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Leftover Straw Gets New Life

Environmentally friendly packaging might soon be made in part from rice or wheat straw left over after harvest. The wedge-shaped corner inserts that hold computer printers snugly in place during shipping, for example, could be molded from a slurry made from these straws.

That's the plan of ARS scientists in Albany, California, and their colleagues at Regale Corporation in Napa. Biobased packaging and other new goods made with straw could become alternatives to today's paper and plastic products.

"These bioproducts may give growers a new, profitable market for their straw," says ARS chemist William J. Orts. He leads the Bioproduct Chemistry and Engineering Research Unit at the ARS Western Regional Research Center. "In addition, the straw could give manufacturers a less expensive raw material for their products."

Limited Options for Leftovers

Today, growers of both wheat and rice face the same problem of what to do with leftover straw. It can be gathered and sold for animal feed or bedding, but those markets are often unprofitable for growers.

Straw can be plowed under, but that costs about $8 to $10 an acre. Alternatively, the straw can be left in place in the field to control erosion and to provide nutrients for beneficial, soil-dwelling microbes. But the leftover straw might also support disease-causing organisms that would attack the next year's crop.

In fact, the added cost of plowing-under old straw and the threat of disease are the main reasons that rice growers in California typically burn their fields after harvest. However, over the past decade, straw burning has been progressively prohibited, except in the case of fields that are already diseased. The ban is meant to boost air quality by reducing smoke.

The amount of straw produced each year is enormous. In California alone, the annual rice crop generates over 300,000 tons of straw. And the state's wheat crop yields an estimated 400,000 tons of straw.

Rice and wheat straw are good sources of cellulose. In turn, cellulose is the basis for strong, biodegradable fibers that can be used for manufacturing, according to Orts. His team is determining the extent to which cellulose fiber from straw can be used in place of wood fiber or plastics derived from petroleum.

"Rice and wheat straw are produced at least once a year," Orts explains. "Trees take longer to mature for harvest, and petroleum is, of course, nonrenewable." So using agricultural fibers such as straw as industrial raw materials may have less impact on the environment than these other options. It should also help growers' profits and the economy of their rural communities.

Pulping Processes Scrutinized

To be used in a product such as packaging for electronics, straw first needs to be put through a pulping process that results in a slurry of straw fibers, water, and additives. At this point, the pulp is molded into the finished shape and dried.

Orts and co-researchers are investigating ways to fine-tune pulping processes so that the straw has the properties that manufacturers, such as Regale, require. Regale executives estimate, for example, that even a 1-second reduction in drying time may mean a savings of many thousands of dollars a year in a manufacturer's energy costs.

A collaborator with ARS in some experiments, the company designs and manufactures innovative custom packaging molded from recycled materials.

At the Albany center, Orts and colleagues are putting rice and wheat straw through both a modified hot-water pulping procedure and the chemical-based kraft one. "By making variations to either pulping process, we might be able to reduce the need for chemicals or to reduce other costs," explains Orts. In addition, changing the minor additives to the pulp might streamline production. Common additives include biopolymers, modified starches, clays, and other natural products.

Other variations may enhance the pulp to make the products stronger and more resistant to the warping effects of humidity, temperature, and time in storage. Additional improvements could boost bioproducts' resistance to water and grease—a must for acceptance for fast-food packaging.

Equally as important, the watery, straw-pulp slurry must be predictable in how it behaves in the manufacturing process. This uniformity is essential, despite natural variations in the straw from harvest to harvest. The pulp has to be consistent so that the finished product doesn't vary from year to year. Otherwise, the biobased product may introduce too many uncertainties for the manufacturer.

A Manufacturing Mystery

"Right now, alternative agricultural fibers are an underused resource for making products that have tight manufacturing specifications," says Orts. That's in part because there's relatively little known about how these novel fibers will behave. We need to learn more about alternative agricultural fibers. A key to consistency in manufacturing is characterization—that is, an understanding of how the fiber will perform under various processing conditions.

"We're starting by looking at the characteristics needed for the end product, such as strength, tear resistance, and market appeal," Orts points out. "Then we'll look at the processing that will ensure that the agricultural fibers will have the requisite properties. For this research, we'll be using scanning electron microscopy, x-ray diffraction, differential scanning calorimetry, and thermomechanical analysis.

