In a technology park just north of Boston, a new model for sustainable chemical research and development is unfolding. Created in 2007, the Warner Babcock Institute for Green Chemistry (WBI), led by organic chemist John C. Warner, is working with industry partners to redefine how scientists solve the technical challenges of developing safer chemical products and greener production processes.
Warner had been frustrated with the limited intellectual freedom of working in a traditional industry research position and with the funding restrictions of the academic environment. Then he hit on the idea of creating an academic-style laboratory but financing it like a contract R&D business, with clients paying experts to help solve their problems. Enter James Babcock, a Harvard-trained corporate lawyer who spent much of his career leading a global investment firm. Babcock, who is the chairman of WBI’s board of directors, provided the seed funding and, with mechanical engineer and entrepreneur William Kunzweiler, helped Warner get started.
In three years, Warner and his research team have become go-to scientists when manufacturing companies have an application they would like to improve but not the chemical expertise to accomplish the task. The institute is creating patentable intellectual property at a rapid pace: WBI has filed for some 140 patents for itself and its clients, and five products it has helped develop are ready to enter the marketplace. WBI is also cash positive from the income it receives from contracts with its clients, Warner says, although he declines to divulge the firm’s annual operating budget. These achievements have come during the worst U.S. economy in decades.
“It’s a successful model,” Warner beams. “I don’t want to paint it as being easy,” he says about the revenue-generating R&D at WBI. “We put in a lot of long hours here. We have a lot of hard-working people.”
WBI scientists are currently developing toxicology screening technologies such as a material that mimics eye tissue to substitute for live-animal testing, a nontoxic aqueous solution for stripping photoresist from silicon wafers, a less energy-intensive process for making solar panels, and alternatives to the controversial chemical bisphenol A used in plastic bottles and cash-register receipt paper. Warner, who serves as WBI’s president and chief technology officer, notes that each of these projects has its roots in green chemistry.
In 1996, Warner and organic chemist Paul T. Anastas literally wrote the book on green chemistry: “Green Chemistry: Theory and Practice.” Anastas is now the assistant administrator in charge of the Environmental Protection Agency’s Office of Research & Development (C&EN, April 26, page 32).
In their “molecular-level how-to guide,” Warner and Anastas established the 12 Principles of Green Chemistry, a framework of concepts such as using less hazardous reagents and solvents, simplifying reactions and making them more energy efficient, using renewable feedstocks, and designing products that can be easily recycled or that break down into innocuous substances in the environment.
“Green chemistry is the mechanics of doing sustainable chemistry,” Warner observes. “By focusing on green chemistry, it puts us in a different innovative space. It is a science that presents industries with an incredible opportunity for continuous growth and competitive advantage.”
Being Green
Warner started his career in 1988 as a research chemist at Polaroid, working on colorless-to-color printing technologies. Yearning to make a bigger difference with green chemistry, he left his lucrative job in 1996 to take an academic position at the University of Massachusetts, Boston, where he established the first doctoral program in green chemistry. In 2004, Warner moved to UMass Lowell, where he founded the Center for Green Chemistry. But Warner still felt the pace of innovation—putting green chemistry into practice—was moving too slowly, prompting him to take a leap of faith and start WBI.
When WBI opened its doors three years ago, it had a staff of 10, Warner notes. Because of its financial success and ability to attract a steady stream of clients—even without advertising—the institute now has about 40 employees, including chemists, biologists, toxicologists, engineers, and physicists.
A walk through WBI’s 42,000-sq-ft facility reveals standard lab benches, fume hoods, and analytical instrumentation, plus an array of specialized lab equipment and instruments for developing, analyzing, and testing films, coatings, and surfaces. Much of Warner’s chemistry, he explains, is based on the concept of “noncovalent derivatization,” which employs hydrogen bonding and π-stacking interactions of aromatic ring compounds.
“Normally, when chemists want to modify a molecule, they use reaction chemistry to change or add functional groups or perhaps form a polymer—changes that often involve multiple steps, hazardous reagents, and create waste,” Warner says. “Sometimes, there’s no need to create new molecules, but instead to intentionally combine an existing molecule with other substances in appropriate ratios and use the noncovalent interactions to obtain the desired effect.” The properties of materials can typically be controlled by pH, temperature, light, or humidity, he notes, and these materials typically have reduced toxicological and environmental impact.
“It’s chemistry controlled by entropy rather than by enthalpy,” Warner says.
One of WBI’s successes is significantly improving the oral availability of a promising Parkinson’s disease drug that was impractical to administer to patients. The drug is now in clinical trials.
