Feature
story

INOAC’s environmentally conscious products that meetthe people’s needs

Earth-friendly andhuman-friendly productdevelopment

The issues of marine pollution caused by microplastics andthe treatment of non-recyclable plastic wastes are now social
issues of a global scale. As such, strong expectations arebeing placed on the plastic industry and each manufacturing
company to confront these problems. Our company isdealing with the environmental problems by promoting a shift
to the use of plant-based resins. Demand for plant-based
products is rising rapidly due to the minimal stress they puton the environment, and this demand is expected toaccelerate even more in the future. In addition, as part of ourefforts to reduce waste, we are reusing thermoplastic resins
by pulverizing and modifying process waste, which could notpreviously be recycled. We are also carrying out productdevelopments that make a shift to using carbon neutralmaterials in the place of plant-based resins to reduce carbon
dioxide emissions.
We are also a member of the Nano Cellulose Vehicle (NCV)
project, which is carried out by various industrial, academicand government institutions, including Kyoto University and21 other universities, research institutes and companies. The
aim of the project is to research the possibilities of cellulose
nanofiber (CNF) from various different angles. Not only is
CNF a natural material, it is also highly ef fective as areinforcement filler for resins, and we anticipate that it will beof significant value in the future. CNF is ideal for creating lightbut very rigid products and has contributed to making cars
lighter and more fuel-ef ficient. Indirectly, it can also
contribute to reducing energy consumption.
In order to continue meeting the diverse needs of the global
market going forward, we will actively promote the use ofplant-based resins, research recycling methods and develop
foam products that are lightweight and have heat insulating
properties, which contribute to saving energy.

World-leading R&D and human resource development
In order to propose and provide new solutions to society,each of our departments and affiliated companies areengaged in developing environmentally friendly products,
with our company’s R&D efforts centered at the INOAC
Technical Center and the Global Technical Division.
Outside of Japan, such as in North America and China,
we are likewise developing environmentally friendly
products that meet the needs of each region. We share
information among the entire group and are committed to
fur ther advancing and enhancing our technologicalcapabilities. We are also actively engaged in humanresource development by working together with raw
material manufacturers and our customers both in Japanand overseas, while also collaborating with educational
institutes and gathering information at exhibitions. In
addition, we organize research opportunities abroad toalways keep up with the latest information as we move
forward with our R&D.

Continuing to be a manufacturer of earth-friendly andhuman-friendly materials
The social structure as we know it, with mass production,
mass waste and mass energy consumption, will no longer
be possible. To realize a recycling-oriented society, therole of materials is extremely significant and their needs
will likely rise even more. Developing technologies thatlead to decreasing environmental burdens and savingenergy is a field that Japan has been leading in over theyears. Going forward, as a material manufacturer that
supports various industries, we will strive to develop andprovide products that are considerate of the earth and its
people’s lives.

Kentaro Iwanaga
Division Director
Global Technology Development Division
INOAC CSR REPORT 201908

Featurestory

Case.1 Product development using plant-based raw materials 1

Earth-friendly andhuman-friendly product development

The polyolefin sheet that reuses sugarcane pomace
At I-Sheet Industry Co., Ltd. of the INOAC Group, we are doing R&D ofpolyolefin sheets that use sugarcane pomace as part of its rawmaterials.

and can be said to be a product that contributes to a recyclingoriented society.

The sheet has the same physical properties and quality as the existing
petroleum-based one, and can be similarly vacuum formed and used.

Sugarcane cultivation does not cause deforestation andenvironmental destruction due to it being grown in areas that areconverted from pastures.

In addition, the sheet does not emit extra CO2 when combusted due
to partially consist raw material (=plant) that absorbed CO 2 in theatmosphere.

The material has another advantage point compared to materials
derived from corn: manufacturing energy costs are lower and has nocompetition with food or feed.

The sheet is compatible with the CO2 life cycle ( “plant absorption” →“manufacturing bioplastic” → “combustion and atmosphericemission” ),We are expanding the sheet sales as an alternative to petroleumderived food and industrial trays.

■ Characteristics of materials using sugarcane pomace● Can be used in the same way as existing

recycling-oriented society
CO2 lifecycle

Development Technology Section
I-SHEET Industry Co., Ltd.

■ Product examples【CO2 lifecycle diagram】*This product is not biodegradable●Trays for food and industrial components(Alternative to petroleum-based products)

petroleum-based products
Same physical properties, quality, formability.
● The material that can contribute to a

Junichiro Kasada

Absorbs
atmospheric CO2

CO2CombustionAtmosphere● No negative effects on environmental

protection or food problems
No deforestation required for manufacturing.
Sugarcane pomace is not used for food andfeed.

Manufacturing
bioplastic
Sugarcane pomace

Polyolefin material

INOAC CSR REPORT 201909

Feature
story

Case.2 Product development using plant-based raw materials 2

Earth-friendly andhuman-friendly product development

Development of urethane foam using plant-based raw materials
We believe that in order to contribute to a sustainable society, oneof the important activities for companies is to effectively utilize
limited resources.
Although most of our company’s main material, urethane foam, ispetroleum-based, we are also engaged in developing plant-based
raw materials to prevent the depletion of limited fossil fuel resources
and to be more environmentally friendly.

from plants (e.g.: castor oil, palm oil, soybean oil).
By continuing to carry out product developments that increase thepercentage of plant-based raw materials, we hope to contribute tothe reduction of CO 2 emissions with carbon neutral materials andprevent global warming.