"The approaches, or recipes, we develop in the laboratory can next be tested on a larger scale under manufacturing conditions in our pilot plant at the Albany center," says Orts. "Then we'll work with our corporate colleagues for industry-scale testing. This scaling up should help us make sure we overcome any potential barriers to commercializing the product."

The center's 35,000-square-foot pilot plant is undergoing a $20 million renovation, scheduled for completion in 2006. This updating will make the plant one of the most modern facilities of its kind in the western United States.

Equipment at the pilot plant is suitable for processing several different agricultural fibers—not just rice and wheat straw. "We've started testing rice hulls and flax," says Orts. "We're interested in many different alternative fibers because we want to meet the needs of a wide range of growers and producers—those who have to deal with leftovers."

He adds, "The fibers are neither profitable for producers nor an economical raw material for manufacturers unless they can be used within a relatively short distance from where they were produced. Otherwise, transportation costs take too big a bite out of potential profits."

Because of the need to be near to the agricultural source, these regional plants, sometimes called biorefineries, might be smaller than conventional manufacturing facilities.

The demand for biodegradable products continues to increase. Experts estimate that goods made in part from renewable resources will make up 10 percent of all American manufacturing by 2020 and 50 percent by 2050. "People feel good about buying these 'green' items," says Orts. "Increasing use of agricultural fibers is one way to give consumers more choices of environmentally friendly products."—By Marcia Wood, Agricultural Research Service Information Staff.

This research is part of Quality and Utilization of Agricultural Products, an ARS National Program (#306) described on the World Wide Web at http://www.nps.ars.usda.gov.

William J. Orts is in the USDA-ARS Bioproduct Chemistry and Engineering Research Unit, Western Regional Research Center, 800 Buchanan St., Albany, CA 94710; phone (510) 559-5730, fax (510) 559-5936.

Source: Agricultural Research magazine April 2002

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'Green' furniture company turns wheat and straw into gold

When Brandrud Furniture crafted its first sofas filled with environmentally friendly foam six years ago, then-owner Larry Green said he had no idea that eventually most of the company's products would be made from such materials as wheat and sunflower seeds.

But the Auburn manufacturer, which specializes in office furniture and products for the healthcare industry, has made great strides.

Not only does Brandrud use agricultural byproducts to help build its furniture, the company also parcels out all of its waste products and ships them off to others so that they can be reused. Sawdust is sent to dairy farms for animal bedding, scrap lumber goes to power plants, and access fabric is passed on to children's museums and day care centers.

"This is going to sound trite," Green said. "But the primary reason we starting doing this was an overall interest in improving the environment. We were introducing some new products and we thought that it might be a good time to see if we could locate materials to use in the new line that would also be environmentally responsible."

Although Green and his partner, Mark Whitman, sold the company last year, new owners Lee Falck and Bobby Holt have continued the effort to make chairs, couches, tables and sofas from materials that deplete natural resources as little as possible.

"We try to work with suppliers that don't harm the environment," Falck said. "We look for sources that take care of the forest and foam suppliers that don't use chemicals. We work with fabric manufacturers who have strong environmental positions."

Brandrud, founded in 1955, started in Seattle. As the company grew -- it now employs about 100 workers -- it needed a bigger space, and in 1981 it moved into a custom-built 50,000-square-foot facility in Auburn. The company's list of clients is impressive -- projects include supplying the Space Needle with some of its first furniture, and, more recently, building products for Nordstrom and Washington Mutual to use around the country.

Earlier this month, Brandrud joined LinkUp, a year-old King County program that offers green businesses technical support and assistance in marketing their products.

"What we've done is reach out to manufacturers who we feel might have potential in products that they make to use recycled materials," said Erv Sandlin, Linkup's project manager. "We give the manufacturers whatever assistance they need."

LinkUp has helped Brandrud balance the added cost of using recycled products with making a profit.

Currently, Brandrud uses wheatboard, a plywood-like material made from wheat straw, to build the interior frames of many of its furniture pieces.

"Anywhere from 20 to 80 percent of a product can be made of recycled materials," Falck said. "Never 100 percent. We make higher end furniture and use native species of hardwood. It's only in the non-structural pieces that instead of lumber or plywood we use wheatboard."

