2009-04

04 | 2009

Bottle Applications | 14 Non Food Sourced Bioplastics | 36 Land Use For Bioplastics | 46

bioplastics

magazine

Vol. 4

ISSN 1862-5258

Highlights:

A G A Z IN

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Plastics For Your Future

Biograde速 C 7500 CL for Colourful Cosmetics Applications

Another New Resin For a Better World

FKuR Kunststoff GmbH | Siemensring 79 | D - 47877 Willich Tel.: +49 (0) 21 54 / 92 51-0 | Fax: +49 (0) 21 54 / 92 51-51 | sales@fkur.com

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dear readers

Photo: European Bioplastics

Guest Editorial

As in the last years, bioplastics MAGAZINE carries reports about the latest bottle applications in the most thirsty period of the year, which points to the fact that from year to year we see considerable progress in this sector. In this issue for example, bioplastics MAGAZINE spoke with Primo Water about their developments, and reports about Naturally Iowa’s achievements for the introduction of PLA bottles.

So, producers and users are obviously making good progress with regard to the technical and environmental performance of such bottles. Yet a few questions seem to require further attention. For example, we still need to define and implement ‘best practice’ for the end of life (or let’s better say, re-use and recovery) of bioplastic bottles. In the technical community for example, the influence of PLA on the recycling of PET is still under discussion. This is quite understandable, as the PET recycling industry needs to secure their well established business and they need to evaluate the potential influence of any other materials, such as PVC, clarified PP or PLA. The findings of NatureWorks, which are documented in this issue, are a very important contribution to this discussion. Such studies will certainly support dialogue and confidence building. The PET industry seems anyway more than interested in learning about PLA. They know perfectly well what it means to introduce a new material to existing markets and to manage the various questions (all coming at the same time), because they lived through this some 20 years ago. Looking at their experiences we will realise that the technical sorting of the bottles is one of the core issues, and we also need to find out what happens along the whole recovery chain. Will at least a considerable share of the bottles find their way into sorting plants? This is the question about the existence and availability of collection systems… Will all sorting plants, dependent on their geography, be equipped with NIR detection? Can mixing of the different material streams destined for recycling safely be avoided? Regardless of such questions, the goal of developing the recycling of PLA and other bioplastics is very promising and the industry is certainly on the right track. It will be further helpful to team up with the PET recycling industry with the aim of achieving good separation of the material streams and, by the way, also for clarification of the influences of the so-called ‘oxo-degradable’ PET bottles (please see NAPCOR’s advice on page 28).

A further editorial focus in this issue is the question of ‘Land use for production of Bioplastics’. Obviously the existence of hunger in this world is not caused by bioplastics, but rather by factors such as distribution, logistics and politics. On the other hand, increasing the demands placed on agricultural resources needs careful consideration of the market mechanisms in order to ensure that our industry will deliver sustainable solutions also in terms of social responsibility. Interesting approaches concerning resource supply can be found in the reports about algae and potato-waste streams as potential sources.

We wish all readers an enjoyable holiday season – with not too many algae in your swimming water …

Yours, Joeran Reske

Joeran Reske is Manager Bioplastics at Interseroh, a leading supplier of secondary raw materials in Europe. Joeran is also Vice Chairman of European Bioplastics bioplastics MAGAZINE [06/08] Vol. 3

bioplastics MAGAZINE [04/09] Vol. 4

Bottle Applications

PLA Bottles - Recyclable and Compostable 16

Green Bottles at Capitol Hill 20

Extrusion Blow Moulding of Bioplastics 22

Using NIR Sorting to Recycle PLA Bottles 24

NAPCOR Bans Degradable Additives 28

Stereocomplex PLA Offers High Durability 29

Biodegradable High Barrier for Packaging 30

Polyamides Based on Succinic Acid 32

PSM –The Renewing of a Brand

34 Novel Device For Aerobic Biodegradability Testing

Land Use for Bioplastics 46

Land Use For Bio-Polyolefins 50

The evelope in which this issue was mailed was sponsored by Sidaplax

14 Bioplastics - from Walkman to Ultra-Slim OLED TVs

Envelope

Coca-Cola Biobottle Algae to Plastics

Editorial contributions are always welcome. Please contact the editorial office via mt@bioplasticsmagazine.com.

Editorial News Application News Event Calendar Suppliers Guide

bioplastics MAGAZINE tries to use British spelling. However, in articles based on information from the USA, American spelling may also be used.

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The fact that product names may not be identified in our editorial as trade marks is not an indication that such names are not registered trade marks.

Bioplastics hot topic at SPE‘s ANTEC 2009

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bioplastics MAGAZINE is read in 85 countries.

Events review

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Interview

bioplastics magazine ISSN 1862-5258

NPE Review

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Andy Sweetman, New Chairman of European Bioplastics

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Impressum Content 03

05

40

51

52

July/August 04|2009 Non Food Bioplastics 36

Hungry for sustainable, durable bioplastics? 37

Applications 38

Testing

44

Basics

Materials

News

Hasso von Pogrell is European Bioplastics‘ New Managing Director Since March 2009 Hasso von Pogrell is the new Managing Director of European Bioplastics, the association of the European bioplastics industry.

Born in Brazil, educated in Portugal, the United States and Germany, Mr. von Pogrell holds a degree in economics from the University of Cologne.

During the last 14 years he has held leading positions in associations of the German construction, retail and optical industry. In his preceding position before joining European Bioplastics, he was Director General of the German Sawmill Industry Association.

“We are very pleased to welcome Mr. von Pogrell as new Managing Director in the association. He brings several years of managing experience in stakeholder associations and suits that job perfectly“, said Andy Sweetman, newly elected Chairman of European Bioplastics.

Now, after nearly 150 days in the new job Hasso von Pogrell adds: “It‘s a big pleasure and an honour for me to take a leading role in the team of European Bioplastics. I see quite a few challenging tasks lying ahead of us and I‘m looking forward to continuing to build on European Bioplastics‘ success for the coming years.“ www.european-bioplastics.org

bioplastics MAGAZINE [04/09] Vol. 4

News

Bioplastics Awards 2009 Now in its fourth year, European Plastics News (Crain Communications) announce the Bioplastics Awards as the only global initiative to recognise achievement in the field of bio-sourced polymers.

As media partner of the event and member of the judging panel bioplastics MAGAZINE encourages all readers to supply suggestions for the Bioplastics Awards 2009. The entry deadline is Friday 18th September 2009.

Categories recognise innovation in R&D or processing, reward outstanding applications in packaging and nonpackaging markets, acknowledge imaginative marketing concepts, and highlight the role of retailers and individuals in the development of the bioplastic marketplace. The categories are carefully selected to provide bioplastics developers, producers, processors and end-users with the perfect opportunity to direct the spotlight onto their achievements.

Best Innovation in Bioplastics Recognising innovation in the bioplastics sector, this category is open to any company or organisation. Judging will be determined on innovation, novelty and potential benefit to the future development and/or commercialisation of bioplastics.

Best Bioplastics Processor Open to any company processing bioplastics, this category will be judged on the quality of the product being manufactured, its innovation, marketing effort and customer service.

Best Bioplastics Application – Packaging Open to any bioplastics product used in a food packaging application. Products can be entered by anyone involved in the development, with judging determined on innovation, market impact, customer response and sustainability.

Best Bioplastics Application – Non-Packaging Open to any bioplastics product used in a non-packaging application. Products can be entered by anyone involved in the development, with judging determined on innovation, market impact, customer response and sustainability.

Best Bioplastics Marketing Initiative Open to material producers, processors, brand owners and end users. Entries will be judged on impact, clarity of message, focus and effectiveness.

Best Bioplastics Retailer/Brand Owner Open to any retailer or brand owner bringing products to the market using bioplastics. Judging will be determined on enthusiasm for bioplastics, profile achieved, market support and impact. Key consideration will be given to how the entrant has addressed sustainability issues.

Personal Contribution to the Bioplastics Industry This is a special award given by the European Plastics News editorial team to an individual that has made an outstanding contribution to the development of the bioplastics sector.

Where and when A shortlist will be compiled and published in November 2009. Winners will be announced online in December 2009 and published in the following editions of European Plastics News and bioplastics MAGAZINE. Winners certificates will be mailed in January 2010 - MT www.bioplasticsawards.com

PURAC Receives Frost & Sullivan Innovation Award PURAC, a leading lactides producer for the bioplastics industry, has been awarded, together with its partners Sulzer Chemtech and Synbra Technology, the 2008 Frost & Sullivan European Polylactic Production Technology Innovation of the Year Award.

This prestigious award recognizes PURAC’s innovations in the area of polylactic acid based (PLA) bioplastics. Together with Sulzer Chemtech and Synbra Technology, PURAC has developed a new cost-effective polymerization process to produce highquality polylactic acid from a renewable source which can subsequently be converted into a variety of value added applications such as expanded PLA based biofoam (see bM 05/2008 and 01/2009).

www.purac.com www.sulzerchemtech.com www.synbra.com

bioplastics MAGAZINE [04/09] Vol. 4

News

European Bioplastics Says “No“ to Oxo‘s Industry association European Bioplastics has published a position paper distancing itself from the so-called ‘oxobiodegradable’ industry. The paper sheds some light on the ‘oxo’-technology, its failure to live up to international established and acknowledged standards that effectively substantiate claims on biodegradation and compostability, and the implications resulting from the different approaches.

“Bioplastics are still a relatively young industry”, says Andy Sweetman, Chairman of the Board of European Bioplastics.

“Inherent implications made on the environmental suitability of our products are subject to close scrutiny by all kinds of stakeholders. It is, therefore, vital that claims on biodegradability or compostability are backed by internationally accepted standards”, he adds.

“We just cannot allow that the public, who are generally very sensitive to ecological issues, be further confused by claims on biodegradability and compostability resulting from conflicting approaches. If certain products that claim to be biodegradable or compostable are proven not to fulfil acknowledged standards, this is liable to impact negatively on our own members’ products, even though they do fully comply”, Sweetman further states. It should, under all circumstances, be avoided that products carrying the compostability mark of European Bioplastics, the seedling, be associated in any way with so-called ”oxo-biodegradable” products and the like.

Products carrying the seedling (see page 9) have undergone rigorous independent testing beforehand. Only if proven to comply with the strict standards on biodegradability or compostability, such as ISO 17088, EN 13432 or other similar standards, can the tested material or product be awarded the seedling.

“This is also why we so vigorously fought against the attempt of the ‘oxo-biodegradable’ industry to water-down the criteria of the EN 13432, requesting longer timeframes for materials to decompose. It would not have been in the public or the composting industry’s interest to have compromised the strict criteria of EN 13432 which ensures the materials are fit for purpose”, the chairman adds. “Fortunately, our position is fully shared by the experts of the plastic and packaging sectors, as was evident during the last meeting of the relevant Working Group of The European Committee for Standardization (CEN) on July 9, 2009, where the requests for revision of the standard were rejected.”

In the next issue bioplastics MAGAZINE will publish extracts from the position paper, the complete version of which can be downloaded from www.bioplasticsmagazine.com/200904 www.european-bioplastics.org

interpack 2011 – Again a Promising Product Think-Tank Five years after the launch of the special show concept ‘Innovationparc‘ the bioplastics theme has become such an established fixture that it will form an integral part of the regular ranges on display at interpack in 2011 (to be held in Düsseldorf,Germany from 12 to 18 May). interpack is the world‘s most important trade fair for the packaging sector, including packaging in glass, metal and aluminium, paper and cardboard as well as conventional plastics, and its relevant processing industries.

Bioplastics made their debut at the ‘Innovationparc Bioplastics in Packaging‘ in 2005 represented by 20 exhibitors on 250m² of rented exhibition space. Three years later this theme was featured four times as prominently at interpack 2008 with 40 companies on 1000 m². Commenting on this, Bernd Jablonowski, the Director of interpack, said: “The development of bioplastics over the past few years confirms our approach of using the innovationparcs to address trend themes that promise ‚substance‘ for the future.“ For interpack 2011, the association European Bioplastics expects further interest on the exhibitors‘ part. “Four months before registration documents are to be sent out, there are already signs of a doubling of the exhibition area occupied by the bioplastics industry compared to 2008,“ says Hasso von Pogrell, Managing Director at European Bioplastics.

Companies wishing to exhibit in the Bioplastics segment of interpack 2011 can register with Messe Düsseldorf from October 2009 on (Mr Grosser, Tel.: +49211/4560-417, GrosserC@messe-duesseldorf.de).

Official deadline for registrations is February 28, 2010. www.interpack.com

bioplastics MAGAZINE [04/09] Vol. 4

News

Biodegradable Bags Project in Thailand Australian Biograde Becomes Cardia Bioplastics Rapidly expanding Australian based global supplier of resins derived from sustainable resources Biograde has rebranded its business and product range to reflect changing technology and market direction. Under the new Cardia Bioplastics® name, the company will continue to expand internationally as a developer, manufacturer and marketer of sustainable resins for packaging and plastic products.

Cardia Bioplastic‘s manufacturing plant and Product Development Centre are in Nanjing, China. The company has offices in Europe and the Americas, and a network of leading distributors across Australia, the Americas, Europe and Asia.

“Growth for our business is fuelled by the global trend towards sustainable packaging,” said managing director Dr Frank Glatz. “Our key people are skilled plastics industry leaders widely recognised for their sustainable resins expertise. We hold a strong patent portfolio and a track record for creating innovative products with our proprietary technology.“ Cardia Bioplastics is a registered name of Biograde Limited, a fully owned subsidiary of Cardia Technologies Limited. www.cardiabioplastics.com

In conjunction with the BioPlastics Asia 2009 forum, the National Innovation Agency (NIA) of Thailand, Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ: German Technical Cooperation), Thai Bioplastics Industry Association (TBIA) and BASF recently announced that they have joined forces in pilot projects to promote the use of biodegradable bags. The inaugural pilot project, which will run from July to December 2009 in the Samut Songkhram Province, aims to use biodegradable bags to collect household organic waste in the most efficient way and produce high-quality compost that will serve as organic fertilizer for the purpose of soil improvement.

“Biodegradable plastics present an important contribution to efficient biowaste management.

Additionally, as a secondary raw material postcomposting, it can also be used to provide an economical and ecologically viable utilization possibility – fertilizer in this case. This kind of organic waste recycling will be an important waste management model and further the evolving bioplastics market in Thailand as well” said Dr Supachai Lorlowhakarn, Director of NIA. The NIA successfully developed the National Roadmap for the Development of the bioplastics industry in Thailand, which was approved by the Cabinet on 22 July 2008.

NIA will support the cost of biodegradable plastic bags and project management to the Development of Environment and Energy Foundation (DEE) for the separation, collection and organic treatment / composting of waste. The composting process will be managed by TCM Environment, with its state-of-the-art bio-digester that will convert the organic waste collected, into endproducts that can be used as fertilizer. For the production of the biodegradable bags, TBIA will compound starch with BASF’s Ecoflex, a fully-biodegradable, compostable polyester which is tear-resistant, puncture-resistant, waterproof, printable and elastic.

“Thailand has an abundant supply of renewable resources, such as tapioca for the production of starch.

As such, starch will be an important raw material for the bioplastic industry development in Thailand. The pilot project in Thailand is another step to build up the domestic market and elaborate on the application of bioplastics for the entire life cycle” said Somsak Borrisutthanakul, Chairman, TBIA - MT.

bioplastics MAGAZINE [04/09] Vol. 4

8 weeks later

News

New Legislative Approach on Bioplastics in Latvia Mirel Bioplastic Certified Compostable by BPI Metabolix recently announced that Mirel™ bioplastic resins (PHA) produced by Telles have been certified compostable by the Biodegradable Products Institute (BPI), an independent North American certifier of compostable material. BPI certification shows that Mirel base resins comply with the specifications established in the American Society for Testing and Materials standard ASTM D6400 for composting in a professionally managed composting facility.

