diff --git a/caddy/factory-auth.caddy b/caddy/factory-auth.caddy new file mode 100644 index 0000000..97b7ecf --- /dev/null +++ b/caddy/factory-auth.caddy @@ -0,0 +1,7 @@ +handle /hemp-bioplastic/process/factory/* { + basicauth { + # Generate a hash: caddy hash-password + # Then add a line here: username + } + file_server +} diff --git a/hemp-bioplastic/process/factory/img/distributed-hub.dot b/hemp-bioplastic/process/factory/img/distributed-hub.dot new file mode 100644 index 0000000..33f30a0 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/distributed-hub.dot @@ -0,0 +1,60 @@ +digraph distributed_hub { + bgcolor="#1a1a2e" + rankdir=TB + node [fontname="Helvetica" fontsize=10 style=filled shape=box] + edge [color="#888888" fontname="Helvetica" fontsize=9 fontcolor="#aaaaaa"] + + label=<distributed hub replication model> + labelloc=t + + subgraph cluster_model { + label="LOCAL FIBER, STANDARDIZED PROCESS, LOCAL PRODUCTS" fontcolor="#cccccc" fontsize=11 fontname="Helvetica Bold" + color="#555555" style=dashed + + subgraph cluster_local_in { + label="LOCAL INPUTS" fontcolor="#4CAF50" fontsize=10 fontname="Helvetica Bold" + color="#4CAF50" style=dashed + + farm1 [label="local hemp farm" fillcolor="#2E7D32" fontcolor="white"] + farm2 [label="nettle foraging\ncommunity land" fillcolor="#388E3C" fontcolor="white"] + farm3 [label="sawmill refuse\nlocal timber" fillcolor="#4E342E" fontcolor="white"] + } + + subgraph cluster_standard { + label="STANDARDIZED PROCESSING" fontcolor="#2196F3" fontsize=10 fontname="Helvetica Bold" + color="#2196F3" style=dashed + + process [label="7-station factory\nstandard equipment\nstandard recipes\nstandard quality checks" fillcolor="#1565C0" fontcolor="white"] + } + + subgraph cluster_local_out { + label="LOCAL PRODUCTS" fontcolor="#FF9800" fontsize=10 fontname="Helvetica Bold" + color="#FF9800" style=dashed + + market [label="local farm market\ndirect to consumer" fillcolor="#E65100" fontcolor="white"] + coop [label="food co-ops\nzero waste shops" fillcolor="#F57C00" fontcolor="white"] + school [label="schools & community\neducation programs" fillcolor="#FF9800" fontcolor="white"] + } + } + + farm1 -> process + farm2 -> process + farm3 -> process + process -> market + process -> coop + process -> school + + subgraph cluster_hubs { + label="HUB NETWORK" fontcolor="#8E24AA" fontsize=11 fontname="Helvetica Bold" + color="#8E24AA" style=dashed + + hub1 [label="Hub A\nrural village\nhemp focus" fillcolor="#6A1B9A" fontcolor="white"] + hub2 [label="Hub B\ncoastal town\nnettle focus" fillcolor="#7B1FA2" fontcolor="white"] + hub3 [label="Hub C\nforest region\nwood refuse focus" fillcolor="#8E24AA" fontcolor="white"] + hub4 [label="Hub D\nyour community\n?" fillcolor="#9C27B0" fontcolor="white"] + } + + hub1 -> hub2 -> hub3 -> hub4 [style=dashed color="#8E24AA" label="shared\nknowledge"] + + replicate [label="each hub adapts\nfiber sources to local ecology\nproducts to local demand\npricing to local economy" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] +} diff --git a/hemp-bioplastic/process/factory/img/distributed-hub.png b/hemp-bioplastic/process/factory/img/distributed-hub.png new file mode 100644 index 0000000..83695ab Binary files /dev/null and b/hemp-bioplastic/process/factory/img/distributed-hub.png differ diff --git a/hemp-bioplastic/process/factory/img/distributed-hub.svg b/hemp-bioplastic/process/factory/img/distributed-hub.svg new file mode 100644 index 0000000..dd6547f --- /dev/null +++ b/hemp-bioplastic/process/factory/img/distributed-hub.svg @@ -0,0 +1,192 @@ + + + + + + +distributed_hub + +distributed hub replication model + +cluster_model + +LOCAL FIBER, STANDARDIZED PROCESS, LOCAL PRODUCTS + + +cluster_local_in + +LOCAL INPUTS + + +cluster_standard + +STANDARDIZED PROCESSING + + +cluster_local_out + +LOCAL PRODUCTS + + +cluster_hubs + +HUB NETWORK + + + +farm1 + +local hemp farm + + + +process + +7-station factory +standard equipment +standard recipes +standard quality checks + + + +farm1->process + + + + + +farm2 + +nettle foraging +community land + + + +farm2->process + + + + + +farm3 + +sawmill refuse +local timber + + + +farm3->process + + + + + +market + +local farm market +direct to consumer + + + +process->market + + + + + +coop + +food co-ops +zero waste shops + + + +process->coop + + + + + +school + +schools & community +education programs + + + +process->school + + + + + +hub1 + +Hub A +rural village +hemp focus + + + +hub2 + +Hub B +coastal town +nettle focus + + + +hub1->hub2 + + +shared +knowledge + + + +hub3 + +Hub C +forest region +wood refuse focus + + + +hub2->hub3 + + +shared +knowledge + + + +hub4 + +Hub D +your community +? + + + +hub3->hub4 + + +shared +knowledge + + + +replicate + + + +each hub adapts +fiber sources to local ecology +products to local demand +pricing to local economy + + + diff --git a/hemp-bioplastic/process/factory/img/extraction-station.dot b/hemp-bioplastic/process/factory/img/extraction-station.dot new file mode 100644 index 0000000..603fb95 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/extraction-station.dot @@ -0,0 +1,45 @@ +digraph extraction_station { + bgcolor="#1a1a2e" + rankdir=TB + node [fontname="Helvetica" fontsize=10 style=filled shape=box] + edge [color="#888888" fontname="Helvetica" fontsize=9 fontcolor="#aaaaaa"] + + label=<station 2: extraction (two paths)> + labelloc=t + + fiber_in [label="PREPARED FIBER\nfrom Station 1" fillcolor="#66BB6A" fontcolor="white"] + + subgraph cluster_naoh { + label="PATH A: NaOH EXTRACTION" fontcolor="#2196F3" fontsize=11 fontname="Helvetica Bold" + color="#2196F3" style=dashed + + naoh_dissolve [label="dissolve NaOH\n5-12% solution" fillcolor="#1565C0" fontcolor="white"] + naoh_soak [label="soak fiber\n80C for 2-3 hours\nor room temp 4 hours" fillcolor="#1976D2" fontcolor="white"] + naoh_filter [label="filter & wash\nuntil pH neutral" fillcolor="#1E88E5" fontcolor="white"] + naoh_dissolve -> naoh_soak -> naoh_filter + } + + subgraph cluster_citric { + label="PATH B: CITRIC ACID CROSSLINK" fontcolor="#FF9800" fontsize=11 fontname="Helvetica Bold" + color="#FF9800" style=dashed + + citric_paper [label="spread fiber\npress into sheets" fillcolor="#E65100" fontcolor="white"] + citric_soak [label="soak in\ncitric acid + glycerol" fillcolor="#F57C00" fontcolor="white"] + citric_cure [label="cure at 140C\nunder pressure" fillcolor="#FF9800" fontcolor="white"] + citric_paper -> citric_soak -> citric_cure + } + + fiber_in -> naoh_dissolve [label="higher purity\nmore waste"] + fiber_in -> citric_paper [label="less waste\nsimpler setup"] + + cellulose_out [label="RAW CELLULOSE\nto Station 3" fillcolor="#64B5F6" fontcolor="#1a1a2e" shape=doubleoctagon] + naoh_filter -> cellulose_out + citric_cure -> cellulose_out + + waste_a [label="NaOH waste liquor\nneutralize before disposal" fillcolor="#37474F" fontcolor="#aaaaaa" shape=ellipse] + naoh_soak -> waste_a [style=dashed color="#555555"] + + note_citric [label="citric acid path\nproduces less waste\n& avoids NaOH hazards" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] + + rotation [label="continuous operation:\n3-4 reaction vessels\nrotating through stages" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] +} diff --git a/hemp-bioplastic/process/factory/img/extraction-station.png b/hemp-bioplastic/process/factory/img/extraction-station.png new file mode 100644 index 0000000..5383f56 Binary files /dev/null and b/hemp-bioplastic/process/factory/img/extraction-station.png differ diff --git a/hemp-bioplastic/process/factory/img/extraction-station.svg b/hemp-bioplastic/process/factory/img/extraction-station.svg new file mode 100644 index 0000000..b24dfe4 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/extraction-station.svg @@ -0,0 +1,167 @@ + + + + + + +extraction_station + +station 2: extraction (two paths) + +cluster_naoh + +PATH A: NaOH EXTRACTION + + +cluster_citric + +PATH B: CITRIC ACID CROSSLINK + + + +fiber_in + +PREPARED FIBER +from Station 1 + + + +naoh_dissolve + +dissolve NaOH +5-12% solution + + + +fiber_in->naoh_dissolve + + +higher purity +more waste + + + +citric_paper + +spread fiber +press into sheets + + + +fiber_in->citric_paper + + +less waste +simpler setup + + + +naoh_soak + +soak fiber +80C for 2-3 hours +or room temp 4 hours + + + +naoh_dissolve->naoh_soak + + + + + +naoh_filter + +filter & wash +until pH neutral + + + +naoh_soak->naoh_filter + + + + + +waste_a + +NaOH waste liquor +neutralize before disposal + + + +naoh_soak->waste_a + + + + + +cellulose_out + + +RAW CELLULOSE +to Station 3 + + + +naoh_filter->cellulose_out + + + + + +citric_soak + +soak in +citric acid + glycerol + + + +citric_paper->citric_soak + + + + + +citric_cure + +cure at 140C +under pressure + + + +citric_soak->citric_cure + + + + + +citric_cure->cellulose_out + + + + + +note_citric + + + +citric acid path +produces less waste +& avoids NaOH hazards + + + +rotation + + + +continuous operation: +3-4 reaction vessels +rotating through stages + + + diff --git a/hemp-bioplastic/process/factory/img/factory-flow.dot b/hemp-bioplastic/process/factory/img/factory-flow.dot new file mode 100644 index 0000000..6671a3a --- /dev/null +++ b/hemp-bioplastic/process/factory/img/factory-flow.dot @@ -0,0 +1,33 @@ +digraph factory_flow { + bgcolor="#1a1a2e" + rankdir=TB + node [fontname="Helvetica" fontsize=10 style=filled shape=box] + edge [color="#888888" fontname="Helvetica" fontsize=9 fontcolor="#aaaaaa"] + + label=<continuous-flow bioplastic factory: 7 stations> + labelloc=t + + s1 [label="STATION 1\nFiber Intake & Prep\nhemp, nettle, wood refuse" fillcolor="#2E7D32" fontcolor="white"] + s2 [label="STATION 2\nExtraction\nNaOH or citric acid" fillcolor="#1565C0" fontcolor="white"] + s3 [label="STATION 3\nWashing & Drying\ncounter-current wash" fillcolor="#1976D2" fontcolor="white"] + s4 [label="STATION 4\nMixing\ncellulose + glycerol + pigment" fillcolor="#7B1FA2" fontcolor="white"] + s5 [label="STATION 5\nPressing & Molding\nhot press 150-240C" fillcolor="#E65100" fontcolor="white"] + s6 [label="STATION 6\nFinishing\ntrim, inspect, stamp" fillcolor="#FF9800" fontcolor="white"] + s7 [label="COMPOST DEMO\ndisplay only\nhot aerobic 60-70C" fillcolor="#795548" fontcolor="white"] + + s1 -> s2 [label="prepared\nfiber"] + s2 -> s3 [label="raw\ncellulose"] + s3 -> s4 [label="dry\ncellulose"] + s4 -> s5 [label="mixed\ncompound"] + s5 -> s6 [label="pressed\nproducts"] + s6 -> s7 [label="demo\nsamples"] + + fiber [label="local fiber sources\nhemp, nettle, wood refuse" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] + fiber -> s1 [style=dashed color="#66BB6A"] + + products [label="durable products\nkitchen, garden, storage\nyears of daily use" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] + s6 -> products [style=dashed color="#FFC107"] + + compost [label="end of life\nhot aerobic compost only\n60-70C, 12-24 weeks" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] + s7 -> compost [style=dashed color="#795548"] +} diff --git a/hemp-bioplastic/process/factory/img/factory-flow.png b/hemp-bioplastic/process/factory/img/factory-flow.png new file mode 100644 index 0000000..6791ef6 Binary files /dev/null and b/hemp-bioplastic/process/factory/img/factory-flow.png differ diff --git a/hemp-bioplastic/process/factory/img/factory-flow.svg b/hemp-bioplastic/process/factory/img/factory-flow.svg new file mode 100644 index 0000000..759cac8 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/factory-flow.svg @@ -0,0 +1,165 @@ + + + + + + +factory_flow + +continuous-flow bioplastic factory: 7 stations + + +s1 + +STATION 1 +Fiber Intake & Prep +hemp, nettle, wood refuse + + + +s2 + +STATION 2 +Extraction +NaOH or citric acid + + + +s1->s2 + + +prepared +fiber + + + +s3 + +STATION 3 +Washing & Drying +counter-current wash + + + +s2->s3 + + +raw +cellulose + + + +s4 + +STATION 4 +Mixing +cellulose + glycerol + pigment + + + +s3->s4 + + +dry +cellulose + + + +s5 + +STATION 5 +Pressing & Molding +hot press 150-240C + + + +s4->s5 + + +mixed +compound + + + +s6 + +STATION 6 +Finishing +trim, inspect, stamp + + + +s5->s6 + + +pressed +products + + + +s7 + +COMPOST DEMO +display only +hot aerobic 60-70C + + + +s6->s7 + + +demo +samples + + + +products + + + +durable products +kitchen, garden, storage +years of daily use + + + +s6->products + + + + + +compost + + + +end of life +hot aerobic compost only +60-70C, 12-24 weeks + + + +s7->compost + + + + + +fiber + + + +local fiber sources +hemp, nettle, wood refuse + + + +fiber->s1 + + + + + diff --git a/hemp-bioplastic/process/factory/img/fiber-intake.dot b/hemp-bioplastic/process/factory/img/fiber-intake.dot new file mode 100644 index 0000000..45a50f4 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/fiber-intake.dot @@ -0,0 +1,50 @@ +digraph fiber_intake { + bgcolor="#1a1a2e" + rankdir=TB + node [fontname="Helvetica" fontsize=10 style=filled shape=box] + edge [color="#888888" fontname="Helvetica" fontsize=9 fontcolor="#aaaaaa"] + + label=<station 1: fiber intake & prep> + labelloc=t + + subgraph cluster_hemp { + label="HEMP" fontcolor="#4CAF50" fontsize=11 fontname="Helvetica Bold" + color="#4CAF50" style=dashed + + hemp_in [label="hemp stalks\nbast fiber, 77% cellulose" fillcolor="#2E7D32" fontcolor="white"] + hemp_ret [label="ret 3-45 days\nor water ret 10 days" fillcolor="#388E3C" fontcolor="white"] + hemp_dec [label="decorticate\nseparate bast from hurd" fillcolor="#43A047" fontcolor="white"] + hemp_in -> hemp_ret -> hemp_dec + } + + subgraph cluster_nettle { + label="NETTLE" fontcolor="#66BB6A" fontsize=11 fontname="Helvetica Bold" + color="#66BB6A" style=dashed + + nettle_in [label="nettle stalks\nbast fiber, 65% cellulose" fillcolor="#2E7D32" fontcolor="white"] + nettle_ret [label="water ret 7-14 days\nfaster than hemp" fillcolor="#388E3C" fontcolor="white"] + nettle_dec [label="strip bast fiber\nby hand or machine" fillcolor="#43A047" fontcolor="white"] + nettle_in -> nettle_ret -> nettle_dec + } + + subgraph cluster_wood { + label="WOOD REFUSE" fontcolor="#8D6E63" fontsize=11 fontname="Helvetica Bold" + color="#8D6E63" style=dashed + + wood_in [label="sawmill offcuts\nchips, shavings, dust" fillcolor="#4E342E" fontcolor="white"] + wood_chip [label="chip to uniform size\n2-5 mm pieces" fillcolor="#5D4037" fontcolor="white"] + wood_sort [label="remove bark, knots\nsort by species" fillcolor="#6D4C41" fontcolor="white"] + wood_in -> wood_chip -> wood_sort + } + + chop [label="chop to 2-3 cm\nuniform fiber length" fillcolor="#66BB6A" fontcolor="white"] + weigh [label="weigh & batch\nrecord fiber source ratio" fillcolor="#81C784" fontcolor="#1a1a2e"] + prepared [label="PREPARED FIBER\nready for extraction" fillcolor="#A5D6A7" fontcolor="#1a1a2e" shape=doubleoctagon] + + hemp_dec -> chop + nettle_dec -> chop + wood_sort -> chop + chop -> weigh -> prepared + + equip [label="equipment:\ndecorticator, chopper\nretting tanks, sorting table\nscale" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] +} diff --git a/hemp-bioplastic/process/factory/img/fiber-intake.png b/hemp-bioplastic/process/factory/img/fiber-intake.png new file mode 100644 index 0000000..e59ada6 Binary files /dev/null and b/hemp-bioplastic/process/factory/img/fiber-intake.png differ diff --git a/hemp-bioplastic/process/factory/img/fiber-intake.svg b/hemp-bioplastic/process/factory/img/fiber-intake.svg new file mode 100644 index 0000000..c0cdaf2 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/fiber-intake.svg @@ -0,0 +1,191 @@ + + + + + + +fiber_intake + +station 1: fiber intake & prep + +cluster_hemp + +HEMP + + +cluster_nettle + +NETTLE + + +cluster_wood + +WOOD REFUSE + + + +hemp_in + +hemp stalks +bast fiber, 77% cellulose + + + +hemp_ret + +ret 3-45 days +or water ret 10 days + + + +hemp_in->hemp_ret + + + + + +hemp_dec + +decorticate +separate bast from hurd + + + +hemp_ret->hemp_dec + + + + + +chop + +chop to 2-3 cm +uniform fiber length + + + +hemp_dec->chop + + + + + +nettle_in + +nettle stalks +bast fiber, 65% cellulose + + + +nettle_ret + +water ret 7-14 days +faster than hemp + + + +nettle_in->nettle_ret + + + + + +nettle_dec + +strip bast fiber +by hand or machine + + + +nettle_ret->nettle_dec + + + + + +nettle_dec->chop + + + + + +wood_in + +sawmill offcuts +chips, shavings, dust + + + +wood_chip + +chip to uniform size +2-5 mm pieces + + + +wood_in->wood_chip + + + + + +wood_sort + +remove bark, knots +sort by species + + + +wood_chip->wood_sort + + + + + +wood_sort->chop + + + + + +weigh + +weigh & batch +record fiber source ratio + + + +chop->weigh + + + + + +prepared + + +PREPARED FIBER +ready for extraction + + + +weigh->prepared + + + + + +equip + + + +equipment: +decorticator, chopper +retting tanks, sorting table +scale + + + diff --git a/hemp-bioplastic/process/factory/img/pressing-station.dot b/hemp-bioplastic/process/factory/img/pressing-station.dot new file mode 100644 index 0000000..d5eaf4b --- /dev/null +++ b/hemp-bioplastic/process/factory/img/pressing-station.dot @@ -0,0 +1,40 @@ +digraph pressing_station { + bgcolor="#1a1a2e" + rankdir=LR + node [fontname="Helvetica" fontsize=10 style=filled shape=box] + edge [color="#888888" fontname="Helvetica" fontsize=9 fontcolor="#aaaaaa"] + + label=<station 5: pressing & mold rotation> + labelloc=t + + compound [label="MIXED COMPOUND\nfrom Station 4" fillcolor="#7B1FA2" fontcolor="white"] + + subgraph cluster_rotation { + label="MOLD ROTATION CYCLE" fontcolor="#FF9800" fontsize=11 fontname="Helvetica Bold" + color="#FF9800" style=dashed + + load [label="LOAD\nfill mold with compound\ncompress, add lid" fillcolor="#E65100" fontcolor="white"] + cure [label="CURE\nhot press 150-240C\n10-30 min under pressure" fillcolor="#FF6F00" fontcolor="white"] + cool [label="COOL\nslow cool in mold\nprevent cracking" fillcolor="#FF9800" fontcolor="white"] + demold [label="DEMOLD\nrelease product\nclean mold for reuse" fillcolor="#FFC107" fontcolor="#1a1a2e"] + + load -> cure -> cool -> demold + demold -> load [label="mold returns\nto loading" style=dashed color="#FFC107"] + } + + compound -> load + + products [label="PRESSED PRODUCTS\nto Station 6" fillcolor="#FFC107" fontcolor="#1a1a2e" shape=doubleoctagon] + demold -> products + + subgraph cluster_molds { + label="PRODUCT MOLDS" fontcolor="#aaaaaa" fontsize=11 fontname="Helvetica Bold" + color="#555555" style=dashed + + bowls [label="bowls & plates\n150-180C, 20 min" fillcolor="#E65100" fontcolor="white"] + pots [label="garden pots\n160-200C, 25 min" fillcolor="#F57C00" fontcolor="white"] + boxes [label="storage boxes\n180-240C, 30 min" fillcolor="#FF9800" fontcolor="white"] + } + + note [label="multiple mold sets\nrotate through cycle\n4-6 presses per day\nper mold" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] +} diff --git a/hemp-bioplastic/process/factory/img/pressing-station.png b/hemp-bioplastic/process/factory/img/pressing-station.png new file mode 100644 index 0000000..829c086 Binary files /dev/null and b/hemp-bioplastic/process/factory/img/pressing-station.png differ diff --git a/hemp-bioplastic/process/factory/img/pressing-station.svg b/hemp-bioplastic/process/factory/img/pressing-station.svg new file mode 100644 index 0000000..072bae1 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/pressing-station.svg @@ -0,0 +1,141 @@ + + + + + + +pressing_station + +station 5: pressing & mold rotation + +cluster_rotation + +MOLD ROTATION CYCLE + + +cluster_molds + +PRODUCT MOLDS + + + +compound + +MIXED COMPOUND +from Station 4 + + + +load + +LOAD +fill mold with compound +compress, add lid + + + +compound->load + + + + + +cure + +CURE +hot press 150-240C +10-30 min under pressure + + + +load->cure + + + + + +cool + +COOL +slow cool in mold +prevent cracking + + + +cure->cool + + + + + +demold + +DEMOLD +release product +clean mold for reuse + + + +cool->demold + + + + + +demold->load + + +mold returns +to loading + + + +products + + +PRESSED PRODUCTS +to Station 6 + + + +demold->products + + + + + +bowls + +bowls & plates +150-180C, 20 min + + + +pots + +garden pots +160-200C, 25 min + + + +boxes + +storage boxes +180-240C, 30 min + + + +note + + + +multiple mold sets +rotate through cycle +4-6 presses per day +per mold + + + diff --git a/hemp-bioplastic/process/factory/img/product-catalog.dot b/hemp-bioplastic/process/factory/img/product-catalog.dot new file mode 100644 index 0000000..2fe3bc7 --- /dev/null +++ b/hemp-bioplastic/process/factory/img/product-catalog.dot @@ -0,0 +1,43 @@ +digraph product_catalog { + bgcolor="#1a1a2e" + rankdir=TB + node [fontname="Helvetica" fontsize=10 style=filled shape=box] + edge [style=invis] + + label=<product catalog: three categories> + labelloc=t + + subgraph cluster_kitchen { + label="KITCHEN & DINING" fontcolor="#FF9800" fontsize=11 fontname="Helvetica Bold" + color="#FF9800" style=dashed + + bowls [label="bowls\n15 cm, 80g\n20% glycerol" fillcolor="#E65100" fontcolor="white"] + plates [label="plates\n22 cm, 120g\n15% glycerol" fillcolor="#F57C00" fontcolor="white"] + cups [label="cups\n250 mL, 60g\n20% glycerol" fillcolor="#FF9800" fontcolor="white"] + trivets [label="trivets\n18 cm, 150g\n15% glycerol" fillcolor="#FFA726" fontcolor="white"] + bowls -> plates -> cups -> trivets + } + + subgraph cluster_garden { + label="GARDEN & GROWING" fontcolor="#4CAF50" fontsize=11 fontname="Helvetica Bold" + color="#4CAF50" style=dashed + + pots [label="plant pots\n10-15 cm, 90g\n15% glycerol" fillcolor="#2E7D32" fontcolor="white"] + trays [label="seed trays\n30x20 cm, 200g\n15% glycerol" fillcolor="#388E3C" fontcolor="white"] + labels [label="plant labels\n12x3 cm, 10g\n15% glycerol" fillcolor="#43A047" fontcolor="white"] + pots -> trays -> labels + } + + subgraph cluster_storage { + label="STORAGE & ORGANIZATION" fontcolor="#8E24AA" fontsize=11 fontname="Helvetica Bold" + color="#8E24AA" style=dashed + + lidbox [label="lidded boxes\n15x15x8 cm, 180g\n20% glycerol" fillcolor="#6A1B9A" fontcolor="white"] + organizer [label="desk organizers\n25x10x8 cm, 160g\n15% glycerol" fillcolor="#7B1FA2" fontcolor="white"] + lidbox -> organizer + } + + lifespan [label="all products:\n3-5 years daily use\nbiodegrade in hot compost\n60-70C, 12-24 weeks" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] + + care [label="care: hand wash\ndo NOT dishwasher >60C\ndo NOT microwave\ndo NOT soak overnight" fillcolor="#263238" fontcolor="#CDDC39" shape=note fontsize=9] +} diff --git a/hemp-bioplastic/process/factory/img/product-catalog.png b/hemp-bioplastic/process/factory/img/product-catalog.png new file mode 100644 index 0000000..98442ad Binary files /dev/null and b/hemp-bioplastic/process/factory/img/product-catalog.png differ diff --git a/hemp-bioplastic/process/factory/img/product-catalog.svg b/hemp-bioplastic/process/factory/img/product-catalog.svg new file mode 100644 index 0000000..acfb3df --- /dev/null +++ b/hemp-bioplastic/process/factory/img/product-catalog.svg @@ -0,0 +1,129 @@ + + + + + + +product_catalog + +product catalog: three categories + +cluster_kitchen + +KITCHEN & DINING + + +cluster_garden + +GARDEN & GROWING + + +cluster_storage + +STORAGE & ORGANIZATION + + + +bowls + +bowls +15 cm, 80g +20% glycerol + + + +plates + +plates +22 cm, 120g +15% glycerol + + + + +cups + +cups +250 mL, 60g +20% glycerol + + + + +trivets + +trivets +18 cm, 150g +15% glycerol + + + + +pots + +plant pots +10-15 cm, 90g +15% glycerol + + + +trays + +seed trays +30x20 cm, 200g +15% glycerol + + + + +labels + +plant labels +12x3 cm, 10g +15% glycerol + + + + +lidbox + +lidded boxes +15x15x8 cm, 180g +20% glycerol + + + +organizer + +desk organizers +25x10x8 cm, 160g +15% glycerol + + + + +lifespan + + + +all products: +3-5 years daily use +biodegrade in hot compost +60-70C, 12-24 weeks + + + +care + + + +care: hand wash +do NOT dishwasher >60C +do NOT microwave +do NOT soak overnight + + + diff --git a/hemp-bioplastic/process/factory/index.html b/hemp-bioplastic/process/factory/index.html new file mode 100644 index 0000000..0847213 --- /dev/null +++ b/hemp-bioplastic/process/factory/index.html @@ -0,0 +1,554 @@ + + + + bioplastic factory — unturf. + + + + + + + + + +
+ +