Falck said the company is also beginning to experiment with Dakota Burl, a composite material made from sunflower seed shells. The material has swirls of creams, tans and browns and looks almost like a piece of marble or granite.

But neither the burl, which comes from Minnesota, nor the wheatboard, which is imported from Canada, is made from byproducts created on Washington farms.

In fact, according to the Washington State Department of Agriculture, there aren't any companies in Washington that actually produce strawboard, which includes both wheatboard and other products made from non-wheat straw.

The Straw Utilization Task Force, a 3-year-old committee run by the state Department of Agriculture with the Washington Association of Wheat Growers, is evaluating potential uses for the state's agricultural byproducts.

After a 1999 agreement in which wheat growers said they would reduce the amount of waste they burn by 50 percent over seven years, the need to find new uses for straw and wheat stubble has increased.

"After the wheat is harvested, the straw needs to come off the fields, so it gets burned," said Linda Crerar, a policy assistant with the Department of Agriculture, who works with the task force. "There are a number of issues around air quality that have made that a less and less viable way of managing the leftover straw."

Crerar said that at least one private company is considering producing strawboard in Walla Walla.

In the meantime, Washington farmers are sending their waste to Idaho.

"We make strawboard from the bluegrass straw the farmers grow every other year to help sustain the soil," said Caj Matheson, marketing manager for Pacific Northwest Fiber in Plummer, Idaho. "All of our straw comes from Washington."

And Brandrud will continue using wheatboard and other materials to build its furniture.

"When we think up a new product, we think about how much recycled material we can put in it," Falck said. "It's part of our culture and it has been for a long time."

Source: SEATTLE POST-INTELLIGENCER

Thursday, June 28, 2001
By MARNI LEFF

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Dow To Enter Biocomposite Wood-Replacement Products Business

Dow Pipeline Ltd., a wholly-owned subsidiary of Dow Chemical Canada Inc., has announced that it has agreed to acquire a majority of the Manitoba assets of Isobord Enterprises, Inc., and enter the business of producing engineered composite panels made from wheat straw and Dow's polyurethane resin. Dow announced the new business following today's approval of the asset sale by the Court of Queen's Bench of Manitoba, Winnipeg Centre. Dow Pipeline Ltd. will be renamed at a later date to reflect the new composite panel business.
The purchase includes a manufacturing facility in Elie, Manitoba, Canada, that produces the wood-replacement products, according to Brad Money, business manager, Dow Polyurethanes New Business Development. "Isobord produces a unique product that fits well with Dow's established name in home construction and remodeling," Money said. "We are fortunate to be able to acquire an existing, modern manufacturing facility and have access to employees with the knowledge and expertise in the composite panel business rather than having to build from scratch in a green field situation." Money will lead the new business after the agreement closes, which is expected to be in mid-June. Details of the agreement were not disclosed.
"Dow is investing in businesses that are consistent with its strategy for growth. In addition, the composite panel products are a natural fit with other Dow products being sold in home construction and remodeling that use Dow polyurethane, which supports the company's intention of growing the polyurethane business. The composite panels also provide an environmental benefit of using an annually renewable resource, which fits with Dow's commitment to sustainable development," Money said. "When you combine Dow's expertise in process technology and polyurethane binders with the experience in composite board production of the Elie workforce, we have an excellent opportunity for improving and growing the business."
Money said that Dow has worked closely with Isobord since the plant began operations in 1998. "We have always believed in the product, and we continue to believe that it has the potential for strong commercial appeal with consumers and contractors," he said.
"We commend Dow and are pleased by its decision to enter the composite panel business. The Isobord panels fit with Home Depot's commitment to provide consumers with high quality, economically viable products that relieve pressure on our natural forest resources," said Mark Baker, executive vice president of merchandising/chief merchandising officer, for Home Depot. "Agrifiber products represent an emerging market, and we believe Dow's resources, know-how and reputation will be a strong factor in bringing environmentally-conserving wood replacement panels more into the mainstream with consumers." Home Depot is a distributor of Isobord products.
The Elie site includes a 215,000-square-foot manufacturing facility and two straw staging areas on 68-acres in Elie, which is near Winnipeg. The plant began operations in August 1998 and has about 70 employees. Following a review to determine business requirements, Dow hopes to be able to offer employment to most of the current employees shortly after the sale closes.
Isobord Enterprises has been in receivership since February. Arthur Andersen Inc. was named receiver and manager by the Manitoba Court and has continued to operate the business.
Agrifiber composite panels are made by combining finely chopped wheat straw with a polyurethane binder. The resulting biocomposite material is formed, pressed and trimmed to the desired size panels. The wood-replacement products can be used for kitchen counters, shelving, ready-to-assemble furniture, cabinets, door core, and floor underlay.
The products have received several environmental awards, including the Sustainable Development Award of Excellence from the Manitoba Round Table and the Salute to Clean Air Industry award from the Manitoba Lung Association. The use of straw and a polyurethane binder helps conserve forest products by using straw, an annually renewable resource. These composite panels do not use formaldehyde, which has been raised as a concern with other composite building materials. Using straw for composite panels reduces the need to burn straw in the fields, which has been a source of air pollution.
Dow's polyurethanes business, a leading supplier of polyurethane raw materials, offers one of the broadest lines of polyurethane products in the industry. Dow's polyurethane raw materials are used in producing rigid foams, flexible foams, adhesives, sealants, coatings, elastomers and agrifibers, as well as many other applications. Applications for these products cover a wide range of end uses, including cushioning for furniture and bedding, carpet backing, automotive seating and instrument panels, office furniture, flooring, and insulation for appliances, sheathing and roofing.