In May Mirel resins received certifications from Belgiumbased Vinçotte of ‘OK Compost“ for industrial composting and ‘OK Compost HOME“ for home composting.

“Materials certification is an important process for the bioplastic industry to embrace,“ said Bob Findlen, Vice President of Sales and Marketing for Telles. “Product manufacturers, brand owners, and their customers need to have confidence that the biodegradability and compostability claims of materials suppliers are substantiated by scientific data and third party validation.“ www.mirelplastics.com

Homo ecos:, the Latvian representation of the bioplastics industry, has initiated a cabinet ordinance that is preparing to implement EN 13432 and EN 14995 standards into national legislation. European Bioplastics, the European representation of the bioplastics industry, supports the new legislative approach in Latvia.

A cabinet ordinance initiated by homo ecos: is currently under way to define biodegradable plastics as certified compostable according to EN 13432/14995. “At the moment we are strongly committed to the translation of the European standards for compostable bioplastics EN 13432 and EN 14995 into Latvian. This is necessary so that the standards can be taken over in national legislation,“ says Andrejs Viks, spokesperson and board member of homo ecos:. A tax on natural resources in Latvia grants packaging made of biodegradable plastics a significantly reduced tariff compared to conventional plastic materials.

The new ordinance makes certification and labeling mandatory for bioplastics products if they want to profit from the lower tariff.

“European Bioplastics welcomes the initiative by homo ecos:. Eastern Europe is a market of great possibilities for our industry.“, states Andy Sweetman, Chairman of European Bioplastics. “It is good to see the visibility of our products growing and the support for bioplastics strengthened in Latvia. We are looking forward to further improve our collaboration locally in all fields of work.“ Homo ecos: is the newest member of the Congress of the European and National Bioplastics Organisations and Networks (CEBON), which is coordinated by European Bioplastics. The concept of homo ecos: is to assemble different sustainable technologies under the roof of one representation. Next to bioplastics, projects in the field of paper and renewable energies are envisaged.

The „seedling“ quality symbol stands for approved compostability. It is awarded to certified products following certification based on european standards EN 13432 and EN 14995.

bioplastics MAGAZINE [04/09] Vol. 4

Interview

Andy Sweetman, New Chairman of European Bioplastics

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nd of April the industry association European Bioplastics elected their new board to be chaired by Andy Sweetman (Innovia Films), After his first 100 days in the job, bioplastics MAGAZINE spoke with Andy Sweetman.

bM: What are your general thoughts about the association. Is it a development from a German to a European ‘thing‘ or is it even recognized and heard globally?

AS: It is gratifying to see how European Bioplastics has transformed itself over the past 5 years from an essential national association in Germany, to become the voice of the Bioplastics industry on a Pan-European basis. During that time it has also witnessed significant growth from representing a small number of different companies and technologies into an association directly representing over 70 different companies and acting as the voice for the entire industry. Beyond that many other regions of the world look to European Bioplastics for advice and guidance on the growth and positioning of the Industry.

In the board elections this spring we said goodbye to a number of board members who have overseen this transition from a small national organisation to a larger and truly European association. A special word of thanks must go to these people who have given so much of their personal time to allow this to happen. Obviously with so much change at once it can be difficult to maintain continuity.

However at the same time it brings fresh views and a fresh drive to move things forward. What I am especially pleased about is that the new board directly represents the different types of company we have within the association. We have board members from companies manufacturing raw resins and polymers and others who process these into finished products; we have materials that are compostable but not necessarily renewable, and others whose interest is principally around renewability. This ensures all the different 'schools‘ are well represented. bM: What are your personal targets for the next one to three years?

AS: I hope that my personal targets for European Bioplastics are closely aligned with the targets of the board and our membership, namely:  To ensure the different backgrounds of our member companies and their product streams are fully represented, regardless of whether one‘s focus is more on composting or renewability or a mixture of both.

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bioplastics MAGAZINE [04/09] Vol. 4

 To concentrate on providing tangible proof of the various benefits of bioplastics within the wider context of packaging and non-packaging applications.  To show the benefits of readily renewable raw materials.  To define the advantages of the various end of life options that bioplastics can bring.  To ensure that LCA methodology can also highlight the benefits of bioplastics more effectively.  To ensure that strong, clear and independent certification schemes are in place for both composting and for the measurement of biobased content. In particular to ensure the industry has an effective choice of providers for these schemes and that there is maximum compatibility behind the schemes offered by the different providers. bM: Where is the association going?

AS: I think we must continue to grow within our European base, but at the same time strengthen our links with similar associations and stakeholder groups inside and outside of Europe. We already have good links with associations such as the Japanese BPS and the BPI in the United States. We have provided strong support to the recently formed Australasian Bioplastics Association, including the licensing of the seedling logo for their use ‘down-under‘. I‘d like to see us continue to proactively support similar activities in other regions.

Realistically we will remain an essentially European organisation, but our position of expertise and leadership can extend much more widely in terms of supporting the activities of local associations around the world. bM: What do you think about bioplastics in the current economic situation?

AS: These are tough times for any industry, the toughest I think any of us have ever known. Our industry is young and realistically most materials within the bioplastics world are still relatively low scale and higher cost. They are therefore unlikely to be part of the ‘value‘ lowest-cost categories that do best in a recession.

However the issues of improving waste management and the needs of business to drive towards sustainability do not simply disappear because of a recession.

What I think many of us are seeing is that retailers, brand owners and other companies almost see this as an opportunity to ‘get their ducks in a row‘ as we say in English; to prepare for the future and make intelligent, positive moves without having to necessarily rush into decisions this year.

I think many of us will actually look back on this period as one when sales growth was less impressive, but when the foundations were built for real progress afterwards. bM: Thank you Mr. Sweetman - and good success …

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General conditions, market situation, production, structure and properties number of pages t.b.d., hardcover, coming soon.

This new book is available now. It is written in German , an English version is in preparation and coming soon. An e-book is included in the package. (Mehr deutschsprachige Info unter www.bioplasticsmagazine.de/buecher).

The new book offers a broad basis of information from a plastics processing point of view. This includes comprehensive descriptions of the biopolymer market, the different materials and suppliers as well as production-, processing-, usage- and disposal properties for all commercially available biopolymers.

The unique book represents an important and comprehensive source of information and a knowledge base for researchers, developers, technicians, engineers, marketing, management and other decision-makers. It is a must-have in all areas of applications for raw material suppliers, manufacturers of plastics and additives, converters and film producers, for machine manufacturers, packaging suppliers, the automotive industry, the fiber/nonwoven/textile industry as well as universities.

Content:  Definition of biopolymers  Materials classes  Production routes and polymerization processes of biopolymers  Structure  Comprehensive technical properties  Comparison of property profiles of biopolymers with those of conventional plastics  Disposal options  Data about sustainability and eco-balance

Important legal framwork Testing standards Market players Trade names Suppliers Prices Current availabilities and future prospects  Current application examples  Future market development       

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Bestellen Sie das deutschsprachige Buch für EUR 299,00. order at www.bioplasticsmagazine.de/books, by phone +49 2161 664864 or by e-mail books@bioplasticsmagazine.com

bioplastics MAGAZINE [04/09] Vol. 4

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Review

NPE Review

E

ven if NPE, ‘The International Plastics Showcase’ in Chicago from June 22 to 26, 2009 had a decrease in the number of visitors by 30%, a good portion of the approximately 44,000 visitors were very interested in bioplastics. At least this was our impression when we attended our booth in the West hall.

After a comprehensive preview of this big plastics show in the last issue, we just add a few more small notes here. www.npe.org

API S.p.A. from Mussolente, Italy presented APINAT biodegradable elastomers.

Apinat is available in softer grades with 60-90 Shore A and in harder grades with 35-85 Shore A. The biodegradability meets EN 13432 and ASTM 6400 standards. Apinat can be processed using all methods for plastics, such as injection moulding. extrusion blow moulding, calendering and hard/soft over- or co-moulding onto most of the biodegradable plastics commercially available. www.apiplastic.com

Polyvel,

Hammonton, New Jersey, USA have developed in conjunction with NatureWorks a series of masterbatches based on Ingeo PLA designed for use in film, foam, injection moulding, blow moulding and sheet extrusion. Their clarifier S-1378 not only improves the clarity of PLA but it also raises the heat deflection temperature, as stated in Polyvel’s NPE brochure. Another clarifier for PLA (S-1417) can be used to reduce the cycle time. www.polyvel.com

Jamplast, Ellisville, Missouri, is the largest distributor of biopolymers in North America. The family-owned company is a one-stop source for biopolymers, engineering polymers and commodity grade thermoplastics. Jamplast is currently an authorized distributor of NatureWorks biopolymers, Cereplast biopolymers, Merquinsa Pearlthane, PSM North America and others. At NPE Jamplast hosted a luncheon with presentations from Mark Verbruggen (NatureWorks), Frédéric Scheer (Cereplast) and Daniel Tein (PSM North America). www.jamplast.com

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bioplastics MAGAZINE [04/09] Vol. 4

PolyOne launched three new products at NPE: The Resound™ platform of biopolymer compounds is formulated with a 30% minimum bio-derived content and offers a substantial boost in performance for current and future bio-based materials. Key improvements include levels of heat tolerance and impact resistance unobtainable with neat bioplastics, as stated by PolyOne. Resound compounds combine compatible engineering thermoplastic resins with bio-based polymers such as PLA, PHB, PHBV, and biopolyesters. Future grades may take advantage of biopolymer resins currently in development but not yet commercially available. Initial Resound grades feature heat resistance (HDT) up to 120°C (248°F) and impact resistance up to 53 J/m (12 ft-lb/in).

Versaflex™ BIO TPEs (Thermoplastic Elastomers) for injection molding are formulated with 63 to 70 % renewable resources, compared to typical compounds that use a maximum of 15 or 20 %. The Versaflex BIO family of TPEs compares favorably to typical styrenic-based TPEs The translucent grades are available in a range of 40 to 70 Shore A hardness.

Merquinsa and PolyOne announced the world’s first halogenfree flame-retardant biobased thermoplastic polyurethane jointly developed by the two companies. Merquinsa’s Pearlthane® ECO technology, a polyether polyurethane based on natural renewable sources will be marketed globally by PolyOne as part of the OnFlexTM family of thermoplastic elastomers. The minimum amount of natural renewable sources in the polyurethane resin 50% (as certified by ASTM D 6866). www.polyone.com

OnFlex for wire and cable applications

Bioplastics hot topic at SPE‘s ANTEC 2009

ANTEC 2009 on June 22 in Chicago was the first opportunity to support the above mentioned mission of the Bioplastics SIG. The two day session provided a great forum to bring the exports together, discuss new results of research and practical aspects of this field. The Monday morning session, which covered papers about the properties of PLA, PLA foams and PLA composite materials, was opened by a keynote lecture given by Mr. Richard Bopp from NatureWorks, titled

‘Advances in Ingeo™ Biopolymer Technology for Durable Applications’.

The afternoon session was dedicated to synthesis of and properties of thermoplastic starch and other bioplastics.

This session was opened by an overview of renewable fillers for thermoplastics - challenges and opportunities, a keynote lecture, given by Prof. Leonardo Simon from University of Waterloo, Canada.

The Tuesday sessions were organized jointly with the Flexible Packaging division, focusing on sustainability. The morning session dealt with processing costs, environmental impact, life cycle estimation and screw design considerations.

Mr. James Huang as a keynote speaker from Bemis Company, Inc. gave a presentation about the design considerations for food packaging using bioplastic materials, while Mr. Eric Greenberg from Eric F. Greenberg, P. C. also as a keynote speaker, gave an overview about the laws associated sustainability. The afternoon session started with another keynote talk, given by Prof. Rafael Auras from Michigan State University, covering the assessment of sustainable packaging systems. The rest of the presentations dealt with property improvements (impact, rheological, thermal) of bioplastic polymers for packaging applications.

www.4spe.org

The Bioplastics Special Interest Group (SIG) at the Society of Plastic Engineers (SPE) was created in September 2008 for the purpose of providing a unified forum for promoting open exchange of scientific and engineering knowledge related to polymeric materials that are fully or partially biobased with the ‘Cradle-to-Cradle’ emphases. The areas of interest include synthesis, characterization, processing, structure-property relationships, degradation, product design and development, application, modeling, regulations and compliance and life-cycle analyses. To achieve these objectives, the Bioplastics SIG collaborates closely with other interested technical divisions of SPE, national and international organizations, associations, and institutions to coordinate dissemination of the accumulated knowledge and understanding through appropriate channels.

Review

Environmental Protection – Easily Retrofitted Production of 6-layer-fuel-jerry cans with barrier properties meeting the strict emission regulations cost effectively retrofitted onto your existing blow molding machine.

More information: www.w-mueller-gmbh.de · 0 22 41bioplastics / 93MAGAZINE 66 -[04/09] 0 Vol. 4

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Bottle Applications

Coca-Cola Biobottle Uses Biobased Ethylene Glycol

By Michael Thielen

I

n the last issue bioplastics MAGZINE reported about the planned launch of CocaCola‘s PlantBottle™. This new plastic bottle will be made partially (up to 30%) from plants. As promised this issue will present a more comprehensive view to this new development.

As stated by Coca-Cola the PlantBottle is a 100% PET plastic beverage bottle. The PET resin used for these bottles is sourced from up to 30% plant-based renewable material. Currently, PlantBottle is made from a blend of petroleum-based and existing sugar cane/molasses-based materials. The long-term focus is on the development of plastic bottles made from lignocellulosic plant waste material such as wood chips, corn stover or wheat stalks. Coca-Cola‘s goal is to bring plastic bottles to market that are fully recyclable and made from 100% renewable raw materials.

Conventional Dasani bottle to be replaced in select markets by PlantBottle

But for the time being, the status-quo is the PlantBottle with up to 30% plant-based renewable material. In a direct conversation with Coca-Cola bioplastics MAGAZINE questioned how the 30% can be understood. PET is made from mono ethylene glycol (MEG) and terephthalic acid (TA). Lisa Manley, Director of Sustainability Communications of The Coca-Cola Company explains that currently the mono ethylene glycol is being produced from renewable resources such as sugar cane and molasses (a by-product when producing sugar from e.g. sugar cane). Based on a molecular weight ratio of the MEG used to make the PET vs. the molecular weight of the final PET, exactly 31.25% of the PET is contributed by the MEG. Thus if all MEG used to produce the PET were made from renewable resources, the renewable content would be 31.25%. Now as all the MEG can be biobased (not necessarily must), Coca-Cola states that up to 30% of the PET will be made from plants. That is how the ‘up to 30%‘ statement is to be understood.

Would the biobased content be calculated according to ASTM 6866, based on the amount of renewable carbon, the picture would look slightly different. (mono ethylen glycol + terephthalic acid  PET + water) or C2H6O2 + C8H6O4  C10H8O4 + 2 H2O (the carbon atoms printed in green being plant based or renewable C14 and those printed in red being fossil based C12) This leads to the conclusion that if all MEG would be plant based, the content of renewable carbon in the PlantBottle PET would be 20%.

This is not at all meant to criticize. It is just to clarify the facts. Coca-Cola‘s approach is absolutely positive as the replacement of as much fossil based carbon in plastics applications as possible is a very important goal. Thus the PlantBottles help to reduce carbon dioxide emissions compared with petroleum-based PET and to reduce dependency on oil which is a finite and non-renewable resource. And to come back to the goal of a 100% biobased bottle, Coca-Cola is of course carefully watching the development in the field of creating a biobased terephthalic acid as Lisa Manley points out.