“Because the dose can be much smaller, less drug has to be manufactured, and that significantly reduces chemical waste, which is very high in pharmaceutical production,” Warner explains. “But more important, with the lower dose, the body excretes less drug or drug metabolites into the environment. We accomplished this by looking at the morphology of the molecule and taking advantage of noncovalent interactions to control its solubility and release kinetics.”
WBI scientists have also created a green hair dye—not one that dyes hair green, but rather one that restores natural hair color while avoiding highly toxic chemicals. For example, Warner points to one popular commercial hair product for men that uses lead tetraacetate, which is toxic and has been banned in some countries.
“We really wanted to work on something to replace that product,” Warner says. “We looked at the structure of human hair pigment and came up with a greener technology to mimic it.”
Not only is Warner one of the inventors of the dye, which is still being tested, he is also a user. He volunteered to test the dye on his own graying hair, restoring the chestnut color and his youthful look from a decade ago.
“We are kind of working all over the place,” Warner notes. “My philosophy is that a molecule doesn’t know what kind of application it’s in—it could care less if it’s in a pharmaceutical, a cosmetic, or a coating material. We rely on our partners to know the application they want. We focus on developing the chemistry to make it happen. It’s a true collaboration.”
Essentially all of the research conducted at WBI goes unpublished. Warner says it’s not his goal to build up an endless publishing record. And the institute shuns public recognition from the companies it partners with, he adds. Warner doesn’t name names when it comes to the institute’s clients either. But they are recognizable, household names, he says.
Warner says he just wants to develop and promote green chemistry as a model way to do science. For that reason, he insists that contracts with clients include an “antiburial clause” to ensure that the intellectual property doesn’t collect dust on a shelf—if it does, the rights revert back to WBI so the invention can be put to use.
Aside from the science, the culture of the Warner Babcock Institute is driven home by the amenities of its research facilities: a full kitchen, workout room, yoga studio, game room, and a replica of Grandma Warner’s living room with a television and sofas. “Our goal is to provide our staff with an environment that enables scientific achievement through interactions of a diverse and multidisciplinary team,” Warner says. “We do everything we can to foster creativity and hard work with laid-back intensity.”
It’s a different approach. Given WBI’s success thus far, Warner and his team seem to have gotten it right.
- Originally published: Chemical & Engineering News
- ISSN 0009-2347
- Copyright © 2010 American Chemical Society















Electronics production in Batam, Indonesia: “OSH is the most important. If we are sick we cannot earn our salaries.”
Tuesday, November 2nd, 2010Category: Occupational Health & Safety
Posted on: October 29, 2010 7:19 PM, by The Pump Handle
by Elizabeth Grossman
Batam, one of Indonesia’s Riau Islands, sits across the smog-choked strait from Singapore, just one degree north of the equator. On October 21 and 22, the days that I’m there, newspaper headlines announce that Singapore is experiencing its worst air pollution since 2006 due to fires, most likely from illegal forest clearing in Sumatra. From a high point above the harbor where we go to see the view, the ship traffic below is mostly obscured by gray haze. A tourist brochure extols the island’s natural features, but what’s most evident is rampant development. Enormous gaudy housing and shopping complexes, strip malls, and new industrial parks appear to be eating up the tropical greenery and eroding the hillsides. Traffic, as in Bandung and Jakarta, is a road-clogging scrum in which motorcycles weave precariously between bumper-to-bumper cars and trucks. It is almost 100ºF, so hot that in the un-airconditioned FSPMI union headquarters, sweat from my hand soaks through my notebook page.
Thanks to much of the island’s designation as a special economic zone beginning in 1989, Batam has been experiencing explosive growth. In the 1970s, the island’s population was under 10,000. Today it has soared to about 900,000 and continues to grow. The industry here is primarily electronics – shipbuilding and general manufacturing are also major industries – with Batam’s workers providing inexpensive labor for assembly line production for Singapore-based operations of international companies. Panasonic, Epson, Sanyo, Siemens, Flextronics, Infineon, Teac, Schneider, Unisem, and Philips are some of the names we see on factory buildings in the Batamindo Industrial Park, one of the island’s largest industrial parks. The website for its Singapore-based developer notes that more than 60,000 people work for the companies located here.
The entrance to the industrial park is guarded, and fencing surrounds both factories and workers’ dormitories. The FSPMI (Federation of Indonesian Metal Workers, which is affiliated with the International Metal Workers Union) union leaders who are driving my colleagues and me around the park caution against taking pictures within sight of the security guards or police we pass frequently on our tour. The dormitories are numbered, three-storey buildings. Laundry hangs from some balconies and fire extinguishers are mounted on outside walls. All windows are completely covered by identical green shades.
