# unturf.

### grow food not lawn

manifesto · eight forms of capital · single-use plastics · hemp bioplastic · recipe · homeschool · factory · free software

## Bioplastic Factory

A continuous-flow factory producing durable everyday products from plant fiber. Not batch processing. Not single-use packaging. Products survive years of daily use but biodegrade fully in hot aerobic compost (60-70C). Three fiber sources feed the same standardized process: hemp, nettle, & wood refuse. Designed for replication as distributed hubs worldwide.

This page describes a complete 7-station production line. Batch recipes live on a process page. A 4-day homeschool curriculum lives on a homeschool page. This factory page covers continuous production at community scale.

OVERVIEW

### 7-Station Flow

fiber enters at station 1, finished products leave at station 6, compost demo runs at station 7.

Station | Name | Input | Output | Equipment | Cycle Time
--- | --- | --- | --- | --- | ---
1 | Fiber Intake & Prep | Raw stalks & wood refuse | Prepared fiber (chopped, sorted) | Decorticator, chopper, retting tanks, scale | Continuous intake
2 | Extraction | Prepared fiber | Raw cellulose | Reaction vessels (3-4), filtration, pH meter | 2-4 hours per vessel
3 | Washing & Drying | Raw cellulose | Dry cellulose | Counter-current wash line, convection dryer | 4-8 hours
4 | Mixing | Dry cellulose | Mixed compound | Heated mixer, scale, pigment dispensers | 60-90 minutes
5 | Pressing & Molding | Mixed compound | Pressed products | Hot press, mold sets, temperature controller | 30-60 min per press
6 | Finishing | Pressed products | Finished goods | Trim station, inspection table, stamp press | 5-10 min per product
7 | Compost Demo | Demo samples | Display & education | Hot compost bin (60-70C), timeline display | Ongoing display

STATION 1

### Fiber Intake & Prep

Three fiber sources converge into a single "prepared fiber" stream. Each source follows a parallel prep path adapted to its characteristics, then all merge at chopping & weighing.

hemp, nettle, & wood refuse follow parallel prep paths before merging.

#### Hemp (primary source)

- Bast fiber from stalks, 77% cellulose content
- Ret 3-45 days (depending on temperature) or water ret 10 days
- Decorticate: separate bast from hurd using decorticator or by hand

#### Nettle (secondary source)

- Bast fiber from stalks, ~65% cellulose content[1]
- Water ret 7-14 days, faster breakdown than hemp
- Strip bast fiber by hand or small decorticator
- Grows wild on marginal land, requires no cultivation

#### Wood Refuse (supplementary source)

- Sawmill offcuts, chips, shavings from local timber operations
- Chip to uniform 2-5 mm pieces
- Sort: remove bark, knots, & resinous species (pine, cedar)
- Hardwoods preferred: beech, birch, poplar offer 40-50% cellulose[2]

#### Convergence

1. Chop all prepared fiber to uniform 2-3 cm lengths
2. Weigh & record source ratio per batch (enables quality tracking)
3. Output: prepared fiber, ready for extraction

Equipment list: decorticator (hand-crank or motorized), fiber chopper, retting tanks (3-4 for rotation), sorting table, digital scale (1g precision), labeled storage bins per fiber source.
STATION 2

### Extraction

Two extraction paths run as factory alternatives. A hub selects one path based on local chemistry comfort, waste handling capacity, & product goals. Both paths accept the same prepared fiber from Station 1 & output raw cellulose to Station 3.

each hub chooses one path. both produce usable cellulose for pressing.

#### Path A: NaOH Extraction

Process:
1. Dissolve NaOH in water (5-12% solution depending on fiber source)
2. Add prepared fiber. Heat to 80C with stirring for 2-3 hours (or soak at room temperature for 4 hours using 5% NaOH)[3]
3. Filter. Wash 4-6 times until pH neutral
4. Output: purified cellulose (removes lignin, hemicellulose, pectin)
Continuous operation: rotate 3-4 reaction vessels through stages. While vessel A soaks, vessel B gets filtered, vessel C gets loaded. No downtime.