Yasumasa Goto

We are currently working to develop products with a highpercentage of plant-based raw materials by using polyols derived■ Maintaining the same properties as existing (petroleum-based) products
Products made from plant-based raw materials are generally hard andtend to weaken easily, so it is difficult to develop products that canmaintain the same properties as those made from petroleum-based rawmaterials. However, with the product we are currently developing we haveachieved a level of maintaining the same properties as existing products.

Urethane Technology Section
Foam Products Department
High Functional Material Division■ Reducing CO2 emissions with carbon neutrality
Using plant-based raw materials contributes to reducing greenhouse gases because
the CO2 emitted when combusting theproduct is the same amount of CO2
absorbed by the plants during
Growththeir growth.
Absorption

Photosynthesis

Biomass

Raw materials■ Advantages of using plant-based raw materials●Reduction of CO2 concentration with carbon neutrality

CO2.Prevents global warmingProduct manufacturing●Reduction of dependence on fossil resources.Prevents the depletion of limited resources

Generation

Disposal after use
Use as electricity/heat

INOAC CSR REPORT 201910Featurestory

Case.3 NCV Project participation

Earth-friendly andhuman-friendly product development

Cellulose nanofiber (CNF) to make products lighter
The Nano Cellulose Vehicle (NCV) Project is run jointly by industrial,academic and government institutions, and our company has been
participating in it since its establishment. The project’s goal is tomake vehicles lighter by utilizing CNF.
Led by Kyoto University and the Ministry of the Environment, theNCV Project is aiming to make vehicles over 10% lighter by 2020 by
utilizing next-generation CNF, which is a fifth of the weight of steel
and over five times stronger. For our part in the NCV Project, we will
test the possibilities that CNF has as automotive components byMarch 2020 and aim to apply it commercially by FY 2025.

to develop resin vehicle components with foamed resin molded
articles, which also make the product more lightweight. By adding
10% of CNF to the resin material and applying our foam molding
technologies, we have succeeded in making the molded articles
20% lighter than before.
Through our R&D efforts, we will contribute to making the shift tocarbon neutral materials, reducing the use of petroleum-based
resin and improving fuel efficiency by making vehicles lighter.

Hiroaki Suzuki
Director
Evaluation Technology Sectionof the Development Division
Global Automotive-related
Products Division

We are currently working to further strengthen resins by using CNF■ NCV Project■ Strengthening resins by adding CNF■ Product example

The NCV Project was launched by the Ministryof the Environment to improve automobile fuelconsumption by making vehicles lighter and toreduce CO2 by applying CNF—a lightweight andhigh-strength next-generation material—to theautomotive field. Kyoto University leads theproject and more than 20 industrial, academic
and governmental institutions participate.

●Characteristics of the technology and product●Foamed resin injection molded article

Adding CNF strengthens the resin to supplement a
decrease in strength caused by foaming.

(Car interior pillar: product with 10% CNF addition)

Strength

Increased strength due to adding CNF

Specific gravityand strength withregular molding
Decreased weightand strength due tofoam molding

Specific gravity

PillarSingle resin
CNF addition

More lightweight whilestrength maintained

INOAC CSR REPORT 201911

Featurestory

Case.4 Realization of material recycling

Earth-friendly andhuman-friendly product development

Recycling process waste of polyethylene foam
We are planning to start material recycling by turning the process waste of polyethylene—produced during themanufacturing (vacuum forming) process of automotive components—into material pellets and reusing themfor different products. Our ultimate goal is to reduce the over 4 tons of industrial waste produced on average
every month by 100% and achieve a “ZERO” industrial waste reality.
In our developments, we will focus our efforts on establishing a recycling method that takes into consideration
the volume reduction method, defoaming method and cross-link cutting method for cross-linked foam.
Until now, we have been undertaking thermal recycling, which reuses the energy produced when combusting
industrial waste. However, from now on, we will also be undertaking material recycling, which reuses industrial
waste as a different product.
Going forward, we will proceed with developments with the aim of establishing a technology capable oftransforming all recycling pellet materials back into products.

■ To achieve a zero industrial waste reality
Our aim is to reduce the over 4 tons ofindustrial waste produced on average
every month by 100%.

Goal
Reduce industrial
waste by 100%

① Crush process

waste

Powderization

Process waste of polyethylene foam

CrusherConvert to pellets

Yoshihisa Takamori

Subsection Chief
Resin Product Development Sectionof the Development Department
Global Automotive-related
Products Division

Resin Material Development Section
Material Technology Department
Global Technology Development
Division■ Recycling process

Process waste➡

Shinji Sugie➡

② Produce pellets

with an extruder☆ Defoam and cutcross-links➡

③ Convert toINOAC product

Crushed powder +defoaming additivePelletization

Extruder(defoams and cuts cross-links)

Special screw design➡
INOAC CSR REPORT 201912