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bioplastics MAGAZINE [04/09] Vol. 4

The product is partly biobased but is not biodegradable.

However, since it is a PET like any other it is fully recyclable. PlantBottle is the first plastic bottle (partly) from renewable sources that can be recycled along with other PET bottles in the existing PET recycling infrastructure. And - again, as it is a PET bottle as any other, PlantBottle has exactly the same performance as the current PET bottle; no differences between shelf life, weight, chemical composition or appearance of the PlantBottle versus existing (petroleum based) PET plastic bottles.

Lisa Manley emphasizes that PlantBottle does not compete with food products or scarce land for food. She explains that they are very excited about this innovation and that Coca-Cola do all they can to ensure the sources are sustainable ones. And even if Coca-Cola won‘t disclose the exact suppliers for competitive reasons she points out that Coca-Cola did an LCA study to make sure that different potential supply points were directionally the right way to go from an environmental point of view.

For example Coca-Cola looked for suppliers that grow their agricultural products in areas of the world where the irrigation of the crops is largely rain fed. Another fact that Coca-Cola took into consideration was that the suppliers set up their operation with the intent to grow sugar cane and produce molasses for non-food use.

The plans for the market introduction comprise pilot launches of Dasani and sparkling brands in select markets in 2009 and vitaminwater in 2010. PlantBottle beverage containers will be identified through on-package messages and in-store point of sale displays. Being asked why the PlantBottles are not (yet?) planned to be used for the big brands like Coca-Cola Lisa comments that of course there still is a cost issue. But over the long-term, the cost of plant-based material is expected to be more stable than the cost of equivalent material made from petroleum. As the demands increases it is expected that the supply increases and the prices fall. So we will all be curious how this development will evolve. www.thecoca-colacompany.com

Think Earth Friendly

Think EarthFirst.

EarthFirstŽ is a registered trademark of Plastic Suppliers, Inc. EarthFirstŽ is made with Ingeo™ Ingeo™ is a trademark of NatureWorks, LLC.

Material

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bioplastics MAGAZINE [04/09] Vol. 4

15

Bottle Applications

PLA Bottles - Recyclable and Compostable

A

mong the increasing number of companies offering their products in PLA bottles is the privately held Primo Water Corporation, headquartered in Winston-Salem, North Carolina, USA. bioplastics MAGAZINE spoke with Tim Ronan, VP Marketing & PR of the ‘UPonGREEN‘ certified company which was incorporated in 2004. bM: What did you do before introducing PLA bottles?

TR: Our mission is to help people live better lives by offering the world‘s best tasting water in environmentally friendly ways.

In 2005 we started with three and five gallon polycarbonate water cooler bottles with a unique ‘Zero Waste‘ bottle recovery system where the bottles never end up in a landfill (bringback - reuse 40-50 times - recycle). Since 2008 we have been offering Energy Star rated stylish, contemporary water coolers/dispensers. We developed that unique system and are now the largest branded water cooler bottle company in the USA. bM: When and why did you start your PLA-bottle activities?

TR: After almost two years of product and in-market testing, we launched nationally in April 2008 in all Kroger grocery stores.

We introduced Primo into a huge but somewhat controversial category of bottled water because we knew there was a better way to offer the convenience of single serve bottled water while not using a valuable, non renewable or sustainable, depleting resource - oil. By using Ingeo™ PLA from NatureWorks, we are using a renewable, sustainable resource and still provide the consumer what they need in a convenient package for refreshing, clean, great tasting bottled water.

Producing the Ingeo resin is also much more environmentally friendly. In production, it emits 75% less greenhouse gases, uses 49% less fossil fuels and 45% less energy versus oil based PET resin production. So from the very beginning, the Primo bottle, made from plants, is better for our environment in multiple ways vs. PET. bM: What did you expect from the project?

TR: We expected everyone to be amazed that you could make a bottle out of plants and have it look just like any other bottle.

And they were amazed. When we tell people “this bottle is made from plants, not crude oil“ their reaction is always “Wow! Really?

That’s great!“ We are educating the public. Many people in the US don‘t know how widely oil is used in packaging, especially beverage bottles. We are introducing an innovation in packaging that is better for our environment today and tomorrow but doesn’t change anything the consumer has to do.

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Bottle Applications

bM: What products are you currently bottling in PLA and planning in future?

TR: We are only bottling Primo water today. There are other beverages that are compatible with PLA including some fruit juices, ready to drink teas, milk. PLA does not react well to carbonated beverages today. We certainly will keep open our options for expanding our offering but are concentrating on bringing some new news, good news, to the bottled water category. bM: What is Primo‘s policy as to ‘end of life‘ of the bottles? Are you taking PLA bottles back too to reuse / recycle them or the like?

The best ‘new life‘ scenario, a phrase I like better than ‘end of life‘ by the way, is recycling because when recovered, PLA can be recycled 100% back into lactic acid which means it could go 100% back into another Primo bottle. In the US Recycled PET plastic oil based bottles are only being recycled back into new bottles at about 8% or so. Most goes into carpeting and strapping. We encourage recycling of our bottle and all beverage bottles. We all need to do a better job at recycling plastic beverage bottles, as our rate of recovery is only 24.6% of the 5.8 billion pounds of plastic beverage bottles available in the US (2007 data). The Primo bottle can be sorted automatically using NIR equipment, a technology that is installed in most major recycling facilities.

Black light ‘off’

And for those recyclers that do not have NIR we invested in developing technology that supports manual sorting. We add a special ‘light signature‘ into our preform so when our bottle is put under low wattage black light, it fluoresces and can easily be distinguished from PET bottles. This is intellectual property that we invested in to help the industry. It’s pretty cool!

Another very unique feature about our Primo bottle is that it’s compostable (under proper composting guidelines). It proves ‘this Primo bottle is different!‘ Composting is a growing desire, especially on college campuses. We‘ve done four tests and each one is very consistent in its results. Michigan State University School of Packaging recently conducted two tests that showed the Primo bottle almost totally decomposed in two weeks! It was completely gone in four weeks. Tests at Community Recycling and Resource Recovery, Inc., Lamont, California showed almost complete degradation of our bottle in two weeks. Dave Baldwin, the General Manager of the facility said “it‘s the fastest I‘ve ever seen a package decompose in my facility. Amazing.“ The tests show that under proper composting conditions (heat, moisture, microbe‘s present) Primo bottles will completely decompose back into CO2, water and biomass in less than 60 days - easily.

It‘s a great ‘return to nature‘ use and it doesn‘t go in the landfill.

That‘s what most important. So the Primo bottle has multiple options for its ‘new life‘ - a term I‘m trying to get people to use. ‘End of life‘ means it‘s over. We want Primo to signal the next life of the plastic. Of course even greenhouse-gas-neutral incineration for energy recovery is an option too, but that should be the last step when no recycling or composting is available.

Black light ‘on’ bioplastics MAGAZINE [04/09] Vol. 4

17

9 8 7 6 5 4 3 2 1 0 Inches

Week 0

Week 1

bM: What are your future plans?

TR: We‘ll continue listening to consumers. They want to be more environmentally friendly but they need simple solutions. If they chose bottled water for refreshment and hydration because it fits their lifestyle and needs, especially versus high sugar beverages, the simple choice is to chose a brand whose bottle does not use depleting, non renewable resources and has multiple recovery options. Why choose an oil based bottle when there’s a better environmental option and, you’re getting great tasting water? There‘s no difference in cost to making that decision and consumers feel like they‘re doing something for their environment and for their children‘s future environment. They want to feel less guilty about drinking bottled water and Primo is that solution.

We‘ll keep looking for ways to bring environmentally friendly packaging to consumers while not sacrificing the

Week 2

Week 4

Week 8

convenience of bottled water and other beverages. And, we‘ll continue working with the industry on new, efficient and effective solutions to managing these new environmentally friendly materials, too. bM: Anything else you‘d like to add?

TR: Everyone needs to realize that we must make changes in how we package consumer goods, especially food products.

Some new packaging, using new innovative resins, might not be perfect today. But they also need to realize that there isn‘t any package today that is perfect either. Take little steps and be open to changes that are better for our environment today and tomorrow. We all need to be in this together. bM: Thank you very much, Mr. Ronan.

www.primowater.com www.upongreen.com

Natalia, adorning our cover-photo in this issue, says: “Bottles made from renewable resources - a good idea! I work with Corvaglia, one of the leading suppliers of caps and closures for the beverage industry. We are also evaluating the use of bio-based plastics for our products.”

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bioplastics MAGAZINE [04/09] Vol. 4

We balance it out. ...using the innovative technology of Uhde Inventa-Fischer

You live and work according to a certain philosophy – and so do we.

Uhde Inventa-Fischer has developed a perfect combination of giving the world innovating and sustainable technologies as well as making sure that investors profit through our knowledge.

We are a leading company undertaking plant engineering for polyesters and polyamides, and also for polylactide (PLA).

Uhde Inventa-Fischer GmbH Holzhauser Strasse 157–159 D-13509 Berlin Tel. +49 30 43 567 5 Fax +49 30 43 567 699 Uhde Inventa-Fischer AG Reichenauerstrasse CH-7013 Domat/Ems Tel. +41 81 632 63 11 Fax +41 81 632 74 03 www.uhde-inventa-fischer.com

Uhde Inventa-Fischer A company of ThyssenKrupp Technologies

Bottle Applications

Green at

T

he first decade of the 21st century has witnessed a steady growth and evolution in consumer interest in products with demonstrated ‘green‘ benefits.

This trend toward environmental responsibility has also influenced governmental policy-making in the United States. For example, at the U.S. Department of Agriculture, the BioPreferred Vendor program (bM 02/2006) gives preferential vendor status to those organizations and products which fulfill the requirements of the program. A good measure of the growth of the BioPreferred program was the recent GSA Expo 2009 in San Antonio, where over 8,000 government purchasing directors and agents met with BioPreferred and other government vendors.

The BioPreferred products were among the most popular and wellreceived items at the show.

Article contributed by Clark Driftmier, President of Fairhaven Strategy Group, Boulder, Colorado, USA

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bioplastics MAGAZINE [04/09] Vol. 4

Another positive development at the Federal level is the new ‘Green the Capitol‘ initiative which is a broad program to bring mainstream environmental responsibility to government, specifically to the U.S. Capitol building and the many offices of the House of Representatives.

Recycling stations have been placed everywhere. Café’s and food service venues serve bottled water in bio-packaging. There is even a composting program for food waste, bio-packaging and other compostables. This program, under the direction of Perry Plumart, is growing rapidly and will expand into other areas of Capitol operations over the next several years.

Bottle Applications

Naturally Iowa, a publicly-traded company from Clarinda, Iowa, USA is one innovative company taking advantage of these positive trends. Naturally Iowa was the world’s first beverage company to use PLA bio-packaging exclusively for its organic and natural dairy products (bM 02/2007). The company’s new Green BottleTM Spring Water, made with water that recently won the world bottled water tasting competition, is made with PLA bio-packaging (bM 06/2008).

Company founder and CEO Bill Horner, a farmer and agricultural entrepreneur, has been successful securing BioPreferred vendor status and subsequently gaining distribution with several governmental agencies, including USDA and the US Capitol. Green Bottle Spring Water is now the exclusive bottled water supplier to the ‘Green the Capitol‘ initiative, is served to Congressional representatives and staff in House offices, and can also be found in the commissaries at USDA headquarters in Washington DC. Green Bottle Spring Water was also featured recently at the GSA Expo 2009 and was the exclusive bottled water provider for the Expo.

Bill Horner sees several important initiatives as he builds the business for Green Bottle Spring Water. According to Horner, “Our business for Green Bottle Spring Water will grow as we expand into a greater number of venues where consumers are oriented in favor of environmentally responsible products that also have superior taste. It’s also important that disposal and ‘end of life’ issues are resolved, which for traditional PET packaging presents a major hurdle.

As many are aware, there is a significant backlash against PET or PC packaging, both for the disposal and waste issues and also due to increasing concerns about the potentially harmful health impacts of BPA (in the case of polycarbonate water bottles). Bio-packaging offers an excellent solution and is the environmentally responsible packaging for bottled water and many other products.” Horner continued, “Fortunately for us, the governmental agencies and food service providers that we have contacted have shown an understanding of these issues and a strong desire to create greener options for their agencies and staff.”

(Photo: iStock)

Bottles™ Capitol Hill “Governmental interest will continue to grow rapidly,” said Horner. “I believe that there will be a rapid acceleration of bio-plastics adoption by governmental agencies, and they will use the BioPreferred program to help demonstrate a positive commitment to environmental stewardship. As a result, this support will significantly reduce the use of petroleum-based plastics for foods and other products sold at these agencies. City governments will also adopt similar policies, as evidenced by the recent actions in San Francisco and other U.S. municipalities to restrict or even prohibit the use of PET bottles. There will also be an increased push in school systems, especially at the Primary level, to reduce or restrict the use of PET bottles for environmental reasons. The alternative, beverages and other foods using bio-plastics, will see greater acceptance and adoption by the food service providers who work with school systems and other institutions.”

Looking to the future, Horner was sanguine about the prospects for bio-packaging. “When I founded Naturally Iowa” said Horner, “the company based its mission on the benefits of bio-packaging and committed ourselves fully to environmental responsibility. Starting with our dairy products, and continuing with Green Bottle Spring Water, every product we have introduced has shown both the promise and the practicality of bio-packaging. Other companies have followed a similar path, and I’m very encouraged by what I now see in the stores, in food service and institutional sales. From bottled water to trash bags to shampoo to baby spinach, products with bio-plastic packaging are growing in both breadth and depth. The next five years will be a period of significant growth for our industry. We plan for Naturally Iowa and Green Bottle Spring Water to fully participate in this growth. We will continue to be a good partner in the promotion of bio-plastics as the best, most environmentallybeneficial way to package products.” www.naturallyiowa.com

Horner noted several important trends which will drive the growth in sales of products using bio-packaging.

bioplastics MAGAZINE [04/09] Vol. 4

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Bottle Applications

Extrusion Blow Moulding

By Michael Thielen

Fig 1: oval and round bottle made

by W. Müller, Troisdorf, Germany

B

esides films and bags, rigid packaging such as trays or clamshells, and bottles, are all part of the huge range of packaging applications where bioplastics are increasingly being used. However, when talking about bioplastic bottles most people immediately think of stretch blow moulded PLA bottles, which look very similar to PET bottles. The first bottles that appeared on the supermarket shelves in the early 1990s were however, extrusion blow moulded shampoo-bottles. Under the brand name Sanara the German company Wella marketed a shampoo that was packed in extrusion blow moulded PHBV (Biopol by ICI, see bM 02/2009). After market introduction in Japan in 1991 and the USA in 1995 these applications disappeared.

Since then I have seen an increasing number of bottle samples that have been extrusion blow moulded from different types of biopolymer. Having worked in the blow moulding industry for almost 15 years I am prepared to say that most of the bottles that came into my hands were of a rather poor quality in terms of rigidity, wall thickness distribution or surface appearance.

The most recent example that I found did however really attract my interest. This generic oval bottle (shampoo or ketchup style) was made from a mix of different grades of Bio-Flex® (PLA/Copolyester blend) developed by FKuR/ Fraunhofer UMSICHT in Germany. The bottles are not yet in the market for any commercial application, but I was impressed by their nice pearlescent, slightly glossy surface, their perfect wall thickness distribution - and the subjective rigidity that comes close to conventional HDPE bottles.