#### Path B: Citric Acid Crosslinking

Process:
1. Spread prepared fiber onto screens, press into sheets
2. Soak sheets in citric acid + glycerol solution
3. Cure at 140C under pressure[4]
4. Output: crosslinked cellulose material (up to 70 MPa tensile strength)
Continuous operation: stagger sheet production. While batch A cures, batch B soaks, batch C gets pressed into sheets.
Honest comparison: citric acid path produces less chemical waste, avoids NaOH safety hazards, & requires simpler equipment. NaOH path achieves purer cellulose isolation & works better with mixed or lower-quality fiber sources. Neither path stays universally superior.
STATION 3

### Washing & Drying

Buffer station between extraction & pressing. Removes residual chemicals, reduces moisture to pressing readiness.

#### Counter-Current Washing

Fresh water enters at the cleanest stage (final rinse). Used water from each stage flows backward to the dirtiest stage (first rinse). This approach reduces water consumption 3-4x compared to batch rinsing.[5]

Wash stages:
1. First rinse (receives used water from stage 2, removes bulk chemicals)
2. Second rinse (receives used water from stage 3)
3. Third rinse (receives used water from stage 4)
4. Final rinse (receives fresh water only, output at pH 7)
pH check: test wash water after each stage. Final output must read pH 7 (neutral). Residual NaOH weakens finished products.

#### Drying

- Convection dryer: forced hot air at 60-80C, 4-6 hours to bone dry
- Solar tunnel (warm climates): passive solar heat, 8-12 hours, zero energy cost
- Critical check: weigh before & after drying. Weight must stabilize. Wet cellulose produces spongy, voided products when pressed.[6]

Moisture kills quality. Steam from trapped water creates internal voids during hot pressing. Every batch must reach stable dry weight before advancing to Station 4. This check represents the single most important quality gate in the entire factory.
STATION 4

### Mixing

Dried cellulose gets combined with glycerol (plasticizer), optional citric acid (water resistance), & optional natural pigments. Glycerol ratio determines product flexibility.

#### Glycerol Ratios

Glycerol % | Result | Products
--- | --- | ---
15% | Rigid | Plates, trivets, plant labels, seed trays
20% | Semi-flexible | Bowls, cups, plant pots, lidded boxes
30% | Flexible | Lids, gaskets, protective wraps

#### Optional Additives

- Citric acid (5% by weight): improves water resistance 7-fold[4]
- Natural pigments: turmeric (yellow), spirulina (green), charcoal (black), beetroot powder (red)

Mixing process:
1. Weigh dried cellulose
2. Calculate glycerol by target ratio (e.g., 100g cellulose + 20g glycerol for 20% semi-flex)
3. Add water to form a workable slurry
4. Heat to 80C & stir for 60 minutes until homogeneous[7]
5. Add citric acid & pigments during last 10 minutes
6. Spread on trays, dry at 60C until weight stabilizes
7. Grind to breadcrumb consistency
8. Output: mixed compound, ready for pressing
STATION 5

### Pressing & Molding

Hot press transforms mixed compound into finished shapes. Mold rotation keeps the press running continuously: while one mold cures, another gets loaded, a third cools, a fourth gets demolded.

mold rotation enables 4-6 press cycles per day per mold set.

#### Product Mold Catalog

Product | Mold Type | Temp (C) | Pressure | Time | Weight
--- | --- | --- | --- | --- | ---
Bowl (15 cm) | Two-part concave | 160 | Medium | 20 min | 80g
Plate (22 cm) | Flat with rim | 150 | High | 15 min | 120g
Cup (250 mL) | Two-part cylinder | 170 | Medium | 20 min | 60g
Trivet (18 cm) | Flat solid | 180 | High | 25 min | 150g
Plant pot (12 cm) | Two-part tapered | 160 | Medium | 20 min | 90g
Seed tray (30x20 cm) | Multi-cavity | 170 | High | 25 min | 200g
Lidded box (15 cm) | Three-part (base+lid+walls) | 180 | High | 30 min | 180g
Desk organizer | Multi-compartment | 180 | High | 30 min | 160g

Press cycle:
1. Coat mold interior with thin vegetable oil layer
2. Fill with dry compound, compress lightly by hand, add lid
3. Load into hot press at target temperature
4. Apply full pressure & hold for target time
5. Release pressure
6. Remove mold, set on cooling rack
7. Slow cool (minimum 30 minutes, longer for thick products)
8. Demold when cool to touch
9. Clean mold & return to loading station
STATION 6

### Finishing

Final quality gate before products leave the factory. Three substations run in sequence.

