Challenge
Cargill, Inc., the largest private company in the United States in the 1990’s, developed a low-cost method to manufacture a plastic polymer, Polylactic Acid (PLA), from an annually renewable feedstock (corn). The objective was to replace traditional hydrocarbon based plastics in targeted applications. In December 1997, with a polymer pilot plant capability, Cargill formed a 50/50 joint venture with the Dow Chemical Company. The goal for the venture was to take two years to look at the market and determine whether there were sufficient market opportunities and whether marketplace would support a 300 million pound world-scale polymer plant.

Process Beginning in 1998, the JV began to explore applications in film, bottles and, as a long-shot, textile fibers. The path forward for textile fibers was to manufacture staple fiber, spun yarns, filament and textured yarns on standard industry equipment without any major modifications. The second objective was to create enough excitement at the "brand-owners" level to "pull" the technology through the manufacturing chain if the polymer plant was constructed.

Solution
NatureWorks™ PLA polymer proved relatively easy to spin and process as fiber and yarn. Resultant fabrics offered a number of favorable performance properties. The joint venture did achieve the necessary interest and commitment from brand-owners. In November 2003, the 300 million pound polymer manufacturing facility came on line. Today, fibers, under the brand name Ingeo™ are now being sold into several diverse markets, including fiberfill in pillows and comforters and yarn for apparel. The NatureWorks polymer has won countless product of the year awards and offers consumers the first commercial alternative to hydrocarbon-based plastics. The venture has spent almost $2 billion on the technology and infrastructure and the production facility is sold out. A second plant is being considered.