June 20, 2001
Source: Clean Edge News

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Making a case for WASTE: President's tax credits for biomass energy development could be boon for two of the state's thriving industries

Included in the Bush administration's 163-page energy plan is a call for tax credits to spur the development of biomass, a form of energy generation that spans everything from old-style wood burning to futuristic processes such as extracting ethanol from agricultural waste.

Although Bush envisions biomass playing a tiny role in solving the nation's immediate energy woes, high-level support for the technology could be important for two California industries: biotechnology and agriculture.

Sharon Shoemaker, director of the California Institute of Food and Agricultural Research at the University of California at Davis, is a proponent of using biotechnology to reinvent biomass as an industry. The aim is to extract clean energy and mineral byproducts from plant waste, while giving distressed farmers a new market for harvest leftovers.

"There's no commercial (biomass) plant like this out there yet, but we're just on the verge of making it happen," said Shoemaker, who will hold a biomass conference at Davis in June.

California's biomass industry, which contributes about 1.5 percent of the state's electricity, is based primarily on burning waste wood from sawmills, forests and orchards.

The keys to reinventing biomass are genetically engineered bacteria and bioengineered enzymes that can turn cellulose -- the material that gives plants their strength -- into ethanol in a process similar to fermenting grain or grapes into alcohol.

In addition to producing ethanol to blend with gasoline, new biomass breweries would extract valuable minerals from plants and even convert the cellulose in plant waste into plastic substitutes.

"Some of our members are making shirts that feel like polyester, but they're made from corn, not oil," said Megan Smith with the American Bioenergy Association, a Washington, D.C., lobby whose members include the Palo Alto biotech firm Genencor International.

After ethanol and mineral byproducts have been extracted from plant waste, biomass plants would burn the remaining material, called lignin -- the substance found in peat bogs. Left alone over geologic time, lignin would compress and turn into coal.

Evidence of Bush's interest in biomass surfaced earlier this year, when the administration slashed research budgets for alternative energy sources such as wind and solar power, but barely touched biomass research. Some of that money came to Northern California biotech firms. Genencor and Novozymes Biotech in Davis each recently won competing $15 million research contracts to cut the expense of turning cellulose into ethanol.

"Today the enzymes used in the process cost 45 cents per gallon of ethanol produced," Novozymes President Glenn Nedwin said. "We want to get it down to 5 cents a gallon."

From political and policy viewpoints, Bush's affinity for biomass is clear. Gregg Morris, director of the Green Power Institute -- a Berkeley nonprofit that performs alternative energy research -- recalled a recent ethanol conference in Las Vegas.

"One of the agricultural lobby guys said that whenever he visits administration officials, he brings a map that shows which states voted for Bush," Morris said. The map showed solid Republican support in the farm-belt states that would benefit most from biomass techniques that provide new markets for field waste.