It all started when a sales manager from W. Müller GmbH of Troisdorf, Germany (a supplier of extruders, heads and auxiliaries for blow moulding machines) came across the BioFlex resins from FKuR. For test runs on W. Müller‘s own brand laboratory machine an existing ketchup bottle mould and a small round bottle mould were chosen.

In order to find the optimum grade for this kind of application, two types of BioFlex were blended in different ratios. Firstly, not all thermoplastic materials can be extrusion blow moulded - a certain melt strength is needed because the extruded tube-like parison needs to hang freely below the die-head of the blow moulding machine. However, even the softer grade BioFlex F 2110 could be processed into a parison and subsequently inflated into the mould to form a bottle. This bottle was, however, rather soft. So, in the next steps, BioFlex F 2110 was dry blended with the more rigid BioFlex F 6510. The most promising results were achieved with a mix of 80% BioFlex F 6510 and 20% BioFlex F 2110.

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Bottle Applications

of Bioplastics The W. Müller WMB 4-100 single station blow moulding machine is a shuttle type machine equipped with a continuous single parison head S1/60 (60mm max. die diameter). The 40mm extruder (L/D=25) was run with a standard PE-screw and a smooth barrel. “Basically the BioFlex resins can be processed on standard blow moulding equipment without any hardware modifications, “says Michael Lang, Laboratory Manager at W. Müller, “The only issue that needs attention is the temperature profile in the extruder and head,“ he adds. The temperatures were all in the range of 170-180°C. The final bottles are currently being tested in different longterm evaluations.

Company Joh. Sieben from Heinsberg, Germany blow moulded the square bottle shown in Fig 2. Mr. Karl Schütt, Technical Manager of Joh. Sieben told bioplastics MAGAZINE that even bottles made from 100% BioFlex F 6510 easily survived a droptest from a height of 1.5 m.

One well known challenge for BioFlex in this kind of application is its limited barrier against water vapour and (depending on the product to be filled) against other media such as oxygen or aromatic compounds. However, the production of a multilayer structure, for instance with a barrier layer embedded between an inner and outer layer of the base material, is technologically an easy task in extrusion blow moulding. And there are already a few biodegradable barrier materials available. Such materials are, for example, Nichigo-G (an amorphous vinyl alcohol, see page 30), PGA and others. Future experiments will be carried out to determine whether these resins are suitable for use in improving the barrier properties.

Even if today‘s bioplastic bottles are almost exclusively stretch blow moulded from PLA, extrusion blow moulding with its tremendous versatility with regard to possible shapes and freedom of design for hollow articles -­ not only for packaging applications - offers a huge potential for bioplastics applications.

Fig 2: Square Bottle made by Joh. Sieben, Heinsberg, Germany

Fig 3: Piggy bank blow moulded from 100% BioFlex F 6510 on a Kautex KEB 5 at Dr. Reinold Hagen Stiftung Bonn, Germany

In any case, most of the 120 customers at W. Müller‘s open house a few weeks ago were as impressed as I was when the BioFlex F bottles were presented for the first time to a broader public. In addition W. Müller showed a 3-layer bottle made from HDPE as the inner and outer layers and with a middle layer made from a starch based biopolymer by Cardia Bioplastics® of Australia. www.w-mueller-gmbh.de www.fkur.de

bioplastics MAGAZINE [04/09] Vol. 4

23

Bottle Applications

Using Near-Infrared

to Recycle

I

Article contributed by

n the last several years, new plastic bottles made from renewably resourced Ingeo™ (polylactic acid) PLA have entered the market. Brand-owner and retailer demand for such bottles continues to be strong, signifying society’s demand for more sustainable products and market development.

Tim Vanyo, Principal Applications Engineer, NatureWorks LLC Minnetonka, Minnesota, USA

Since Ingeo bottles look and feel similar to PET bottles, recyclers often assume that material identification between the two is difficult and have been concerned that appreciable contamination of PET with PLA may result.

In order to continue to introduce Ingeo biopolymer into the plastic bottle market in a responsible way, NatureWorks LLC and Primo Water Corp. conducted a commercial-scale bottle recycling evaluation to determine whether automated systems being used today in the recycling industry are capable of separating PLA bottles from PET bottles with good accuracy and efficiency. In this evaluation, near-infrared (NIR) equipment was used since it is a common sortation technology in large recycling operations and can accurately identify many different types of polymers.

Objectives The objective of the work was to determine whether plant made PLA materials can be effectively separated from the PET plastic bottle recycling stream and does not appreciably contaminate downstream recycled PET (rPET) extrusion processes. The test involved spiking in a known level of Primo’s PLA bottles into a PET deposit stream during the sortation process. That level was chosen so as to simulate market share significantly above today’s level. The field tests, held earlier this year at major recycling and rPET sheet extrusion facilities, were conducted under actual operating conditions. A TITECH near-infrared optical sorter already being run at the facility was used for the test.

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Set-up and calibrate NIR equipment for PLA bottle sortation.

Spike known amt. of PLA bottles into clear PET deposit bale during largescale run.

Determine sorting process efficiencies.

Make lab plaques and compare test flake to control flake after the washing process.

Complete largescale PET sheet run. Determine how spiked PLA level affects PET sheet quality.

Figure 1 - Process Flow for NIR Sortation Study using PLA Bottles

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Is PET sheet spiked with PLA sellable and accepted by market?

Bottle Applications

Sorting PLA Bottles The objectives of this work:  Determine whether NIR equipment now in the field is able to recognize PLA’s NIR signature and capable of sortation at commercial-scale production rates

Fig 2: Flake Samples (Left – rPET Control Flake; Right – rPET Test Flake)

 Process and evaluate using existing equipment under normal processing conditions  Determine sorting process efficiencies  Compare the clear rPET test flake (spiked with PLA bottles) with the clear rPET control flake in terms of haze and color in lab plaque samples  Validate the impact clear rPET test flake (spiked with PLA) has on commercial sheet quality (haze and color) and endproduct value (sellable or not).

Field test The process flow in figure 1 illustrates the steps carried out for this sortation study.

Tests were conducted on a commercial recycling line where a feedstock of PET bottles was being run at over 2,000 kg/hr.

For the test, Primo bottles, made with Ingeo biopolymer, were inserted into the PET stream at a volume assuming Primo were the fourth largest water brand in North America (a level significantly higher than Primo’s current market share). The spiking level was achieved by adding in a calculated number of Primo bottles matched to the measured throughput of the PET feedstock on the sorting line.

Current industry guideline suggests levels of more than 1,000 parts per million (ppm) of PLA in the PET post-sort stream would cause contamination. The amount of Primo bottles that entered the recycled PET stream after NIR sorting was measured at 453 ppm. The low amount of PLA in the recycled PET was due to high efficiency in sorting the PLA from PET using the NIR Titech sorter already in use at the facility.

The sorter was calibrated and fine-tuned by a technician for PLA recognition before the test run without any significant problems. The Titech NIR sorting efficiency test results are summarized in [Table 1].

Using the control and test rPET flake from the sorting tests, commercial sheet was made to determine how the spiked PLA material would affect PET sheet extrusion and product quality.

1.3 mm (0.021-0.022 inch) sheet was made on an existing

Parameter

Result

TITECH sorter effective width

40 inches

Type of sorting (for PET)

Positive

Bale spiking level

0.68 %

PLA spiking level in clear PET flake 0.75 % Total line throughput

2118 kg/hr

Removal efficiency

3%

Table 1: TITECH NIR Sorting Efficiency Results for PLA Bottles

bioplastics MAGAZINE [04/09] Vol. 4

25

Fig 3: Sheet samples: (Left Sample – Using rPET Control Flake; Middle & Right Samples – Using rPET Test Flake)

90

rPET control rPET test (w/ PLA) 50/50 blend

80 70

At the beginning of the run, sheet was made first using the rPET control flake (70% rPET control flake/30% virgin PET). Right after, and without stopping the extrusion process, sheet was then produced using the rPET test flake (70% rPET test flake/30% virgin PET representing a PLA bottle flake content of 317 ppm). Samples were taken over the course of the run (6 hrs.) for color and haze analysis.

CIELab, 10 degrees, D65

60 50 40 30 20 10 0 -10

commercial sheet extrusion line. The control and test rPET flake was dried normally at typical PET conditions and no drying problems were noted by the sheet manufacturer.

White-Black Scale

Green-Red Scale

Yellow-Blue Scale

Haziness

Table 2: 3mm Lab Plaque Color and Haze Comparison

In order to compare the commercial sheet samples an independent testing laboratory was engaged. Clean flake from both the rPET control and rPET test material was provided to Plastic Forming Enterprise (PFE) from the sheet manufacturer. PFE, a third-party plastics and recycling test lab, produced and analyzed 3 mm plaque samples made from the rPET control and test flake.

PFE’s analysis concluded there was no appreciable color or haze difference between the rPET control and rPET test plaque samples [Table 2]. Also, there was no appreciable color or haze difference throughout the 6 hour course of the commercial sheet run.

For all commercial intents, the rPET sheets were identical and both sold successfully in the end market.

Conclusion

Reflectance

PET

Nanomenters

Fig 4: Schematic of a typical NIR-Spectrum, PLA and PET peaks clearly distinguishable

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bioplastics MAGAZINE [04/09] Vol. 4

PLA

The study showed that PLA can automatically be sorted from PET using Near Infrared (NIR) technology down to very low levels. (only 453 ppm PLA bottles entered the recycling stream after NIR sorting). This amount does not result in any measurable effects for the recycled PET. These results compare favorably with TiTech’s NIR sorting claims of high purity (up to 98%) and efficiency (up to 95%) using their technology. The findings of this field test should help pave the way for further market development.

www.natureworksllc.com www.titech.com www.primowater.com

2nd PLA Bottle Conference

14-16 September 2009

within the Supporting Programme of

Munich, Germany | Holiday Inn City Centre

Organized by

PLA, a ‘green’ alternative for PET? PLA for hot-fill applications?

Barrier enhancement for PLA bottles?

End-of-Life Options for PLA bottles?

Automatic sorting of PLA / PET? Experiences from bottlers using PLA?

Want to hear more about these topics? All these subjects and many more such as labels and caps, additives and colorants, challenges and opportunities … are being openly discussed at the 2nd PLA Bottle Conference.

Visit

www.pla-bottle-conference.com

to see the programme and to register.

Bottle Applications

Photo Erema Engineering Recycling Maschinen und Anlagen Ges.m.b.H

NAPCOR Bans Degradable Additives

T

he (US) National Association for PET Container Resources (NAPCOR) recently urged restraint in the use of degradable additives in PET packaging. NAPCOR, the trade organization for the PET packaging industry, is concerned that no data has been made publicly available to substantiate or document: 1) the claims of degradability of PET resin products containing degradable additives; 2) the effect of degradable additives on the quality of the PET recycling stream; 3) the impacts of degradable additives on the products made from recycled PET; and 4) the true impact on the service life of these products.

“We urge manufacturers of PET resin and packaging to refrain from introductions of degradable additive−containing products until data is made available for review and verification so we can better understand these products and their potential ramifications,” said Tom Busard, NAPCOR’s Chairman.

In 2007, 1.4 billion pounds of PET post consumer containers were recycled in the United States. The post consumer recycled PET infrastructure depends on the quality of the recyclate and its suitability for a variety of next−life product applications. The value of recycled materials, such as PET, is an important economic driver for curbside recycling programs throughout the country.

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“Without the testing and data necessary to understand the potential impacts of degradable additives in PET, it’s not an overstatement to say that they could potentially put the whole PET recycling system at risk,” said NAPCOR Executive Director Dennis Sabourin. “We don’t yet understand the impacts that these additives could have on the quality of the PET recycling stream, let alone the impacts on the safety and functionality over time of next−use PET products like recycled−content PET packaging, carpeting, or strapping.”

NAPCOR calls for restraint: proper testing and verification must be conducted before degradable additives are introduced into the consumer product stream. Moreover, NAPCOR calls on brand owners and decision makers to fully consider the impacts behind the use of degradable additives in light of the larger issues of sustainability, climate change and resource conservation.

Founded in 1987, NAPCOR is the trade association for the PET plastic industry in the United States and Canada.

NAPCOR is committed to being the credible voice and champion of the PET industry; to facilitate solutions to PET recycling; and to provide education on the benefits of PET packaging. www.napcor.com

Materials

Stereocomplex PLA Offers High Durability Comparable to PET

T

eijin Limited from Osaka, Japan, announced that it has upgraded its BIOFRONT™ bioplastic with substantially improved resistance to hydrolytic degradation in hot and humid conditions, creating new opportunities for the plant-based material’s use in high-heat and high-humidity applications, such as automotive and electronics.

The new Biofront is at least 10 times more hydrolytic resistant than conventional commercial bioplastic, meaning that Teijin’s plant-derived bioplastic now offers virtually the same level of durability as polyethylene terephthalate (PET).

Biofront, which was first developed in 2006 and launched in the following year, is the world’s first mass-produced stereocomplex PLA, made with plant-based Poly-L-lacticacid polymer (conventional polylacticacid polymer) and their enantiomer poly-D-lacticacid polymer. This highly stable stereocomplex structure, based on Teijin’s polymer technology, has made possible the melting point that is over 40°C higher than that of poly-Llacticacid polymer, putting Biofront’s heat resistance on a par with oil-based polybutylene terephthalate (PBT). As with other bioplastics, however, its polymers were susceptible to hydrolytic degradation in hot or humid conditions, meaning that Biofront had limited applications in certain conditions compared to regular PET. In response, Teijin developed new technology to control reactions against high heat and humidity at the molecular level of polymers. The result is the nearly complete elimination of such reactions without any impact on Biofront’s intrinsic heat-resistance properties.

By proving levels of hydrolytic and hygrothermal resistance similar to engineering plastics such as PBT and PET, the new Biofront is now suitable for a much wider range of applications. In addition to offering increased durability in its existing capacity as a car seat fabric, the new Biofront can be used in components and materials exposed to harsh conditions in high-temperature or high-humidity environments

Pillar cover and front panel made of Biofront

This new technology will be one of the core technologies used in the production of Biofront at the medium-volume pilot production plant scheduled to be launched in early August at Teijin’s Matsuyama plant in Ehime Prefecture. Production is expected to be expanded thereafter, with the aim of positioning Biofront at the core of the Teijin Group’s ‘Green Chemistry’ business.

Teijin Limited recently announced that it had transferred its 50% ownership in NatureWorks LLC back to Cargill and terminated the joint-venture contract with Cargill regarding NatureWorks as of June 30. www.teijin.co.jp

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Materials

Biodegradable High Barrier for Packaging

S

oarus LLC from Arlington Heights, Illinois, USA recently introduced ‘Nichigo G-PolymerŽ’, a unique multi-functional barrier and water solution polymer developed by its parent company, Nippon Gohsei of Japan. Unique properties of Nichigo G-Polymer include: 1. Biodegradability 2. Water solubility at room temperature 3. Non-foaming when dissolved in water 4. Outstanding gas barrier (200-fold better oxygen barrier dry versus EVOH) 5. High clarity 6. Extrudability with wide melt temperature processing window 7. In water solution:

A. Chemical reactivity - receptive to crosslinking agents

B. Protective colloid for acrylic emulsions

C. Dispersing agent for inorganic materials

8. Polymer design flexibility to meet specific application needs Nichigo G-Polymer is a totally new high amorphous content vinyl alcohol resin where crystallinity can be tailored down to the point of total amorphous character.

Nichigo G-Polymer combines two typically traded-off functions; although it may be an amorphous resin, it also has crystalline-like functions. Such combination functions are evidenced by the excellent gas barrier properties and good chemical resistance of Nichigo G-Polymer similar to PVOH (polyvinyl alcohol) and EVOH (ethylene vinyl alcohol copolymer) resins, along with surprisingly excellent water solubility and far lower crystallinity.