#### Trimming

- Remove flash (excess material squeezed from mold edges)
- Sand any rough surfaces or mold lines
- File edges smooth

#### Inspection

Check | Pass | Fail (regrind)
--- | --- | ---
Surface | Smooth, uniform color | Bubbled, porous, discolored
Sound (tap test) | Solid "click" | Hollow "thud" (internal voids)
Flex | Appropriate for glycerol ratio | Brittle cracks or too soft
Weight | Within 10% of target | Under (voids) or over (wet)
Water drop | Beads or absorbs slowly | Absorbs instantly (needs more citric acid)

Failed products get reground & returned to Station 4 for remixing. Nothing gets wasted.

#### Stamping

- Production date (month/year)
- Fiber source (H = hemp, N = nettle, W = wood, or combo)
- Compost instructions: "HOT COMPOST 60C+ ONLY"
- Hub identifier code

STATION 7

### Compost Demo Station

Display, not production. Shows customers & visitors exactly what happens to these products at end of life. A maintained hot compost bin (60-70C) contains products at various stages of decomposition.

Composting requires specific conditions. These products biodegrade ONLY in hot aerobic compost reaching 60-70C for sustained periods. They do NOT break down in cold compost piles, landfills, waterways, or soil burial at ambient temperature. "Compostable" means compostable under controlled thermophilic conditions, not "throw anywhere & it vanishes."

#### Decomposition Timeline (Hot Aerobic Compost, 60-70C)

Week | Observation
--- | ---
0-2 | No visible change. Product retains shape & strength.
2-4 | Surface softening begins. Color shifts darker.
4-8 | Product deforms under compost weight. Surface texture becomes rough.
8-12 | Fragmentation begins. Product breaks into large pieces when handled.
12-16 | Pieces fragment further. Material becomes indistinguishable from surrounding compost.
16-24 | Full decomposition. Only cellulose fibers remain, fully integrated into compost.

NOT cold pile. NOT landfill. NOT water. A cold backyard compost pile rarely exceeds 40C. These products survive cold piles indefinitely (which counts as a feature during their useful life, not a composting failure). Direct customers to municipal hot compost facilities or dedicated thermophilic composting setups.
PRODUCTS

### Product Catalog

all products share the same base material. glycerol ratio & mold shape create variety.

#### Kitchen & Dining

Product | Dimensions | Weight | Glycerol | Lifespan | Care
--- | --- | --- | --- | --- | ---
Bowl | 15 cm diameter, 7 cm deep | 80g | 20% | 3-5 years | Hand wash, dry promptly
Plate | 22 cm diameter | 120g | 15% | 3-5 years | Hand wash, dry promptly
Cup | 250 mL, 9 cm tall | 60g | 20% | 2-3 years | Hand wash, no hot liquids above 80C
Trivet | 18 cm diameter, 1 cm thick | 150g | 15% | 5+ years | Wipe clean

#### Garden & Growing

Product | Dimensions | Weight | Glycerol | Lifespan | Care
--- | --- | --- | --- | --- | ---
Plant pot | 10-15 cm diameter | 90g | 15% | 2-3 seasons outdoors | None needed (degrades slowly in soil contact)
Seed tray | 30x20 cm, 6 cells | 200g | 15% | 3-5 seasons | Rinse between uses, dry before storing
Plant label | 12x3 cm | 10g | 15% | 1-2 seasons | Write with pencil (survives weathering)

#### Storage & Organization

Product | Dimensions | Weight | Glycerol | Lifespan | Care
--- | --- | --- | --- | --- | ---
Lidded box | 15x15x8 cm | 180g | 20% | 5+ years | Wipe clean, keep dry
Desk organizer | 25x10x8 cm | 160g | 15% | 5+ years | Wipe clean

Dishwasher temperatures above 60C soften products. Hand wash only. Products tolerate brief water contact (washing, rain) but should not soak overnight. Prolonged hot water exposure reverses the crosslinking that provides rigidity.
ECONOMICS

### Factory Economics

#### Throughput

Metric | Daily | Weekly (5 days) | Annual (250 days)
--- | --- | --- | ---
Fiber processed | 20-30 kg | 100-150 kg | 5,000-7,500 kg
Products pressed | 40-80 pieces | 200-400 pieces | 10,000-20,000 pieces
Revenue (at $5-15 avg) | $200-1,200 | $1,000-6,000 | $50,000-300,000

