Bioplastics — How One Virginia Company is Making Plastic out of Feathers

Friday, 28 March 2014 11:45 by
Eastern BioPlastics has successfully commercialized a process to make plastic out of chicken feathers. By using what was formerly a waste product, the company is making plastic components in a sustainable way...

Eastern BioPlastics has successfully commercialized a process to make plastic out of chicken feathers. By using what was formerly a waste product, the company is making plastic components in a sustainable way.

Co-founders Sonny Meyerhoeffer and Dr. Justin Barone established the company in Mount Crawford, Va., in 2008. They combined Meyerhoeffer’s background as an entrepreneur in the poultry industry with Barone’s engineering expertise as a professor at Virginia Tech to accomplish a difficult task — commercializing R&D into an effective process.

The company replaces up to 50 percent of the petroleum component of plastics with fiber made from chicken feathers. This chicken feather fiber, called feather fiber intermediate, has a number of advantages over petroleum. It is a renewable resource and makes use of something that was previously viewed as a waste product. In addition, the chicken feather fibers are very strong yet lightweight, making them ideal for plastic products.

Eastern BioPlastics has developed a proprietary technique that cleans and processes the chicken feathers in a cost-competitive way. The feather fiber intermediate is blended with polyolefins in a resin, and then extruded into pellet form. These pellets are then sold to original equipment manufacturers that use injection molding to form any number of end products for use in the automotive, furniture and sports equipment industries. The company is currently beta testing this product with customers.

Eastern BioPlastics has also developed a second product called Environmental BioProtector. Feathers are extremely oil absorbent; news coverage of massive oil spills illustrates how birds suffer because the oil becomes trapped in their feathers. The company has developed a product using chicken feathers to help clean up oil spills, from large-scale disasters to consumer use for car oil leaks. Environmental BioProtector is USDA certified and made of 99 percent bio-based material, making it one of the most eco-friendly and low cost oil absorbing solutions on the market today. The company has been selling this product since May 2013.

Creating an entirely new product in 2008 was no easy feat, especially during the economic downturn of 2009-2010. According to co-founder Meyerhoeffer, “Back then nobody wanted to take a chance on anything new. We had to figure out how to break in and create a market with a brand new product.”

When asked why he kept going during these early days, Meyerhoeffer responded, “I was never led to quit and we stayed at it because we knew there was something there that was better. You have to persevere through the tough times. I think a lot of entrepreneurs are that way. You know you’ve got something viable and it’s just about continuing through to the end.”

The founders of Eastern BioPlastics exemplify the entrepreneurial spirit and innovation that’s alive and well in the Commonwealth. To learn what Virginia offers and why it’s a great place to start a business, click here.

Eastern BioPlastics co-founder Sonny Meyerhoeffer displays his Bioplastic Composite Resins made from chicken feathers. 


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