Nichigo G-Polymer also has superior extrusion properties, orientability, shrinkability and

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transparency. It can be used in all extrusion processes. The resin is particularly suited for processes such as melt-spinning, oriented film, transparent containers, injection molding and more. Nichigo-G is biodegradable (as to Japanese Compostability test JS K690, similar to EN 14851.

Certification tests according to ASTM 6400 are in progress). Thus the resin lends itself to a variety of applications such as new packaging materials that are environmentally friendly.

Not only does it have excellent oxygen barrier but the highest level of hydrogen barrier. It therefore has potential use in household power fuel cell systems and fuel-cell powered cars, hydrogen gas stations, and the like.

Nichigo G-Polymer, when used in combination with other resins in applications such as bicomponent fibers, nonwoven fabrics, filters, polymer alloys, and multi-layer films, makes possible the development of high-strength, flexible, antistatic, and hydrophilic functional products.

Another unique characteristic of Nichigo GPolymer is water solubility. It dissolves very rapidly in water, even cold water. It has superior solubility characteristics, which include low foaming and good viscosity stability at low temperatures. Furthermore, its impact on the environment is minimal, being that it is biodegradable, it does not require antifoaming agent, and it results in increased operating and energy efficiency. This excellent water solubility property of the material paves the way for its use in applications such as water soluble films, fibers, and coatings.

Because Nichigo G-Polymer is a reactive vinyl alcohol polymer, chemical reactions such as acetalization, urethane formation, and others take place with ease, making possible functional products with extremely uniform quality and structure.

Materials

Article contributed by James D. Swager, Soarus LLC, MSI Technology Arlington Heights, Illinois, USA

Amorphous content

High Transparency High Solubility High Reactivity

High

Nichigo G-Polymer

Co

nv en

tio

na

lv

iny

la

lco h

ol

Low

re s

in

Hydrogen bonding strength

Strong

High Gas Barrier High Bonding Strength High Dispersability

Finally, Nichigo G-Polymer has the exceptional ability to improve the dispersion and stability of inorganic compounds in water systems. Therefore it has applicability as a sintered binder and coating agent for silica, aluminazol, and other inorganic compounds used in the manufacture of electronic parts and inkjet papers.

With all of these multi-functional, high performance characteristics, the new resin opens the door to a wide range of application development.

The initial grades in the G-Polymer product line have been established. Nippon Gohsei has set up a semi commercial facility at its Kumamoto plant (Uto City, Kumamoto JAPAN) for annual production of 300 tons in 2009. There are also commercial production facilities for 2000 tons per year, to be ready in 2009 at its Kumamoto and Mizushima (Kurashiki city, Okayama JAPAN) plants. Nippon Gohsei is also considering expanded production capability including USA production sites. www.soarus.com www.g-polymer.com

100

EVOH (44mol%) 10

OTR (cm³ 3µm/m² day atm)

Another valuable application is its use as a functional polymer protective colloid agent in emulsion polymerization of various acrylic emulsions. With Nichigo G-Polymer it is possible to manufacture emulsions with good stability and stable viscosity at low temperatures. This allows the creation of surfactant-free acrylic emulsions and emulsion powders, which until now have been difficult to achieve. The functionality of the polymer makes possible the crosslinking of films produced from such emulsions, as well as improves the adhesion properties to various polar substrates such as cellulose. Such acrylic emulsions and emulsion powders are already being manufactured and sold by Nippon Gohsei.

EVOH (29mol%) 1

Nichigo G-Polymer

0.1

PVOH

Temperature : 20°C 0.01

0

10

20

30

40

50

60

70

80

90

100

Relative humidity (%RH)

G/Polymer

<3 (Below measurable limit)

26

EVOH 29mol%

EVOH 44mol%

Test Temperature: Nichigo G-Polymers: 41°C EVOH: 41°C Nylon resin: room temperature

444

896

Nylon 66

Nylon 11

5597

0

1000

2000

3000

4000

5000

6000

H2 permeability (cm³ 20µm/m² day atm)

Hydrogen Gas Barrier Property

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Materials Article contributed by Andrea Springer, Fraunhofer UMSICHT, Business Unit Renewable Resources, Oberhausen, Germany

Polyamides Based on Biotechnological Succinic Acid

T

he Fraunhofer research group develops innovative biobased polymers.

The aim of one particular research group at Fraunhofer UMSICHT, funded by the German Agency for Renewable Resources (FNR), is the development of polymers based on renewable raw materials. The main targets of the project described in this article are polyesters and polyamides based on biotechnologically produced succinic acid.

Background Polyamides are high-value polymers. Thanks to their excellent thermal and mechanical properties they are mainly used in special applications. The focus of the research group is the synthesis of polyamide 44 from the monomers succinic acid and 1,4-diaminobutane.

high priced, special applications

The properties of polyamide 44 are expected to be similar to those of polyamide 46 which is already available on the market. Polyamide 46 is, as shown in fig. 1, a product in the mid price range which is primarily used in demanding applications.

For polyamide 44 equivalent uses and similar or higher prices are expected. Thus it appears that industrial production of PA 44 can be competitive.

From renewable raw material to the polymeric product Succinic acid is a dicarboxylic acid with a 4-carbon chain (fig 2). It is regarded as a favourable platform molecule in a sustainable chemical economy. Succinic acid can easily be produced from renewable resources by biotechnological

PEEK

PPS

mid priced, technical applications

volume

price

PTFE

Figure 2: Chemical Structure of Succinic Acid (C4H6O4)

PA 46 PA 66

low priced, commodity

PA 6

PBT

PET PP

PS

requirements

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Figure 1: Price ranges, production volumes and requirements of polymers

Materials Renewable resources Solvents Fermentation

THF g-Butyrolactone Dialkylsuccinates Polyester 44 Monomers

Platform

1,4-Diaminobutane 1,4-Butanediol

Succinic acid Intermediates

Polyamide 44

Succinic acid anhydride Succinodintrile

Figure 3: From renewable raw materials to industrial end products

synthesis, and there are different chemical pathways for the derivation of other important chemicals (see fig. 3) such as solvents, intermediates or monomers for the production of technical polymers.

Presently, succinic acid is produced by a chemical process starting from crude oil via maleic acid anhydride. White biotechnology offers a good alternative to this petrochemical pathway. Succinic acid as an intermediate of the citric acid cycle and one of the end products of anaerobic metabolism can easily be produced via biotechnological processes.

In the literature Anaerobiospirillum succiniciproducens, Actinobacillus succinogenes and Mannheimia succiniciproducens MBEL55E are mentioned as natural overproducers and potential candidates for industrial scale biotechnological succinic acid production. Handicaps of these micro-organisms are the expensive media, their slow growth and the low space/time yields. Worldwide research groups working on this subject pursue different ways to become competitive with the petrochemical route - mainly cost and yield optimisation as well as genetic modification of the micro-organisms.

On account of the observable market fluctuations concerning volumes and prices the process under development needs to be operable with different renewable raw materials. Furthermore, cost reduction and yield increase by optimisation of the fermentation medium is being investigated. After the fermentative production downstream processes purify the succinic acid for the following steps: ‘chemical conversion‘ and ‘polymerisation‘.

Chemical reactions convert succinic acid into technically relevant platform chemicals and into the monomers for polycondensation. The development of the synthesis routes takes into account the use of already existing petrochemical plants, so that no large investments are needed.

Together with the products from its chemical conversion, especially 1,4-diaminobutane and 1,4-butandiole, succinic acid is used in polycondensation reactions leading to polyesters and polyamides. Their properties can be adapted according to market needs by copolymerisation. The overall process plant design should be suitable for large scale production.

Expected properties and possible applications The expected properties of polyamide 44 will be similar to those of existing polyamides, which are characterised by good strength together with a high degree of hardness and stiffness. Furthermore, high abrasion resistance and dimensional stability are typical for polyamides.

Estimates of the physical data of PA 44 can be extrapolated from those of polyamide 66 and PA 46. PA 44 will be characterised by an extremely high melting point and a very high crystallinity, but also by high moisture absorption.

These qualities lead to the following three possible product groups:  Thermally and/or mechanically high resistant parts (preferably in water-free surroundings), for example oil-immersed gearbox or pump parts and other engine compartment units, soldering electrically resistant boxes and electronic components  Tear-proof fibres with high water absorption, e. g. for outdoor wear or textile adhesives  Hydrophilic and strong polymer membranes, e. g. for the use in filter technology www.umsicht.fraunhofer.de

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Materials

PSM –The Renewing of a Brand Article contributed

by Daniel Tein, VP of North American Sales, PSM North America, Warrenville, Illinois

A

s the world of bioplastics becomes more and more a mainstream industry, it seems it is also destined to become more and more confusing. Everything from inadvertent greenwashing to intentional misrepresentation is now commonplace in the eco-movement of bio-materials.

Unfortunately, PSM (plastarch material) from PSM (HK) Co. Ltd in Hong Kong is not exempt from such treatment. PSM’s claim to fame is its large percentage of starch content. This allows it to maximize the heat stability of the finished product. There are few, if any, bioplastics available today that can really match up to PSM’s heat tolerance. This makes PSM, which uses only non-GMO (non-genetically modified) starch sources, a very appealing material for a wide swath of applications. As a material, PSM is ASTM D6400-04 compliant up to a full 2.5mm of thickness, has a melting point of 156°C, and softening point around 127°C. Despite its success, or perhaps due to it, there has been quite a few instances of counterfeit PSM, both in resin form, and in finished products. PSM is currently manufactured in China with plans to expand production globally.

Coincidentally, much of the counterfeit products in question originate from China and Southeast Asia. Other companies have been producing and selling ‘PSM‘ resin, only to have the finished product become moldy within weeks.

Counterfeit products in certain niche markets have become out-of-hand. For example, nearly 90% of the starch cutlery sold in the USA is made from plastic blended PSM. PSM North America have started stating, ‘if you didn’t buy it from us or a source authorized by us, assume it’s not PSM’.

Despite these unfortunate distractions, PSM is looking forward to improving the material for use in more applications. Previously, PSM was limited heavily to thermoforming and injection molding applications. Recent engineering breakthroughs now allow PSM to be used in extrusion blow molding, injection blow molding, as well as blown film applications. Foaming applications currently are still limited to packaging void fill. Commercialized PSM applications vary widely from foodservice and green construction materials to packaging and consumer goods. PSM does not intend to stop there. It is planned to introduce PSM for use in foam extrusion and coating applications.

When asked how a manufacturer using Polypropylene could make an immediate ecological impact with their products, the answer is easy: “PSM is incredibly compatible with PP such that a dry mix is all that is needed; there is no need to re-pelletize or compound. Even if a relatively small percentage of PSM is blended with PP, this can be a first step towards eco-friendliness without impacting product performance or base cost. By mixing with plastics, plastics processors can immediately have a partly biobased component to their offerings, however – not biodegradable – of course. This allows the producer to tell a sustainable/renewable story. For a compostable compliant product, PSM should be used as a 100% standalone material.” www.psmna.com

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In the second, extended edition of the Business Directory for Innovative Biomaterials (BIB 2010) companies in the field of biomaterials are invited to place their innovative products and services. Through the business directory, which is sent with a circulation figure of at least 5,000 copies and as a PDF free of charge to biomaterial decision makers in industries and science, potential customers and matching suppliers can easily get in touch.

Already the successfully launched BIB'09 provided for the first time an overview over the entire market for the new biomaterials. The 116 pages long book presents 50 companies and actors from six countries. 90% of its print edition have been distributed by now. Our advertisers are greatly satisfied with the market response. Free download on http://www.biowerkstoff.info Information and contact In our understanding, biomaterials comprise materials, which contain at least 20% renewable raw materials. Among these count bio-degradable and durable bioplastics, innovative derived timber products like Wood-Plastic-Composites (WPC) or thermally modified timber as well as natural fibre reinforced plastics. In the centre of attention are manufacturers and suppliers of biomaterials and products made of biomaterials as well as raw material suppliers, mechanical engineering companies, associations and research institutes operating in the wide field of biomaterials.

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nova-Institut GmbH | Chemiepark Knapsack | Industriestrasse | 50354 Huerth | Germany | contact@nova-institut.de | www.nova-institut.de/nr

Non Food

Algae to T Plastics Article contributed by Ross O. Youngs Chief Executive Officer Univenture, Inc. Marysville, Ohio, USA

he newly formed company Algaeventure Systems is the latest quest of Univenture, Marysville, Ohio, USA, a media packaging company with a twenty-year history of innovation and packaging. The challenge began as Univenture sought bio-based feedstocks as a material option for its products. An exhaustive analysis was conducted on a wide range of bio-based materials throughout the world. Besides criteria such as product performance, material availability, potential supply chain or logistical issues, one aspect remained consistently important material costs.

One of Algaeventure Systems’ studies included a comparative analysis of yield per acre of the primary bio-based sources. Here was found that algae are capable of doubling its biomass in as little as two hours. In addition, algae produce fifty percent of the world’s O2 while accounting for only 1% of the world’s biomass. The extraordinary yield results motivated a deeper study of algae.

As Algaeventure Systems have discovered, algae can be grown most effectively and economically when co-located for capital and operational savings. Collocation examples would be coal-fired power plants, wastewater treatment plants, food manufacturing facilities or animal waste facilities. Nutrients are provided by these sources for the growth of the algae as well as waste heat to maintain the proper water temperature for optimal algae growth.

... growing algae ...

Algae contain lipids or hydrocarbons that can range from C10 to higher than C50 that can provide the raw material for refining to bio-diesel. When enough lipids are obtained from within the algae cell it is possible to hydrocrack that oil. Thus precursors to polymer molecules can be obtained, which in further polymerization steps can be processed into plastics. Essentially any product today that is made based on petroleum could in the foreseeable future be replaced with algae.

As algae grow naturally or in a system, such as Algaeventure Systems‘ Rapid Algae Farming (RAF) system, CO2 is used to make the biomass while oxygen is released. If algae growth systems are co-located with a coal-fired power plant for example, the CO2 from the facility can be fed as nutrients to the algae. When the carbon from the algae is used for making plastic, the carbon becomes sequestered in an eco-friendly bio-plastic.

Algaeventure Systems (AVS) developed the Harvesting, Dewatering Drying technology (AVS HDD) - a system designed to emulate nature. The AVS HDD system utilizes very little energy and makes the economic viability of algae as a petroleum source foreseeable in the near future. The energy costs before the AVS HDD technology was $875 per ton to remove the water from algae.

The energy costs with the AVS HDD is $1.92 per ton. With the most significant cost barrier behind them, Algaeventure Systems can now explore the limitless opportunities that algae can bring.

Algaeventure Systems is actively innovating technologies to help make algae a viable bio-based renewable resource for plastics and other products. www.algaevs.com

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Hungry for sustainable, durable bioplastics?

Article contributed by Michèl Verdaas Product Manager Solanyl Bioplastic Rodenburg Biopolymers B.V. Oosterhout, The Netherlands

Non Food

Article contributed by Michèl Verdaas, Product Manager Solanyl Bioplastic, Rodenburg Biopolymers B.V., Oosterhout, The Netherlands

A

s experienced during the food crisis of 2008, renewable technologies have a strong impact on the way agricultural land and irrigation water is used. Or at least, that clearly is the public perception nowadays. One solution to avoid the ‘food vs. renewable raw materials‘ discussion is to use alternative raw material streams instead of ‘food grade crops”. As inventors and producers of the bioplastic Solanyl, Rodenburg Biopolymers has been confronted with the mentioned public perception as well. We spend quite some time to explain our customers and their end customers that our product is not based on raw material that could have been food and that this material is indeed GMO-free.