#### Equipment Startup Costs

Item | Minimum (used/DIY) | Mid-range | Professional
--- | --- | --- | ---
Decorticator (hand-crank) | $500 | $2,000 | $8,000
Fiber chopper | $200 | $800 | $3,000
Retting tanks (3-4) | $300 | $1,000 | $4,000
Reaction vessels (3-4) | $600 | $2,500 | $10,000
Filtration & wash line | $400 | $1,500 | $6,000
Convection dryer | $800 | $3,000 | $12,000
Heated mixer | $300 | $1,200 | $5,000
Hot press (hydraulic) | $2,000 | $8,000 | $25,000
Mold sets (8 products) | $1,500 | $4,000 | $12,000
Finishing station | $200 | $500 | $2,000
Safety equipment | $300 | $500 | $1,000
Workspace setup | $5,000 | $10,000 | $25,000
Total | $12,100 | $35,000 | $113,000

#### Labor

- Minimum crew: 2 people run all 6 production stations
- Comfortable crew: 3 people (fiber prep, chemistry, pressing)
- Training time: 2-4 weeks from novice to independent operation

HUBS

### Distributed Hub Model

One factory proves the concept. Many factories change material culture. Each hub adapts fiber sources to local ecology & product mix to local demand while following a standardized process for quality consistency.

each hub sources locally, processes consistently, sells locally.

#### Hub Specification

Component | Standardized | Localized
--- | --- | ---
Equipment | Same specs, same layout | Sourced from local suppliers where possible
Recipes | Same ratios, temps, times | Adjusted for local fiber cellulose content
Quality checks | Same inspection criteria | Same pass/fail thresholds
Fiber sources | Same prep standards | Whatever grows locally (hemp, nettle, kenaf, jute, wood)
Products | Same mold designs available | Hub selects product mix based on local demand
Pricing | Cost-plus formula | Adjusted to local purchasing power
Training | Same curriculum & certification | Delivered in local language by local trainers
Branding | Shared quality mark | Hub name & local identity

Replication Checklist
☐ Identify local fiber sources (minimum 2 for supply resilience)
☐ Secure workspace: 80-150 m2, ventilated, water access, 3-phase power
☐ Source or build equipment (see startup cost table)
☐ Recruit & train crew of 2-3 people (2-4 week training program)
☐ Run 50 test batches before selling (refine recipes for local fiber)
☐ Establish local fiber supply agreements with farmers or foragers
☐ Set up composting partnership (municipal or dedicated facility)
☐ Launch with 3-4 products, expand based on demand
☐ Document local adaptations & share with hub network

### Honest Summary

A bioplastic factory at community scale requires real investment ($12k-113k), real labor (2-3 full-time people), & real fiber supply chains. Products compete on durability & compostability, not on price. A bowl that lasts 5 years & composts afterward occupies a different market than a $1 petroleum plastic bowl that persists for centuries.

The distributed hub model works only if each hub achieves consistent quality. Standardized recipes & inspection criteria make that possible. Local fiber sourcing makes each hub resilient to supply disruption. The goal: dozens of hubs producing everyday objects from local plant fiber, each adapted to its ecology & economy.

None of this replaces reducing consumption. Using fewer things remains better than producing more compostable things. But for everyday objects that communities need regardless, growing the material locally & composting it locally closes a cycle that petroleum never can.

### Sources

1. Bodros & Baley (2008), "Study of the tensile properties of stinging nettle fibres (Urtica dioica)," Materials Letters. Nettle bast fiber composition & mechanical properties. ↩
2. Rowell et al. (2005), "Cell Wall Chemistry," in Handbook of Wood Chemistry and Wood Composites. Hardwood cellulose content ranges 40-50%. ↩
3. Dhakal et al. (2022), PMC 9182753. 5% NaOH treatment of hemp at room temperature for 1-4 hours. Gentlest effective protocol. ↩
4. Beluns et al. (2023), "Sustainable hemp-based bioplastics with tunable properties via reversible thermal crosslinking of cellulose," Int J Biol Macromol. Citric acid crosslinking at 140C, up to 70 MPa tensile strength, 7-fold water uptake reduction. ↩
5. Geankoplis (2003), Transport Processes and Separation Process Principles. Counter-current washing principles & water reduction factors. ↩
6. Robert Murray-Smith, "Hot Press Molding Hemp Casein Plastic" (2020). On moisture & pressing: "if it's wet and you heat it and press it, you'll press off a lot of steam and it won't form properly." ↩
7. Bio-protocol (2025). Hemp cellulose + glycerol + NaOH, stirred 60 min at 80C, hot pressed at 240C for 10 min. ↩

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