DuPont is a 203 year-old company with over 60 years of experience in polymer and textile science. Tate & Lyle PLC has almost a century of expertise in the development of food and industrial ingredients from renewable resources such as corn and the efficient production of such ingredients at scale. In May 2004, the two companies announced a joint venture to build one of the largest bio-materials processing facilities in the world in Loudon, Tenn. When the plant is operational in 2006, it will produce 100 million pounds per year of a new bio-material, Bio-PDO™ that could transform markets, reducing the global economy’s reliance on petroleum-based materials.
DuPont recently developed a patented process to create 1,3 propanediol (PDO) using corn as the raw material in place of petroleum. PDO has a number of potential uses, either as a material itself or as an ingredient in or building block for the production of other materials. Looking to bring this new product, called Bio-PDO™, to market, DuPont found a partner in Tate & Lyle, a company with strong scientific and research capability and a mission to become “consistently first in renewable ingredients”. Tate & Lyle has excellence in fermentation technology and, together, the two companies have patented several innovations in the commercialization of Bio-PDOTM.
Bio-PDO™ is the key ingredient for Sorona®, the latest polymer invention from DuPont. Fibers that contain these polymers have unique properties that include a very soft hand-feel, comfort stretch and recovery, easy dyeability, natural stain resistance and easy-care characteristics. Additional attributes imparted to fabrics by fibers made from Sorona® polymer are chlorine and UV resistance, rapid drying, colorfastness, static protection, and resilience. Sorona® is currently sold to licensees throughout the world based on PDO produced from petroleum-based and will be converted to the bio-material offering when the Loudon plant becomes operational.
A new line of residential carpeting offered by Mohawk Industries includes the innovative technology of DuPont™ Sorona®. Mohawk’s Smartstrand™ with DuPont™ Sorona® polymer is available in stores now. Mohawk Industries’ CEO Jeffrey S. Lorberbaum said, “This product will do things that others cannot, making it the biggest fiber innovation we have seen in 20 years. Our confidence in this product is evidenced by Mohawk’s first-ever Limited Lifetime Warranty offer for stain resistance. SmartStrand™ made with DuPont™ Sorona® polymer offers consumers the durability of nylon with remarkable stain resistance. Rarely do consumers get a luxuriously soft carpet with these benefits.”
In 2003, the U.S Environmental Protection Agency presented DuPont with its annual "Presidential Green Chemistry Award" for the company’s research leading to the development of the Bio-PDO™ process.
In June 2005 the project received additional recognition. The innovative work by the combined DuPont-Tate & Lyle team on this biologically-derived polymer earned the 2005 DuPont Sustainable Growth Award. The Award presented by a panel of DuPont experts and global sustainability leaders was given for the development of this low cost and environmentally friendly alternative to petrochemical based production.