The starch used in our production process solely originates from the potato-processing industry as a byproduct stream. Traditionally, the several by-product streams are used for live stock feed, but in Holland there is an abundance of such by-products. The type of by-product used for Solanyl amounts at least 100 tonnes/year just in Holland. Already in 1998 Rodenburg identified this stream as a high potential material for starch-plastics.

As one may expect, this stream as is, needs further treatment before it can be used as raw material for starch-plastic. The technology to do so, including the conversion into TPS, obviously is Rodenburg’s ‘CocaCola secret‘. The resulting starch-plastic is fully biodegradable and certified compostable (EN 13432) up to 1.7 mm thickness. The material is engineered for injection moulding and over time Rodenburg gained experience to deliver a wide range of grades that will meet many demands. Research has always been an important part of Rodenburg’s activities and at the moment efforts are focused on the next generation Solanyl to add thermoforming and blow-moulding as processing technologies.

Rodenburg has a fully owned subsidiary in Brazil and a joint venture in Canada, called Solanyl Biopolymers Inc. Partly through the efforts of Solanyl Biopolymers inc. the Clean Air Tree Kit™ (www.wcafi.org) has been developed. The package in the shape of a globe is based on Solanyl combined with PLA shrink wrap film. Another application is the ‘Greenbadge’. This is a name badge for fairs and events to which you can attach your business card (www.greenbadge.be). These, and other applications such as brooms for street cleaning, a storage box, frisbees, a piggy bank, and a brochure holder can be seen in the picture.

Rodenburg’s philosophy to use a by-product stream is a conscious one and this approach can also be applied to other agricultural waste streams. Therefore Rodenburg thinks that the next generation of bioplastics should focus more than ever on the raw material side of the production chain. By carefully choosing components we can prevent an unjustified public blemish on the green products the bioplastics industry is creating nowadays. www.biopolymers.nl

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Applications

Bioplastics from Walkman to Ultra-Slim OLED TVs

S

ony uses annually around 1.4 million tons of various materials such as plastics, metals, papers, etc., worldwide. In order to contribute to the creation of a sustainable society, Sony promotes the use of materials made from renewable resources. One typical renewable material is bioplastics made, from biomass resources.

Sony has, since 2000, been continuously increasing the use of bioplastics in its electronics products. At this point in time, Sony has applied the use of bioplastics to twenty parts in over ten products, including WalkmanÂŽ casings and the accessory cap of digital SLR cameras. Not only is the application of bioplastics environmentally friendly, it is also beneficial in hedging the price risk of fossil-based plastics, because such prices are expected to go up in the long term.

Thus products with bioplastics pose an attractive offering to customers.

Bio-polyamide for Ultra-slim TV Sony recently applied bio-polyamide and its blend to some parts of the Ultra-slim OLED (Organic Light Emitting Diode) television, XEL-1, manufactured for the European region.

Polyamide 11 is applied in the use of the terminal cover on the back of the television, and ABS/ polyamide 11 blend is used in the bottom casing and in the battery cover of the remote controller. This is the worldâ&#x20AC;&#x2122;s first application of high performance bioplastics for use in a television set.

In applying ABS/polyamide 11 for the remote controller reuse of existing mould tools originally designed for ABS was a prerequisite. Re-use of tools is one of the effective measures

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in consumer electronics to save manufacturing costs. It requires high precision to manufacture electronics products, thus the mould shrinkage had to be strictly controlled. For this reason, ABS/polyamide blend, which has a similar shrinkage ratio and mouldability to ABS, was adopted.

In applying ABS/polyamide 11 for the product casings, good surface appearance of the moulding was required.

Flash, flow marks, or sink marks were not permissible. With conventional plastics such as ABS it is comparatively easy to achieve good appearance, because they have a relatively wide range of moulding conditions, and moulders have sufficient experience to handle them. However, the biopolyamide exhibited completely different flow properties, so mould tests had to be carried out a number of times before finally identifying the optimum moulding conditions.

PLA sheet for contactless IC card Sony also applied bioplastic to contactless IC cards. The contactless IC cards are now widespread as e-money or security cards and employ Sony FeliCa contactless smart card technology. Highly secure and tamper-resistant, FeliCa cards also support speedy data transfer. Card data can be rewritten, so that cards can be used for a long period of time. The card consists of a printed circuit board with IC chip, antenna inside and plastic lamination sheets on both sides. Sony themselves developed the PLA-based lamination sheets. This new bioplastic IC card has been adopted as a student and faculty ID card by Shohoku College in Kanagawa, Japan.

Applications Characteristics of bioplastic application in Sony In general, the main applications of bioplastics are in non-durable goods such as packaging, but Sony aims to further develop its applications in durable goods since the company uses significantly more plastic in electronics products. Thus the durability of the material is an important requirement. However, compostability of the material is not a priority, because in many countries electronics products are required by law to be recycled. Additionally, compostability sometimes conflicts with durability, and in this case, the products are designed to prioritize durability rather than compostability.

In consumer electronics, ABS, PC and PC/ABS blends are mainly used, thus bioplastics are required to satisfy the same level of physical properties as these plastics. Regarding content ratio of biomaterials, blends of bioplastics and conventional plastics are permissible, because the main objective in using bioplastics is to reduce the use of fossil-based materials by using renewable materials. Thus polymers from bio-based monomers and fossil-based monomers are also allowable.

Conclusion Applying new materials to products requires various technologies. It needs not only polymer technology, but also compounding, moulding, design, and material evaluation technology. Thus close collaboration with suppliers to aggregate the technologies and accelerate commercialization is extremely important.

Article contributed by Yuko Fujihira, Researcher, and Hiroyuki Mori, Senior eco-products producer Sony Corporation, Tokyo, Japan

Sonyâ&#x20AC;&#x2DC;s product category is very wide, including consumer electronics, games, and non-consumer electronics and devices. Each product has its own requirements with regard to material properties, such as heat resistance, shock resistance, flame resistance, stiffness, durability, and printability. No bioplastic can satisfy all requirements, thus it is expected that many kinds of bioplastics and material combinations will be introduced in the market. By applying significantly more bioplastics to products, Sony are doing their best to contribute to the creation of a sustainable society. www.sony.com

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Application News

Water Inc. Introduces PLA Shrink Labels Printpack Inc., Atlanta, Georgia, USA, is printing and converting Earthfirst® PLA shrink film labels for Body Glove Water Filtration Systems, manufactured by 3M and distributed by Water, Inc.. The label is part of Water Inc’s commitment to producing sustainable packaging.

The Body Glove water filters are the latest addition to the ECO products for eco-friendly consumers. The package was designed to build the product line with as many environmental considerations as possible. Cartridges, tapered in design, make a paper label difficult to fully wrap around the recyclable filter housing, therefore, the printed full sleeve shrink label was the ideal label since it conforms to the shape of each cartridge. Each label covers the entire filter from top to bottom and has a 360-degree image area with room for a complex graphic design that sets it apart from the rest of the water filter industry. The PLA film shrinks quickly requiring less heat. This label allows the consumer to understand what the water filter will do for them and the environment. www.printpack.com

PLA Desktop Accessories Mako Plastics Ltd., Vaughan, Ontario, Canada noticed a lack of true variety and style in desk top accessories offerings and very little sensitivity to the environment. Up until recently, most manufacturing gave only secondary attention to the eco-market and offered recycled plastic products as a means to lower production costs not to conserve the environment.

Thus Mako decided to start creating and manufacturing its own unique line of desk top accessories, now offered under the brand name ‘Carta‘.

All Mako Collection Carta products are made of Ingeo™ PLA material by NatureWorks.

Jeff Lloyd, National Sales Manager of Mako Plastics: “Our strategy is to focus 100% of our efforts on the market for eco-friendly manufacturing and product development. By focusing all of our efforts and energy on this particular niche, we expect to quickly develop and maintain a leadership position. We believe that our singular focus will give us significant advantages.“ Mako continues to develop and introduce new Carta products helping consumers make smart choices, work better while enjoying our unique style. www.makocollection.com

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bioplastics MAGAZINE [04/09] Vol. 4

Application News

SunChips PLA Snack Bag SunChips, Frito-Lay’s popular line of multigrain snacks, announced in April in Plano, Texas, USA, that in 2010 it will introduce the first fully compostable snack chip bag made from plantbased materials. The change is designed to significantly improve the environmental impact of its packaging.

Recently, the SunChips brand took the first step towards this transformational packaging. The outer layer of packaging on 10 ½ oz size SunChips snacks bags is made from PLA. By Earth Day 2010, PepsiCo‘s Frito-Lay North America division plans to rollout a package for its SunChips snacks where all layers are made from PLA material so the package is 100% compostable.

“We know environmentally-friendly packaging is a priority for our SunChips consumer,” said Gannon Jones, vice president, marketing, Frito-Lay North America. “(The) launch of packaging made with 1/3 renewable materials is an important first step towards having a fully compostable chip bag in market by Earth Day 2010.”

This packaging innovation is line with the commitment

by PepsiCo, Frito-Lay’s parent, to reduce the company‘s impact on the environment through water, energy and packaging initiatives. www.fritolay.com

Gucci Shoes With a Heel Made From Liquid Wood The shoes designed by Sergio Rossi, a subsidiary of the Gucci group, are made from renewable resources.

The heel is made from a liquid wood that was developed

by Fraunhofer researchers in collaboration with their colleagues at the Fraunhofer spin-off Tecnaro GmbH. The days are gone when one could recognise at once shoes produced by ‘green’ and ecologically friendly methods. The new shoe by Sergio Rossi/Gucci, the ‘EcoPump’, has an elegant and rather attractive look about it, but it also has an additional plus point: it is made from renewable resources. The heel is made from a liquid wood. Researchers at the Fraunhofer Institute for Chemical Technology (ICT) in Pfinztal and Tecnaro GmbH, a Fraunhofer spin-off business, jointly developed the material, known as ARBOFORM®.

But what are we supposed to understand by the term ‘liquid wood’?

“For paper manufacturing the pulp and cellulose industry separate wood into its three main components - lignin, cellulose and hemicellulose“, explains Emilia Regina Inone-Kauffmann, team leader at the ICT. “The lignin is however not used in the production of paper. Our colleagues mix the lignin with fine natural fibres from wood, hemp or flax, and natural additives such as wax.

They use this to produce plastic granules that can be melted and injection moulded“.

There are already several products being made from this bio-plastic material, such as car parts, figures for Christmas cribs, loudspeaker cases and urns. “For the shoe we had to make some technical modifications to the material in order that the heel will stand up to the loading to which it is submitted,“ says Jürgen Pfitzer, managing partner of Tecnaro GmbH. “We managed to do that by making a slight change to the composition“.

Photos: Business Wire

www.ict.fraunhofer.de www.tecnaro.de

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bioplastics MAGAZINE [04/09] Vol. 4

World Fair for Beverage and Liquid Food Technology

Photo: iStock [m]

www.plastekcards.com

drinktec

Biodegradable Plastic Cards

Go with the flow.

The PLA corn cards are a new family of Plastek Card‘s eco-friendly biodegradable plastic cards. They are manufactured from polylactic acid (PLA). Corn cards look and feel just like the PVC cards, and in addition to the environmental advantages of PLA the durability, life span and printing of the PLA corn cards are all very similar to PVC plastic cards.

wob München

Plastek Cards, headquartered in Dublin, Ohio, USA, is proud to introduce biodegradable plastic cards. One of three new plastic cards is made from PLA. “We are very pleased to add these new eco-friendly biodegradable plastic cards to our product line,“ said Peter Tung, Director of Plastek Cards. “We hope to do our part in reducing waste and helping protect the global environment.“

Tamper Evident Products from Clarifoil Clarifoil, the makers of cellulose acetate films for labels, seals, carton windows and lamination, have published a free brochure and samples of their growing range of Integuard tamper evident labels and seals. Integuard tamper evident film has been specially engineered to retain tensile strength necessary for automatic processing but fragment if removal is attempted for instance in store, enabling store staff to tell at a glance if the pack is intact.

Effective tamper evidence is desirable in all sectors such as pharmaceuticals, perfume, cosmetics and high end food and drink products, all areas where Clarifoil special-effect films are widely used for pack enhancement. Another area of application is high priced electrical goods, as in mobile phones or MP3 players.

Clarifoil Marketing Manager Marion Bauer said: “Tamper evidence continues to concern manufacturers and retailers and we want to provide packaging and label designers and producers with up to date information about Integuard and its uses. They can use the samples provided to test their own products”. www.clarifoil.com

Buy your ticket online! www.drinktec.com

14–19 September 2009 New Munich Trade Fair Centre Information Tel. (+49 89) 9 49-1 13 18 . Fax (+49 89) 9 49-1 13 19 info@drinktec.com bioplastics MAGAZINE [04/09] Vol. 4

43

Testing

Novel Device For Aerobic Biodegradability Testing

M

ore and more resources are being invested by industry in the field of biodegradable packaging. But just how biodegradable are these products? Have all of them really been tested or is â&#x20AC;&#x2DC;biodegradableâ&#x20AC;&#x2DC; just a marketing argument?

Wetlands Biosciences has developed a reproducible and cost effective test for the biodegradability of plastic materials. It is able to function with a high degree of autonomy, that limits labour costs and has a high degree of scientific accuracy through auto-calibration and continuous validation. The device can be used both by research centres and testing and certification laboratories.

Incubator

Aerobic biodegradability of polymers can be examined by the method described in ISO standard 14855-1. In this procedure pieces of the test material of a defined size (2x2 cm) are mixed with mature municipal compost and incubated at 58°C for up to 6 months. The biodegradability of the material is assessed by comparing the amount of CO2 produced by the mixture with the theoretical maximum evolution of CO2 from the test material, corrected for the evolution from the compost itself and the organic and inorganic matter remaining.

Method

Average cumulated grammes of CO2 by test

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bioplastics MAGAZINE [04/09] Vol. 4

A group of three 3-litre glass vessels with airtight lids and one inlet and outlet were used per experimental sample. The first group of three, the positive control group, contained 46 g of microfibrous cellulose (Sigma-Aldrich) in 400 g of compost.

The second group contained 46 g of polylactic acid (PLA), cut into pieces measuring 2x2 cm, in 400 g of compost. The last group, the blank sample, contained only 400 g of compost. At the start of the experiment all mixtures were humidified to the extent that manual squeezing of the compost produced a small amount of fluid. Vessels were aerated from the bottom by a diffuser and were made independent by virtue of the use of a separate pressure regulator for each individual vessel.

Aeration flow was set individually for each vessel with a high

Article contributed by Rob Onderwater, Christian-Marie Bols and CĂŠline Dubois Wetlands Biosciences SA, Louvain-la-Neuve, Belgium

Bioreactors

precision manual valve. During the experiment the humidity of the compost was kept at around 50%, and the oxygen concentration was maintained above a minimum of 6% by regulating the flow of aeration. The compost was regularly mixed to ensure maximal homogeneity and minimize the formation of preferential routes for the aeration.

Results For all vessels the initial aeration flow rate was set at 0.5 litres/min. The vessels in the positive control group with cellulose started to produce significantly more CO2 than the blank sample group after 4 days. In order for the carbon dioxide concentration to be within range of the sensor, the flow rate was increased in the positive control group to 0.6 litres/min after 5 days, but was decreased again to 0.5 litres/min after 7 days. The vessels in the experimental group with PLA only started to produce significantly more carbon dioxide than the control group after 15, 28 and 32 days respectively. Initially carbon dioxide production in the PLA sample group was slightly inhibited as compared to the control group which resulted in a difference in cumulative production of carbon dioxide only being evident after 26, 36 and 42 days respectively. Carbon dioxide production in the blank sample group remained very stable throughout the experiment with a small difference between the vessels. In the blank sample group 1.75 +/- 0.35 g of CO2 was produced in the first 10 days. In the positive control group 70.3 +/- 1.72 g of CO2 was produced after 108 days (2.5% variability).