The policy rationale for biomass energy was laid out in a 1999 article titled "The New Petroleum" that appeared in the influential journal Foreign Affairs. The authors, Sen. Richard Lugar, R-Ind., and former CIA Director James Woolsey, warned that America was headed for economic disaster and another Gulf War unless it reduced oil imports. The vehicle, they said, was to use biotechnology to turn abundant farm waste into ethanol.

"If genetically engineered biocatalysts and advanced processing technologies can make a transition from fossil fuels to biofuels affordable, the world's security picture could be different in many ways," they said, making another oil embargo or Mideast war less likely.

The nation annually consumes about 120 billion gallons of gasoline and produces about 1.9 billion gallons of ethanol.

The new biomass fever must be tempered by recognition that today's biomass industry is controversial and subsidized, and the futuristic processing plants envisioned by boosters exist only in the pilot stage.

California, for instance, has 29 biomass plants in operation, fueled primarily by wood waste, Morris said. An equal number of biomass plants has been idled or dismantled for a variety of reasons, including a lack of wood for fuel. The fastest way to ramp up the wood supply would be thinning the state's forests, but that could stir environmental opposition, Morris said.

In the Midwest, biomass has a different, though no less controversial, meaning. In the grain-producing states, biomass means turning corn kernels into ethanol. The same kernels that might get popped in the movie theater or fed to the livestock are instead put through an ethanol conversion plant.

Two factors make this possible. First, corn kernels are rich in starch, which is relatively easy to ferment. The stalks and the cobs -- which contain the cellulose so valued in biomass dreams -- are thrown away because they aren't economical to convert.

Second -- and steeped in controversy -- is a 53-cent-per-gallon federal subsidy that helps put it on par with competing petroleum products. Free market groups, such as the Cato Institute in Washington, D.C., have attacked this as a handout to the corn belt that primarily benefits one company -- Archer Daniels Midland -- the nation's leading ethanol producer.

Backers of the new biomass are counting on that subsidy to help support the challenging task of taking ethanol from cellulose waste. "Without the 53-cent- a-gallon subsidy, the corn ethanol industry wouldn't be here today," said Mike Bryan of BBI Associates, a Colorado firm that conducts feasibility studies for ethanol plants. "The cellulose ethanol industry will need similar support for a while."

Although much of the talk about biomass centers on futuristic applications, the newest aspect of the Bush energy plan benefits the oldest form of biomass - - burning waste to generate power.

Smith, the Bioenergy Association lobbyist, said Bush has proposed giving biomass power generators access to an existing, but unused, tax credit of 1.7 cents per kilowatt hour.

When Congress enacted the credit in 1992, it was intended for biomass generators who burned plant matter specifically grown to harvest as fuel.

"This has cost the treasury nothing, because nobody does it," said Morris, the Green Power expert in Berkeley.

Bush has proposed making this credit available to biomass furnaces that burn waste wood, something that would benefit California biomass generators.

San Fransisco Chronicle, May 18, 2001

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$1.2 MILLION AWARDED TO RICE STRAW DEMONSTRATION PROJECTS

Each year approximately 500,000 acres of rice are cultivated in the Sacramento Valley, producing about 1 million tons of straw. California's moratorium on rice straw burning has left growers with limited options and high costs for straw disposal. In 1997, the Rice Straw Demonstration Fund was created to provide cost-sharing grants for projects that promote self-sustaining commercial uses for straw.

Seven grant requests were received for fiscal year 1999-2000. Based on the results of the review process, five projects were awarded a total of approximately $1.2 million. These projects have the potential to use as much as 800,000 tons of rice straw annually after five years. The winning proposals are:

  • Kuhn Hay to open markets, establish infrastructure and develop a treatment protocol for rice straw export to Japan.
  • BC International (BCI) and the Rice Straw Cooperative (RSC) to evaluate the degradation of stored rice straw and its effectiveness for making ethanol.
  • Broken Box Ranch to develop a commercial scale composting plant utilizing rice straw and livestock waste. Organic compost will be sold in bulk to nearby rice growers who are looking for alternative soil amendments.
  • Arkenol Holdings, LLC to further research into the commercial production of ethanol from rice straw.
  • Smith Ranches to evaluate the logistics and effectiveness of producing rice straw silage for cattle feed.