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

+ +
+ 7-station continuous-flow bioplastic factory overview +
fiber enters at station 1, finished products leave at station 6, compost demo runs at station 7.
+
+ + + + + + + + + + + + + + +
StationNameInputOutputEquipmentCycle Time
1Fiber Intake & PrepRaw stalks & wood refusePrepared fiber (chopped, sorted)Decorticator, chopper, retting tanks, scaleContinuous intake
2ExtractionPrepared fiberRaw celluloseReaction vessels (3-4), filtration, pH meter2-4 hours per vessel
3Washing & DryingRaw celluloseDry celluloseCounter-current wash line, convection dryer4-8 hours
4MixingDry celluloseMixed compoundHeated mixer, scale, pigment dispensers60-90 minutes
5Pressing & MoldingMixed compoundPressed productsHot press, mold sets, temperature controller30-60 min per press
6FinishingPressed productsFinished goodsTrim station, inspection table, stamp press5-10 min per product
7Compost DemoDemo samplesDisplay & educationHot compost bin (60-70C), timeline displayOngoing 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. +

+ +
+ Three fiber sources converging: hemp, nettle, wood refuse +
hemp, nettle, & wood refuse follow parallel prep paths before merging.
+
+ +

Hemp (primary source)

+ + +

Nettle (secondary source)

+ + +

Wood Refuse (supplementary source)

+ + +

Convergence

+
    +
  1. Chop all prepared fiber to uniform 2-3 cm lengths
    2. +
  2. Weigh & record source ratio per batch (enables quality tracking)
    3. +
  3. Output: prepared fiber, ready for extraction
    4. +
+ +
+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. +

+ +
+ NaOH extraction path versus citric acid crosslinking path +
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

+ + +
+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 %ResultProducts
15%RigidPlates, trivets, plant labels, seed trays
20%Semi-flexibleBowls, cups, plant pots, lidded boxes
30%FlexibleLids, gaskets, protective wraps
+ +

Optional Additives

+ + +
+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 cycle: load, cure, cool, demold +
mold rotation enables 4-6 press cycles per day per mold set.
+
+ +

Product Mold Catalog

+ + + + + + + + + + + + + + +
ProductMold TypeTemp (C)PressureTimeWeight
Bowl (15 cm)Two-part concave160Medium20 min80g
Plate (22 cm)Flat with rim150High15 min120g
Cup (250 mL)Two-part cylinder170Medium20 min60g
Trivet (18 cm)Flat solid180High25 min150g
Plant pot (12 cm)Two-part tapered160Medium20 min90g
Seed tray (30x20 cm)Multi-cavity170High25 min200g
Lidded box (15 cm)Three-part (base+lid+walls)180High30 min180g
Desk organizerMulti-compartment180High30 min160g
+ +
+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

+ + +

Inspection

+ + + + + + + + + + + +
CheckPassFail (regrind)
SurfaceSmooth, uniform colorBubbled, porous, discolored
Sound (tap test)Solid "click"Hollow "thud" (internal voids)
FlexAppropriate for glycerol ratioBrittle cracks or too soft
WeightWithin 10% of targetUnder (voids) or over (wet)
Water dropBeads or absorbs slowlyAbsorbs instantly (needs more citric acid)
+ +

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

+ +

Stamping

+ + + + + + +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)

+ + + + + + + + + + + + +
WeekObservation
0-2No visible change. Product retains shape & strength.
2-4Surface softening begins. Color shifts darker.
4-8Product deforms under compost weight. Surface texture becomes rough.
8-12Fragmentation begins. Product breaks into large pieces when handled.
12-16Pieces fragment further. Material becomes indistinguishable from surrounding compost.
16-24Full 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