Observations Positive control (Cellulose): At the beginning of the experiment an intense activity was observed, evidenced by the strong CO2 increase. This phase is facilitated by the fact that the cellulose was added in the form of powder. After this phase, a strong, but stable activity remains before reaching a plateau phase due to the depletion of cellulose.

PLA: The PLA was in the form of film in 2x2 cm pieces and not in the form of powder or in crushed form. The advantage

of using the PLA in this way is that it was possible to observe its degradation visually. The launching phase is slower than in the positive control sample, this can be explained by the difficulty of the micro-organisms in degrading the PLA presented in this form. According to literature, the first phase of mineralization comes from the degradation of short chains which are immediately available to the micro-organisms.

This was noted by the PLA pieces becoming firstly opaque and the subsequent formation of blisters on the material.

The remaining fragments of highly crystalline PLA are much more resistant to degradation. Therefore, after a period of weak mineralization, which is relatively long, an increase in CO2 evolution and progressive fragmentation of the material was noted.

Blank: The CO2 release comes only from the internal activity of the already matured starting compost without addition of degradable material. A weak and stable release of carbon dioxide is thus observed over the experimental period.

NB: Each agitation and re-humidification of the bioreactors excited the activity of the micro-organisms temporarily, which resulted in a spike in CO2 production.

Conclusions The newly developed device was shown to function autonomously over an extended experimental period with limited intervention required (periodic agitation and humidification). Sensor integrities were maintained throughout the period and validation values remained OK. Values measured showed a high degree of accuracy, and little variability was observed among the vessels of the positive controls and among the vessels of the blanks. Variability among the vessels of the clearly highly biodegradable PLA was shown to be primarily due to the onset of mineralization. www.umic-science.com

bioplastics MAGAZINE [04/09] Vol. 4

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Basics

Land Use for Bioplastics Article contributed by Michael Carus and Stephan Piotrowski, nova-Institut GmbH, HĂźrth, Germany

T

here is an ongoing public, political and industrial debate, with wide-reaching implications, on the competition between food, animal feeds and industrial markets for agricultural raw materials. This has created a lot of confusion and insecurity within the bioplastics industry. The German automotive industry in particular has decided not to use bioplastics based on potential foodstuffs such as sugar, starch or edible oil. This article offers some basic facts for this debate, which will be back on the agenda as soon as the world economy recovers and food prices rise again. The bioplastics industry should be well prepared for this debate.

Should we use food crops for bioplastics when people are starving?

This question is really misleading. People have been using agricultural raw materials for energy and materials as long as mankind has been on the earth. It is quite common to use agricultural feedstock for biomaterials and this has been done on a large scale for decades.

The additional impact of bioplastics is extremely small.

The reason for hunger is not a shortage of land for food or animal feed production. We have more than enough space to produce sufficient food to feed everybody. And we are producing the food already. The main reasons for hunger are distribution, logistics and financial resources.

Or in other words, mankind is producing enough food and there are still huge areas free or unused. These areas can be used for energy and industrial raw material production without any harm, without any impact on food and animal feed production. Using these areas for energy and industrial materials will provide additional income to many farmers, who will be able to buy food for their families. After all, three out of four poor people in developing countries live in rural areas.

Deciding which crops are cultivated for fuel or industrial use on free agricultural areas should only be questions of efficiency, economy, ecology, sustainability etc. â&#x20AC;&#x201C; but not a question of whether this crop could be also used as food or animal feed. This is the wrong question.

Very often food crops are the most efficient industrial crops too, because they have been optimised by selective breeding over the last 50 years. Using less efficient, non-food crops for fuel or industrial materials would mean the inefficient use of farmland.

There is no real reason not to use food crops to produce fuel or industrial materials, especially if they are the most efficient crops for these applications.

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Basics

100

Residential area; road and rail (ca. 3%)

1.500 Available rainfed arable land (cropland)

Cropland today

“Free” agricultural area in 2006

Fig 1: ‘Free’ potential agricultural area in 2006 and the global demand for agricultural land in 2020

800

Potential forest land

3.300

570

570

in Mio. ha

Source FAO 2008, OECD 2007, OECD-FAO 2007, FAPRI 2007, nova 2007, FAO 2000

330

Protected area (ca. 10%)

The global demand on land in 2020:

year 2006

year 2020

1. Increasing demand of food per capita due to an

increase in purchasing power (more meat, ...)

ca. 96 Mio. ha

2. Increasing demand of food due to population growth

ca. 64 Mio. ha

3. Residential area, road and rail

ca. 32 Mio. ha

4. Biofuel in the most important Biofuel countries

ca. 18 Mio. ha ∑ 210 Mio. ha

Availability and use of arable land There are 3,300 million hectares of naturally irrigated potential arable land available on this planet. They are used for crop cultivation (1,500 million hectares), residential areas, road and rail (100 million hectares), protected areas (330 million hectares) and potential forest land (800 million hectares), so there are still 570 million hectares left. Those areas are in Russia, Kazakhstan, Africa and South America – often far away from any agricultural infrastructure. Until 2020 further huge areas will be put into production for crops, but still 360 million hectares are expected to remain ‘free‘ for other agricultural uses (see Figure 1). To activate this potential, huge investments and reform in rural areas will be necessary.

Even in the European Union about 8 million hectares are free and could be used for bioenergy or biomaterials. Most of this land is located in the new member states in Eastern Europe.

Even more important than activating new agricultural areas is to increase productivity on areas already in use.

Modern agricultural processing can increase the productivity up to ten times compared to traditional farming. Even in the European Union there is still much scope for productivity increases. In Romania, for example, yields for most crops are less than 50% of the corresponding yields in the EU-15, despite good quality soils.

As the OECD and FAO state: “Finally, over the longer term, agricultural supply is facing increased uncertainties and limitations on the amount of new land that can be taken into cultivation. Public and private investments in innovation and increasing agricultural productivity, particularly in developing countries, would greatly improve supply prospects by helping

to broaden the production base and lessen the chance of recurring commodity price spikes” [1] In July 2009 the world leaders pledged to commit $20 billion over three years for a ‘food security initiative‘ to develop sustainable agriculture in poor countries. Addressing the G8, FAO Director-General Jacques Diouf said, “I am convinced that you will ‘walk the talk’ not only for natural ethical considerations but also for sound economic reasons and, last but not least, to ensure peace and security in the world” [2]. This commitment will trigger further investment in agriculture and will ease the supply situation.

Some facts about biofuels and bioplastics From a mass flow perspective, the amount of raw materials used for the production of bioplastics is very small compared to the amount of raw materials used for biofuels.

Different estimates by the nova-Institute show that the impact of biofuels was about 250 times more significant than the impact of bioplastics on food markets, agricultural prices and land competition in 2008.

92% of the cultivated land in the world is used for food and animal feed production, 6% for industrial materials and 2% for biofuels. That means that even the impact of biofuels is very limited. Agricultural land used for bioplastics is less than 0.1%.

Some facts about food prices and recent food price increases Compared to other raw materials the price increase for agricultural raw materials has been moderate over the last six years (see Figure 2). In inflation-adjusted terms, price levels in 2008 were even much lower than in the 1970s (see Figure 3).

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47

2400

nova-index 17 corn soybeans wheet live cattle lean hogs gold

2200

1000

silver copper cocos coffee sugar cotton

orange juice platinum crude oil heating oil petroleum gas

nova-index energy

nova-index agriculture

crude oil heating oil petroleum gas

corn soybeans sugar cotton

Recently the impact of bioplastics has been about 250 times lower than the impact of biofuels, hence lower than 0.1%. Therefore, the impact of bioplastics on the world food market is negligible.

Additionally, producing biofuels or bioplastics means in most cases also producing high value protein-rich by-products that can be used as animal feed.

800

600

400

200

2008

2006

2004

2002

2000

1998

1996

1994

1992

1990

1988

1986

1984

1982

1980

1978

0

The main driver for the price increase of agricultural products is the fast growing demand for meat and milk products (see Table 1). According to a special Biofuels Digest report, ‘Fat vs Fuel’, 70 % of US corn and soy production is devoted to animal feed, not food for humans, and not fuel.

Feed for animals is to provide meat, dairy and other livestock by-products. According to the FAO and the USDA, US meat consumption has increased to 62 kg per person since the 1950s, with a resulting increase in grain usage of 170 kg per person (i.e. the grain which is fed to cattle and poultry). Cheese consumption has increased faster than milk’s decline, and Americans consume an extra 81 kg of milk, which uses up another 29 kg of grain.

nova-indices, January 1978 = 100 The commodities are equally balanced among all indices

Fig. 2: nova price indices for agricultural and non-agricultural commodities and energy

700

Wheat

600

500

UDS/t

400

300

200

Today

100

Nominal

2017

2015

2010

2005

2000

1995

1990

1985

1980

1975

1971

0

Real (inflation adjusted)

Fig 3: Inflation adjusted price movement of wheat Note:Real prices deflated by USA GDP deflator; 2007 = 1 (Source OECD-FAO)

“The commodity price spikes witnessed in the last couple of years, and in particular most recently, are exceptional when viewed from the perspective of the last decade or so, but not so much so when seen in a longer historical context … the recent price spike is neither the only, nor even the most important one to occur in the last 30-plus years.

In inflation adjusted terms, today’s prices fall well short of the peaks achieved in the early 1970s, and neither current maize nor wheat prices are averaging much above levels achieved as recently as the mid-1990s” [1].

Until now biofuels have had only a small effect on world food prices.

But, while smaller than the increase in food and animal feedstuffs, biofuel demand is the largest source of new demand for decades and a strong factor underpinning the upward shift in agriculture commodity prices.

The medium-term impact of biofuels on crop markets should not be overestimated at least until 2017, having had an influence on cereal and oilseed prices of 3% to a maximum of 10% [3].

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2050

People on our planet 6.5 Billions

9.0 Billions (+38%)

Meat Production

229 Mio. t

465 Mio. t (+103%)

Milk Production

580 Mio. t

1.043 Mio. t (+90%)

Table 1: Increasing meat and milk demand worldwide (Source: Ernährungsdienst 2008) High prices for agricultural raw materials are good for some and bad for others. Unpredictable movements in food prices can still provide problems in the future. With high prices the consequences in terms of hunger or malnutrition, especially in poor urban areas, will surface. But with low prices the consequences for poor farmers will be disastrous.

Until recently, hundreds of millions of farmers could not lift themselves out of poverty because of low food prices. 75% of the world‘s hungry people are still living in rural areas and are dependent on agriculture for their livelihoods. Over time, high agricultural prices should benefit them.

In poorer urban areas of the world the expenditure for food makes up, on average, about 50% of an individual‘s disposable income. As such, price increases in these regions have dramatic effects.

This percentage climbs to 65% if the food prices rise by 30%. In wealthy countries, these effects, on the other hand, will be limited to 1 to 2% of an individual‘s income.

Apart from this, the hunger issue is, however, only partially attributable to the demand for biofuels

Basics and is much more attributable to bad policy and the poor performance of the markets [4].

Summary To sum up, the target should be to cultivate crops that use the land most efficiently for their intended purpose, independently of whether these are food or non-food crops. Even if an increasing share of arable land is used for energy and industrial material use there is still much scope for the expansion of agricultural areas and even more scope for productivity increases.

However, biofuels have so far had a very small impact on food prices and the impact of bioplastics was, at 250 times less, clearly negligible. Even if they did have a significant impact, a higher agricultural price level, together with the international commitment to support sustainable agricultural development, is necessary for more investment in the agriculture sector to increase the production and secure the supply in the future.

Although high food prices certainly have adverse effects for some, they will lead to the activation of agricultural land that is currently not in production and also to higher productivity on land already cultivated, which would increase the aggregate production of food, animal feed and renewable raw materials. Furthermore, high prices for agricultural products are necessary for poor farmers in developing countries to sustain their livelihoods.

nova-Institute: Experts of the nova-Institute department â&#x20AC;&#x2DC;resource managementâ&#x20AC;&#x2122; are continuously analyzing the raw material markets and especially the markets for agricultural raw materials in industrial applications. www.nova-institut.de/nr

Sources: [1] OECD-FAO 2008: Agriculture Outlook 2008-2017 [2] www.fao.org/news/story/en/item/24457/icode [3] OECD 2008: Biofuel Support Policies â&#x20AC;&#x201C; an economic assessment [4] Banse, M., Nowicki, P., van Meijl, H. (LEI Wageningen UR) 2008: Why are current world food prices so high? Report 2008-040.

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Basics

Plantation of sugar cane in Brazil (Photo: Ricardo Azoury, istockphoto)

Amazon

Land Use For Bio-Polyolefins

C

ompanies such as Braskem or Dow announced the production of polyolefins (polyethylene, polypropylene) from sugar cane based bio-ethanol. In Triunfo, Brazil, Braskem is implementing a project to produce green polyethylene on an industrial scale with a capacity for 200,000 tonnes/year, with operations projected to begin in 2011 and recently the company announced first the investment of R$ 8.25 million in the expansion of research on development of green polypropylene based on renewable resources.

A venture owned by Dow and Crystalsev announced they will grow 8 million tonnes of sugarcane and turn that into 350,000 tonnes of Dowlex.

Being asked about the recurring question concerning sugar cane plantations and the Brazilian rainforest, J.C. Grubisich, CEO of Braskem stated that in Brasil the rainforests are in the north of the vast country, whereas the sugarcane plantations are in the southeast. In addition, land and climate in the north – the rainforest area - isn’t appropriate for sugarcane production. Jeff Wooster of Dow presented a map at a recent conference in Orlando, Florida, showing where sugar cane is being harvested (see map above).

For the projected 350,000 tonnes of LLDPE, roughly a total area of 160,000 ha (620 sq. mi) of land will be required, Wooster estimated. “We will be planting new trees on some of the land and protecting existing sensitive areas as well,” he said. “For example, the land along waterways will remain covered with grass and trees in order to prevent erosion and run-off into the waterways. So, only about 70% of the 160,000 ha area (net area about 110,000 ha) will be planted to sugar cane.“ - MT

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bioplastics MAGAZINE [04/09] Vol. 4

(Luciana Bueno, istockphoto)

And to be a little more precise about the land use, Jeff Wooster explained that in Brazil by governmental regulation a portion of the land for any new project such as the sugar cane plantation for bio-polyethylene is required to be maintained in a natural state. Dow plans to maintain 25-30% of the land area for its project for environmental conservation purposes.

