[Report] Samyang's Magic: "Making Plastic from Oksusu (Corn)"

Jeonbuk Gunsan Samyang Inochem Isosorbide Production Plant
First Commercialization in Korea and Second Worldwide Success
"Superior Heat Resistance and Transparency Compared to Petroleum Fuel Products"
Leaping Forward as a Global Specialty Company

Inside the commercial plant of Isosorbide at Samyang Inochem, Gunsan, Jeonbuk. Photo by Choi Seoyoon

[Gunsan=Asia Economy Reporter Choi Seoyoon] On the 16th, at Samyang Inochem's Isosorbide commercialization plant located in the Gunsan Free Trade Zone, Jeonbuk. The four-story factory, built on a 23,000㎡ (7,000 pyeong) site, produces high-purity isosorbide used as an eco-friendly plastic material in large quantities daily. The annual production capacity is 15,000 tons. Samyang Group began development in 2009 and succeeded in commercialization after 13 years. It is the first in Korea and the second in the world after France. Thanks to this, eco-friendly plastic manufacturers such as SK Chemicals can now reliably procure isosorbide domestically, which was previously entirely imported from France.

Isosorbide is a raw material for eco-friendly plastics gaining attention worldwide amid the global carbon neutrality trend. It is made by chemically processing starch extracted from plant resources such as corn and soybeans and is called a white bio material. It can replace petroleum-derived bisphenol A (BPA), known as a harmful substance to humans, to produce eco-friendly plastics. Since no carbon dioxide is emitted during production, it is classified as a carbon-neutral material.

The isosorbide production process consists of six steps. The factory is equipped with 300 major facilities, including numerous intertwined pipelines, pumps, and centrifuges. The first process starts on the top floor, the 4th floor. About 10 tons of sorbitol (produced from starch) are each loaded into three cylindrical tanks with a diameter of 2 meters and reacted under vacuum conditions. After 5 to 6 hours of reaction, isosorbide and by-products are produced. In the next process, 'distillation,' by-products are separated using their different boiling points. The isosorbide with low purity, just separated from the by-products, is sent down to the 2nd floor through pipes.

Liquids used or produced at each process stage. From the left: Sorbitol, reaction solution, distillate, crystallization solvent, 80% product solution (20% water), solid product. Photo by Choi Seoyoon

The next step is the crystallization process. When the temperature is lowered, isosorbide crystals form like salt. The crystals themselves are pure isosorbide, while the remaining impurities dissolve in the solvent. Then, through the refining process, physically pure isosorbide is finally extracted. Jang Jaesu, Head of Production Technology at Samyang Inochem, explained, "At six refining facilities, even extremely fine impurities as small as one-millionth are filtered out."

Once the isosorbide produced in this way is processed into liquid or solid products according to customer requirements, the process is complete. Jang said, "The entire process takes about a day," adding, "Since everything is automated, only about two employees are assigned on-site, and most of the management is done 24 hours a day from the control room."

Why did Samyang Group venture into isosorbide development? It started with an idea from Kim Yoon, Chairman of Samyang Holdings (then CEO and Chairman of Samyang Corporation). The intention was to develop new products by integrating the food and chemical businesses that Samyang operates.

Samyang Group is the only domestic company that simultaneously possesses food technology capable of processing starch extracted from corn and chemical technology producing engineering plastics and other materials. Kang Hoseong, CEO of Samyang Inochem, said on this day, "White bio products themselves are food-based," adding, "We have tried various research approaches to utilize starch as a plastic raw material, and isosorbide is the first product of that effort."

Isosorbide solidified using coolant. Photo by Choi Seoyoon

It is not simply because it is an eco-friendly material. CEO Kang explained, "During the research process, we discovered that the physical properties of products made from isosorbide are superior in heat resistance and transparency compared to petroleum-based products," adding, "Although there were many trials and errors, we spared no expense on R&D (about 35 billion KRW) and succeeded in securing isosorbide commercialization technology as the second in the world in 2014."

Preparations for overseas market entry are also underway. Jang said, "There are more polymer factories in China, Japan, and Korea than in Europe, where competitors exist, so we have a geographical advantage." Product testing is already underway with Japan's Mitsubishi Chemical Group. Chairman Kim said, "Ultimately, we plan to increase our global market share," adding, "We will expand our presence starting with Japan." Next year, they are also considering entering the U.S. market in two fields: personal care and semiconductor materials.

Samyang Group has set and is executing a mid-to-long-term plan to generate more than 60% of its profits from specialty (high-functionality) products by 2025. In October last year, they acquired a 49.92% stake in semiconductor materials company NChem, accelerating the achievement of 'Vision 2025.'

Expansion through mergers and acquisitions (M&A) is expected to become visible next year. CEO Kang stated, "Last year, we conducted domestic M&A in the semiconductor sector, and by the second quarter of next year, we will be able to show concrete progress on overseas M&A in personal care and electronic control fields."

On the 16th, Jang Jae-su, Head of Production Technology at Samyang Innochem, explains to the press in the control room of the isosorbide production plant in Gunsan, Jeonbuk. Photo by Choi Seo-yoon