+ +
+ Three product categories: kitchen, garden, storage +
all products share the same base material. glycerol ratio & mold shape create variety.
+
+ +

Kitchen & Dining

+ + + + + + + + + + +
ProductDimensionsWeightGlycerolLifespanCare
Bowl15 cm diameter, 7 cm deep80g20%3-5 yearsHand wash, dry promptly
Plate22 cm diameter120g15%3-5 yearsHand wash, dry promptly
Cup250 mL, 9 cm tall60g20%2-3 yearsHand wash, no hot liquids above 80C
Trivet18 cm diameter, 1 cm thick150g15%5+ yearsWipe clean
+ +

Garden & Growing

+ + + + + + + + + +
ProductDimensionsWeightGlycerolLifespanCare
Plant pot10-15 cm diameter90g15%2-3 seasons outdoorsNone needed (degrades slowly in soil contact)
Seed tray30x20 cm, 6 cells200g15%3-5 seasonsRinse between uses, dry before storing
Plant label12x3 cm10g15%1-2 seasonsWrite with pencil (survives weathering)
+ +

Storage & Organization

+ + + + + + + + +
ProductDimensionsWeightGlycerolLifespanCare
Lidded box15x15x8 cm180g20%5+ yearsWipe clean, keep dry
Desk organizer25x10x8 cm160g15%5+ yearsWipe 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

+ + + + + + + + + +
MetricDailyWeekly (5 days)Annual (250 days)
Fiber processed20-30 kg100-150 kg5,000-7,500 kg
Products pressed40-80 pieces200-400 pieces10,000-20,000 pieces
Revenue (at $5-15 avg)$200-1,200$1,000-6,000$50,000-300,000
+ +

Equipment Startup Costs

+ + + + + + + + + + + + + + + + + + + +
ItemMinimum (used/DIY)Mid-rangeProfessional
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

+ + + + + + +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. +

+ +
+ Hub replication model: local fiber, standardized process, local products +
each hub sources locally, processes consistently, sells locally.
+
+ +

Hub Specification

+ + + + + + + + + + + + + + +
ComponentStandardizedLocalized
EquipmentSame specs, same layoutSourced from local suppliers where possible
RecipesSame ratios, temps, timesAdjusted for local fiber cellulose content
Quality checksSame inspection criteriaSame pass/fail thresholds
Fiber sourcesSame prep standardsWhatever grows locally (hemp, nettle, kenaf, jute, wood)
ProductsSame mold designs availableHub selects product mix based on local demand
PricingCost-plus formulaAdjusted to local purchasing power
TrainingSame curriculum & certificationDelivered in local language by local trainers
BrandingShared quality markHub 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. + +
  2. Rowell et al. (2005), "Cell Wall Chemistry," in Handbook of Wood Chemistry and Wood Composites. Hardwood cellulose content ranges 40-50%. ↩
    3. + +
  3. Dhakal et al. (2022), PMC 9182753. 5% NaOH treatment of hemp at room temperature for 1-4 hours. Gentlest effective protocol. ↩
    4. + +
  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. + +
  5. Geankoplis (2003), Transport Processes and Separation Process Principles. Counter-current washing principles & water reduction factors. ↩
    6. + +
  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. + +
  7. Bio-protocol (2025). Hemp cellulose + glycerol + NaOH, stirred 60 min at 80C, hot pressed at 240C for 10 min. ↩
    8. +
+
+ +
+ +

← recipe (full process) · homeschool recipe · hemp bioplastic overview · single-use plastics

+ +
+ + + + + + + diff --git a/hemp-bioplastic/process/homeschool/index.html b/hemp-bioplastic/process/homeschool/index.html index 511233f..ffc731e 100644 --- a/hemp-bioplastic/process/homeschool/index.html +++ b/hemp-bioplastic/process/homeschool/index.html @@ -507,7 +507,7 @@ Full chemistry, equipment lists, & scaling details: ← recipe (full process) · hemp bioplastic overview · single-use plastics

+

← recipe (full process) · factory · hemp bioplastic overview · single-use plastics

diff --git a/hemp-bioplastic/process/index.html b/hemp-bioplastic/process/index.html index 4f05a4d..9ebcf50 100644 --- a/hemp-bioplastic/process/index.html +++ b/hemp-bioplastic/process/index.html @@ -457,7 +457,7 @@ None of this replaces buying groceries in glass jars or using cloth bags — tho
-

← hemp bioplastic overview · homeschool recipe · single-use plastics · manifesto

+

← hemp bioplastic overview · homeschool recipe · factory · single-use plastics · manifesto