Events

Event Calender September 03, 2009 NVC Kurs Nachhaltige Verpackungsinnovationen Hotel Novotel Düsseldorf City West Düsseldorf, Germany www.nvc.nl

September 8-10, 2009 Biopackaging 2009 Copthorne Tara Hotel Kensington, London, UK www.biopackconference.com

October 06-07, 2009 3. BioKunststoffe Technische Anwendungen biobasierter Werkstoffe Duisburg, Germany www.hanser-tagungen.de/biokunststoffe

October 22, 2009 Timeproof biopolymers: durability of biobased materials PEP (Pôle Européen de Plasturgie) Bellignat, Franceopéen de Plasturgie) jt.pep@poleplasturgie.com

September 9-10, 2009 naro.tech 2009 7th international symposium Mess Erfurt, Germany www.narotech.de

October 26-27, 2009 Biowerkstoff Kongress 2009 within framework of AVK and COMPOSITES EUROPE Neue Messe Stuttgart, Germany www.biowerkstoff-kongress.de

September 9-10, 2009 7th Int. Symposium ‘Materials made of Renewable Resources‘ Messe Erfurt Erfurt / Germany www.narotech.de

September 14-16, 2009 2nd PLA Bottle Conference hosted by bioplastics MAGAzINE within the framework of drinktec Munich / Germany www.pla-bottle-conference.com

October 29, 2009 NVC Kurs Nachhaltige Verpackungsinnovationen Hotel Novotel Düsseldorf City West Düsseldorf, Germany www.nvc.nl

November 10-11, 2009 4th European Bioplastics Conference Ritz Carlton Hotel Berlin, Germany www.european-bioplastics.org

December 2-3, 2009 Dritter Deutscher WPC-Kongress Maritim Hotel Cologne, Germany

September 28 - October 01, 2009 4th Biopolymers Symposium 2009 Embassy Suites, Lakefront - Chicago Downtown Chicago, Illinois USA www.biopolymersummit.com

www.ismithers.net

June 22-23, 2010 8th Global WPC and Natural Fibre Composites Congress an Exhibition Fellbach (near Stuttgart), Germany www.wpc-nfk.de

You can meet us!

www.innoform-coaching.de

March 16-17, 2010 EnviroPlas 2010 Brussels, Belgium

Please contact us in advance by e-mail.

www.wpc-kongress.de

September 16-17, 2009 International Conference: Bio polymers in applications of films Würzburg / Germany

bioplastics MAGAZINE [04/09] Vol. 4

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10

Suppliers Guide

2. Additives / Secondary raw materials

1. Raw Materials 20

30

40

50

60

70

BASF SE Global Business Management Biodegradable Polymers Carl-Bosch-Str. 38 67056 Ludwigshafen, Germany Tel. +49-621 60 43 878 Fax +49-621 60 21 694 plas.com@basf.com www.ecovio.com www.basf.com/ecoflex 1.1 bio based monomers

80

90

100

110

120

150

160

Plantic Technologies Limited 51 Burns Road Altona VIC 3018 Australia Tel. +61 3 9353 7900 Fax +61 3 9353 7901 info@plantic.com.au www.plantic.com.au

Natur-Tec® - Northern Technologies 4201 Woodland Road Circle Pines, MN 55014 USA Tel. +1 763.225.6600 Fax +1 763.225.6645 info@natur-tec.com www.natur-tec.com

PSM Bioplastic NA Chicago, USA www.psmna.com +1-630-393-0012

1.2 compounds

Division of A&O FilmPAC Ltd 7 Osier Way, Warrington Road GB-Olney/Bucks.

MK46 5FP Tel.: +44 844 335 0886 Fax: +44 1234 713 221 sales@aandofilmpac.com www.bioresins.eu

Huhtamaki Forchheim Herr Manfred Huberth Zweibrückenstraße 15-25 91301 Forchheim Telles, Metabolix – ADM joint venture Tel. +49-9191 81305 Fax +49-9191 81244 650 Suffolk Street, Suite 100 Mobil +49-171 2439574 Lowell, MA 01854 USA Tel. +1-97 85 13 18 00 Fax +1-97 85 13 18 86 www.mirelplastics.com

Tianan Biologic No. 68 Dagang 6th Rd, Beilun, Ningbo, China, 315800 Tel. +86-57 48 68 62 50 2 Fax +86-57 48 68 77 98 0 enquiry@tianan-enmat.com www.tianan-enmat.com 1.6 masterbatches

170

1.4 starch-based bioplastics 180

190

200

210

220

230

240

250

PolyOne Avenue Melville Wilson, 2 Zoning de la Fagne BIOTEC Biologische 5330 Assesse Naturverpackungen GmbH & Co. KG Belgium Werner-Heisenberg-Straße 32 Tel. + 32 83 660 211 46446 Emmerich info.color@polyone.com BIOTEC Biologische Germany www.polyone.com Naturverpackungen GmbH & Co. KG Tel. +49 2822 92510 Werner-Heisenberg-Straße 32 Fax +49 2822 51840 46446 Emmerich info@biotec.de Germany www.biotec.de Tel. +49 2822 92510 Fax +49 2822 51840 info@biotec.de Sukano Products Ltd. www.biotec.de Chaltenbodenstrasse 23 CH-8834 Schindellegi Cereplast Inc. Tel. +41 44 787 57 77 Tel: +1 310-676-5000 / Fax: -5003 Fax +41 44 787 57 78 pravera@cereplast.com www.sukano.com www.cereplast.com European distributor A.Schulman : Tel +49 (2273) 561 236 christophe_cario@de.aschulman.com

260

270

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bioplastics MAGAZINE [04/09] Vol. 4

3.1 films

1.5 PHA

1.3 PLA PURAC division Arkelsedijk 46, P.O. Box 21 4200 AA Gorinchem The Netherlands Tel.: +31 (0)183 695 695 Fax: +31 (0)183 695 604 www.purac.com PLA@purac.com

Du Pont de Nemours International S.A. 2, Chemin du Pavillon, PO Box 50 CH 1218 Le Grand Saconnex, Geneva, Switzerland Tel. + 41(0) 22 717 5428 Fax + 41(0) 22 717 5500 jonathan.v.cohen@che.dupont.com www.packaging.dupont.com 3. Semi finished products

Du Pont de Nemours International S.A. 2, Chemin du Pavillon, PO Box 50 CH 1218 Le Grand Saconnex, Geneva, Switzerland Tel. + 41 22 717 5428 Transmare Compounding B.V. Fax + 41 22 717 5500 Ringweg 7, 6045 JL jonathan.v.cohen@che.dupont.com Roermond, The Netherlands www.packaging.dupont.com Tel. +31 475 345 900 Fax +31 475 345 910 info@transmare.nl www.compounding.nl

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140

FKuR Kunststoff GmbH Siemensring 79 D - 47 877 Willich Tel. +49 2154 9251-0 Tel.: +49 2154 9251-51 sales@fkur.com www.fkur.com

Maag GmbH Leckingser Straße 12 58640 Iserlohn Germany Tel. + 49 2371 9779-30 Fax + 49 2371 9779-97 shonke@maag.de www.maag.de

www.earthfirstpla.com www.sidaplax.com www.plasticsuppliers.com Sidaplax UK : +44 (1) 604 76 66 99 Sidaplax Belgium: +32 9 210 80 10 Plastic Suppliers: +1 866 378 4178 3.1.1 cellulose based films

INNOVIA FILMS LTD Wigton Cumbria CA7 9BG England Contact: Andy Sweetman Tel. +44 16973 41549 Fax +44 16973 41452 andy.sweetman@innoviafilms.com www.innoviafilms.com

alesco GmbH & Co. KG Schönthaler Str. 55-59 D-52379 Langerwehe Sales Germany: +49 2423 402 110 Sales Belgium: +32 9 2260 165 Sales Netherlands: +31 20 5037 710 info@alesco.net | www.alesco.net

Arkhe Will Co., Ltd. 19-1-5 Imaichi-cho, Fukui 918-8152 Fukui, Japan Tel. +81-776 38 46 11 Fax +81-776 38 46 17 contactus@ecogooz.com www.ecogooz.com

Forapack S.r.l Via Sodero, 43 66030 Poggiofi orito (Ch), Italy Tel. +39-08 71 93 03 25 Fax +39-08 71 93 03 26 info@forapack.it www.forapack.it

Minima Technology Co., Ltd. Esmy Huang, Marketing Manager No.33. Yichang E. Rd., Taipin City, Taichung County 411, Taiwan (R.O.C.) Tel. +886(4)2277 6888 Fax +883(4)2277 6989 Mobil +886(0)982-829988 esmy325@ms51.hinet.net Skype esmy325 www.minima-tech.com

natura Verpackungs GmbH Industriestr. 55 - 57 48432 Rheine Tel. +49 5975 303-57 Fax +49 5975 303-42 info@naturapackaging.com www.naturapackagign.com

NOVAMONT S.p.A. Via Fauser , 8 28100 Novara - ITALIA Fax +39.0321.699.601 Tel. +39.0321.699.611 Info@novamont.com

Pland Paper® WEI MON INDUSTRY CO., LTD. 2F, No.57, Singjhong Rd., Neihu District, Taipei City 114, Taiwan, R.O.C. Tel. + 886 - 2 - 27953131 Fax + 886 - 2 - 27919966 sales@weimon.com.tw www.plandpaper.com

President Packaging Ind., Corp.

PLA Paper Hot Cup manufacture In Taiwan, www.ppi.com.tw Tel.: +886-6-570-4066 ext.5531 Fax: +886-6-570-4077 sales@ppi.com.tw

7. Plant engineering

Uhde Inventa-Fischer GmbH Holzhauser Str. 157 - 159 13509 Berlin Germany Tel. +49 (0)30 43567 5 Fax +49 (0)30 43567 699 sales.de@thyssenkrupp.com www.uhde-inventa-fischer.com

MANN+HUMMEL ProTec GmbH Stubenwald-Allee 9 64625 Bensheim, Deutschland Tel. +49 6251 77061 0 Fax +49 6251 77061 510 info@mh-protec.com www.mh-protec.com

suppguide@bioplasticsmagazine.com Stay permanently listed in the Suppliers Guide with your company logo and contact information.

8. Ancillary equipment 9. Services

For Example:

9. Services Siemensring 79 47877 Willich, Germany Tel.: 02154/9251-0 , Fax: -51 carmen.michels@umsicht.fhg.de www.umsicht.fraunhofer.de

6. Machinery & Molds

Molds, Change Parts and Turnkey Solutions for the PET/Bioplastic Container Industry 284 Pinebush Road Cambridge Ontario Canada N1T 1z6 Tel. +1 519 624 9720 Fax +1 519 624 9721 info@hallink.com www.hallink.com

Simply contact: Tel.: +49-2359-2996-0

For only 6,– EUR per mm, per issue you can be present among top suppliers in the field of bioplastics.

Bioplastics Consulting Wiedmer AG - PLASTIC SOLUTIONS Tel. +49 2161 664864 info@polymediaconsult.com 8752 Näfels - Am Linthli 2 www.polymediaconsult.com SWITzERLAND Tel. +41 55 618 44 99 10.1 Associations Fax +41 55 618 44 98 www.wiedmer-plastic.com

FAS Converting Machinery AB O zinkgatan 1/ Box 1503 27100 Ystad, Sweden Tel.: +46 411 69260 www.fasconverting.com

Suppliers Guide

BPI - The Biodegradable Products Institute 331 West 57th Street, Suite 415 New York, NY 10019, USA Tel. +1-888-274-5646 info@bpiworld.org

Polymedia Publisher GmbH Dammer Str. 112 41066 Mönchengladbach Germany Tel. +49 2161 664864 Fax +49 2161 631045 info@bioplasticsmagazine.com www.bioplasticsmagazine.com

10 35 mm

4. Bioplastics products

Sample Charge: 35mm x 6,00 € = 210,00 € per entry/per issue

Sample Charge for one year: 6 issues x 210,00 EUR = 1,260.00 € The entry in our Suppliers Guide is bookable for one year (6 issues) and extends automatically if it’s not canceled three month before expiry.

European Bioplastics e.V. Marienstr. 19/20 10117 Berlin, Germany Tel. +49 30 284 82 350 Fax +49 30 284 84 359 info@european-bioplastics.org www.european-bioplastics.org 10.2 Universities

Michigan State University Department of Chemical Engineering & Materials Science Professor Ramani Narayan East Lansing MI 48824, USA Tel. +1 517 719 7163 narayan@msu.edu

University of Applied Sciences Faculty II, Department of Bioprocess Engineering Prof. Dr.-Ing. Hans-Josef Endres Heisterbergallee 12 30453 Hannover, Germany Tel. +49 (0)511-9296-2212 Fax +49 (0)511-9296-2210 hans-josef.endres@fh-hannover.de www.fakultaet2.fh-hannover.de

bioplastics MAGAZINE [04/09] Vol. 4

20

30 35

Companies in this issue Company A&O Filmpac Alesco Algaeventure Systems API Arkhe Will BASF Bemis Company bioplastics 24 Biotec BPI Braskem Cardia Bioplastics Carl Hanser Verlag Cereplast Clarifoil Coca-Cola Community Recycling and Resource Recovery Crystalsev Dow DuPont Eric F. Greenberg European Bioplastics European Plastics News Fachhochschule Hannover FAS Converting Machinery FKuR Forapack Fraunhofer Inst. F. Chemical Technology Fraunhofer UMSICHT Frito-Lay Frost & Sullivan Gucci Hallink Homo ecos: Huhtamaki Innovia Films Jamplast Japan BioPlastics Association (JBPS) Joh. Sieben Maag Mako Plastics Mann + Hummel Protech Merquinsa Messe D端sseldorf (interpack) Michigan State University Minima Technology

Next Issue

54

Editorial

Advert 52 53

36 12 8 13

9 50 8, 23 12 43 14 17 50 50

53 52 35 52 53

5 52

52 13 5, 7 6

22 42 22, 32 42 6 42

53 53 53 2, 52 53 53

53 9 10 12 11 23

52 52

52 40 53 12 7 13, 17

53 53

Company NAPCOR natura Verpackung Naturally Iowa NatureWorks NaturTec Neue Messe M端nchen (drinktec) Nippon Goshei nova Institut Novamont Plantic Plastek Cards Plastic Forming Enterprise Plasticker Polymediaconsult Polyone Polyvel President Packaging Primo Water Printpack PSM Purac Rodenburg Sidaplax Soarus Sony SPE SPI Sukano Sulzer Synbra Tecnaro Teijin Telles Thai Bioplastics Industry Association (TBIA) Tianan TiTech Transmare Uhde Inventa-Fischer Univernture University of Waterloo (Canada) Vincotte W. M端ller Wei Mon Wetlands Bioscience Wiedmer

Editorial Focus:

Basics:

Seo/Oct 05.10.2009

Fibers / Textiles / Nonwovens Paper Coating

Basics of Starch Based Biopolymers

Month

Publ.-Date

Editorial Focus (1)

Editorial Focus (2)

Basics

Nov/Dec

30.11.2009

Films / Flexibles / Bags

Consumer Electronics

Anaerobic Digestion

Advert 53

3, 21 3, 12, 13, 16, 24, 29 52 43 30 46

35 53, 56 52

43 26 35 53 52

12 12

53 1, 16, 24 40 12, 34 6 37

52 52 15, 52

30 38 13 12 52 6 6 42 29 9 8

52, 55 39, 52

24 52 19, 53 36 13 9 22

13 41, 52

44 53

For the next issue of bioplastics MAGAZINE (among others) the following subjects are scheduled:

Next issue:

bioplastics MAGAZINE [04/09] Vol. 4

Editorial 28

Fair Specials

EcoComunicazione.it

2008 and Terra Madre to us G l de ne lo Sa 80,000 e del Gusto 1 n lo Sa f o rs o it is V 26,000 Terra Madre Meals served at kg 7,000 ced* Compost produ kg 13,600 CO2 saved ection – Novamont proj * data estimate

The future, with a different flavour: sustainable Mater-Bi® means biodegradable and compostable plastics made from renewable raw materials.

Slow Food, defending good things, from food to land.

For the “Salone del Gusto” and “Terra Madre”, Slow Food has chosen Mater-Bi® for bags, shoppers, cutlery, cups and plates; showing that good food must also get along with the environment.

Sustainable development is a necessity for everyone.

For Novamont and Slow Food, it is already a reality.

info@novamont.com www.novamont.com