The full text of grant awards proposals is available at: http://www.arb.ca.gov/rice/ricefund/rfsr051500.pdf

Excerpt from: Carbohydrate Economy

NEW REPORT LOOKS AT USES FOR RICE STRAW IN COLUSA COUNTY, CALIFORNIA

California law mandates that open burning of rice straw be reduced to 25 percent of historic levels by 2001. In an attempt to provide growers with an alternative to this traditional means of rice straw disposal, a new study commissioned by the Western Regional Biomass Energy Program and conducted by the Rice Straw Feedstock Joint Venture looks at the issues surrounding alternative forms of rice straw utilization. It focuses on Colusa County, California, the largest rice-producing county in the state.

The report examines rice straw availability; collection, transportation, and storage issues; possible end uses for rice straw; and ways in which these factors can be integrated to provide viable alternatives for rice farmers in California. Applications for rice straw discussed include energy generation, building materials, paper production, erosion control, animal feed, and chemical production. Updates on projects currently using rice straw for various applications - particleboard, housing and sound walls, erosion control mechanisms, and animal feed and bedding are provided.

To access a copy of this report, visit Western Regional Biomass Energy's web page at: http://www.westbioenergy.org/ricestraw/

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FIBERBOARD GOES INTO PRODUCTION IN PLUMMER, IDAHO

Plummer, ID - In less than six months, Pacific Northwest Fiber has gone from a start-up company on paper to a factory in full production. The Plummer-based Pacific Northwest Fiber fabricates particleboard from the straw residue of bluegrass seed fields in eastern Washington and northern Idaho. The facility was established in March 1999.

The plant is a joint venture of Seeds, Inc., Tekoa, WA; the Coeur d'Alene Tribe and Prairie Forest Products of Hutchinson, KS. According to Pacific Northwest Fiber's General Manager, Dave Bauermeister, board production began on August 1. "The plant will use a significant portion of the straw that was produced in the 1999 and 1998 seed crops in Spokane County." The plant in Plummer represents a $5 million investment in equipment and provides 35 jobs and a payroll exceeding $1 million annually.

For more information, contact: Dave Bauermeister at (208) 686-6800.

STRAWBOARD MAKERS NUMBER THREE IN NORTH AMERICA

Three North American manufacturers now produce particleboard made of [residual] wheat straw instead of wood: PrimeBoard, Inc. in Wahpeton, North Dakota; Prairie Forest Products, in Hutchinson, Kansas; and Isobord Enterprises, Inc. in Elie, Manitoba. An [annually renewable] agricultural product, strawboard generally sells for the same price as wood particleboard. It can replace wood particleboard or medium-density fiberboard in non-structural applications like furniture, cabinets, store displays, door panels, moldings, and other fixtures. Strawboard is about 97 percent straw and three percent methylene diphenyl diisocyanate (MDI), a resin that is five times as expensive as urea formaldehyde, the most common wood particleboard resin. Though formaldehyde-free, the petroleum-derived MDI resin is classified as a hazardous air pollutant, and at least two strawboard makers are working to develop a vegetable-based resin. Strawboard's nail- and screw-holding capacity and moisture resistance outperform competitors. It machines smoothly, offering a superior laminating surface. An acre of wheat usually produces about a ton of straw. Generally farmers harvest only about half of this for strawboard leaving the rest on the field for soil nutrition, and [in the Midwest], farmers harvest a field for strawboard only once every two to three years. But in the state of Washington, where fertile soil and irrigation produce as much as two to three tons per acre, farmers frequently burn straw in the field since there is too much to plow into the soil. The burning has created air quality problems and led to strong interest in developing a local strawboard plant.

Clip from: The Carbohydrate Economy, Spring 99, p. 12.

For more information, contact:
PrimeBoard: http://www.primeboard.com
Prairie Forest Products: 316-665-7000
Isobord Enterprises: http://www.isobord.com

ARISA PROCEEDS WITH PLANS FOR NON-WOOD PULP MILL IN AUSTRALIA

Arisa LTD (Melbourne, Australia) says it is going ahead with plans for a $31.5 million public float this year to raise funds to develop a paper pulp mill in western Victoria. The company is launching its second private share issue, seeking to raise $2.21 million. The mill would be the first in Australia to make non-wood market pulp using wheat straw to produce about 38,000 metric tons/yr for the domestic market.


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