At a union meeting
FSPMI hosts an evening meeting so workers can share information. We meet in a hotel that specializes in accommodations for people making the haj to Mecca. Clocks behind the reception desk show “Jakarta time,” “Singapore time,” and “Mecca time.”
That electronics workers here are unionized is remarkable, as unions are the exception throughout the electronics industry worldwide – a legacy of the historical anti-union bias of the microchip industry. But there are several different unions representing workers in Batam. Wages have traditionally been the focus, with occupational safety and health often being overlooked, one of the FSPMI leaders says. “But OSH is the most important issue,” he says. “Because if we are sick we cannot work and cannot earn our salaries.”
There are about two dozen people around the table, roughly three-quarters of them men and the rest from the union’s Women’s Forum. Most of the women wear headscarves. People introduce themselves by describing the companies they work for and the products they work on. “Epson – printer scanner.” “Singapore company supplying Sanyo, Epson, Philips.” “Unisem – integrated circuits.” “Seagate Technology. “Alcatel manufacture for AT&T, Dell, Compaq, Bose.” “Japanese company making Blu-Ray, DVD, CD disks.” “Wiring systems for Toyota, Sumimoto, Honda, Suzuki.” “Varta – lithium battery. “Techtron – MP3 and toys.” “Sanyo – battery for mobile phone.” “Fujitsu, HP – hard drive.” And the list goes on.
Along with this information, people share some of the concerns they have about the health effects of this work. Heat, dust, noise, physical discomfort, muscoskeletal and ergonomic problems are mentioned. Problems with eyesight are cited by people who use what they call “scopes” to examine products.
One union member describes his hearing loss after working at the same factory for ten years. He’s had to go to Jakarta (about 540 miles away) for treatment, he says, showing us copies of his audiometry tests. Another, who’s worked for Varta for 15 years making nickel metal hydride batteries, tells us of colleagues suffering from cancer. Yet another union member tells us about co-workers who’ve been diagnosed with lung disease official diagnosis is TB – “from printed circuit board cutting dust.”
Several people mention women’s reproductive health concerns, among them menstrual problems, miscarriages, birth defects, and quadruplets. One man puts his hand on his wife’s shoulder and tells us of her breast cancer. She’s spent 15 years working in a plant assembling lithium batteries. No one knows if there’s a connection, but when pressed, the company management paid for her treatment.
The FSPMI Women’s Forum was established in 2009 so women could discuss workplace issues specific to them. Among these are reproductive health hazards and reproductive health rights, including those for pregnant workers. We’re told of one plant where almost 90 percent of the workers are women.
“No information or training on chemicals”
The next day, I speak with a young woman named Wulan, who tells me that many of the women who work in the plant with a 90 percent female workforce have come to Batam from far away in other parts of Indonesia, many recruited just after high school.
Wulan came to Batam from Yogyakarta in west central Java – near Mount Merapi, the volcano currently erupting – in 2007. Until her contract was ended recently, she had been working at a Panasonic plant in safety control. Her job was to prepare protective gear for the workers and make sure everyone going into the clean room was properly outfitted with face mask, booties, hairnet, coveralls, etc. A typical working day is 7 a.m. to 7 p.m., she tells me, with three hours of that, 4 p.m. to 7 p.m., as overtime. But there’s also a night shift. She tells me she calls her family every day.
She also tells me that co-workers in line production have become sick from work they do cleaning parts. “There are lots of solvents,” she days. People have problems with their legs from whole days standing. Reproductive health problems are mentioned again.
“The union has tried to investigate chemicals using MSDS (material safety data sheets) and found that all the chemicals being used are dangerous,” one union member tells us. “The MSDS says because of gas respiratory protection should be used but workers only use paper or cotton masks,” he says. Methylene chloride, benzene, TCE, lithium, methanol, metal solvent, nickel metal hydride, isopropyl alcohol, nickel, Pergasol, and other metals and solvents are among the chemicals people have questions about.
When I ask if workers are given any special training on handling hazardous chemicals, I am told, “No information or training on chemicals. Just what we learn from MSDS.” Another issue raised is that workers move from factory to factory – many on short-term contracts, some only three moths long – so it’s difficult to build leadership on these issues, let alone organize workers. This also makes it difficult to trace diseases.
At one plant assembling circuit boards, recounts one union member, the management said theirs was a “clean industry” because “they collect all the particles.” We’re also told that at some plants workers are offered milk at the end of the day – with the intent of counteracting chemical effects. When concerns about health impacts of chemical exposure were raised with management, one response from employers has been, “What is your scientific proof that this industry can be hazardous?”
Some of the factories described are apparently ISO certified or ROHs compliant. But none of this guarantees employees the right to know the identity or hazards of the chemicals they’re working with. The people we meet are working hard to inform themselves.
Tags: electronics, safety testing, worker EHS
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