable products.

“This project really began in 2005 when Regina hosted the Jeux du 2005 Canada Summer Games with the organizing committee  looking for various ways to ‘green the games’,” explains Stilling. “One idea was to replace Styrofoam products with biodegradable, compostable products made from an annual raw source.” At that time, the only available sources were sugar cane and wild reed products from Asia, which were used for the games. This led to the search for potential local fiber alternatives to create such products.

“Aligned with Flax2015 initiative to identify and utilize value-added opportunities for flax, this project provides an innovative use for flax straw,”  says Stilling. “Last year, 1.25 million acres of flax were grown in Saskatchewan and about 45,000 acres in Alberta, with each acre producing about 0.4 to 0.58 tons/acre .  Indeed, an abundant source of flax straw exists.” A few companies are buying flax fiber for use in fine writing and cigarette paper and as an additive to polymers for decking or other biocomposite materials.
 

 

 

Photo credit: D. Stilling, University of Regina.

Stilling explains that flax fiber is very interesting but doesn’t degrade very well as a whole stalk, which is why farmers tend to bunch and burn the straw. Burning the straw increases CO2 emissions and harmful toxins, and many jurisdictions have introduced legislation restricting burning. “These disposal issues at the farm level combined with consumer demand for convenient, single use items that are environmentally friendly make flax fiber an ideal raw source for value-added products.”

From Prototype to Commercialization
 
Stilling collaborated with Urban Forest Recyclers (UFR) of Swift Current to prove technology and concepts for moulded, flax-based containers, receiving funding from Saskatchewan Agriculture and the Crown Investments Corporation. “We have successfully developed a pulping and molding process to use flax and other fibers to make biodegradable, single use dinnerware and other products,” says Stilling. “With the commercial distribution industry very interested in these products, we are looking at options for setting up commercial ventures for production.” Some of the potential markets include fast food outlets, institutional food services and resort camps.

“Manufacturers will have to be able to match costs of mass produced polystyrene products or wood pulp products,” explains Stilling. “This opportunity would provide a small income to farmers, probably between $25 to $50 per large round bale, and eliminate the hassle of bunching, burning and permits,” says Stilling. “Although it won’t be a lucrative income source, it is a new secondary growth revenue stream for farmers.”

Different commercial options are being explored, but are expected to include some local collection and pre-processing opportunities. “Opportunities for diversification and creating cottage industries that are sustainable by being able to use a secure annual renewable source of flax straw is very positive,” says Stilling. “We also have established north-south trade corridors for tapping into the U.S. and other global markets.”  Stilling and UFR received the Regina Chamber of Commerce 2009 Paragon Business Excellence Award of Innovation for this green project.

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