2009-05

ISSN 1862-5258

05 | 2009

Highlights: Fibre Applications | 10 Paper Coating | 18 Basics: Land Use - part 2 | 34

bioplastics

magazine

Vol. 4

Starch Bioplastics | 42

tics M bioplas

A G A Z IN

in is reandtries 85 cou

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Plastics For Your Future

Knife handle made of BIO-FLEX速 P 7550

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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Editorial

ISSN 1862-5258

dear readers 05 | 2009

September is over, and so too is our 2nd PLA Bottle Conference. The very well received event in Munich again attracted a good number of delegates and a great deal of positive comment. For those interested in bottle applications please see the detailed report on page 8.

Otherwise you might prefer to read more about paper coating or fibre and textile applications. These are the two topics of our editorial focus in this issue. Furthermore, we present an extract from the new book’Technische Biopolymere‘, effectively serving as part two of the ‘land use for bioplastics‘ discussion.

Highlights: Paper Coating / Laminating | XX Fibres, Textiles, Nonwovens | XX

bioplastics

MAGAZINE

Vol. 4

In the ‘Basics‘ section you‘ll find out about starch and starch based biopolymers, and last but not least we also cover the ‘oxo-subject‘ once again.

This summer a number of press publications reported on different standpoints concerning the ‘pros‘ and ‘cons‘ of oxo-degradable plastics. However, instead of the rather tabloid way of reporting, and calling the debate a “lively spat“, a is read inies “rumbling row“ or even a “battle“, bioplastics MAGAZINE is trying a more factual 85 countr approach. Thus we contacted the main stakeholders and offered to let them put their points of view in our magazine and to provide the scientific support for their claims. In this issue we publish a slightly shortened version of the position paper from European Bioplastics. And while we are still waiting for Symphony‘s scientifically based article on their products and their compliance with ASTM D6594 the Canadian supplier EPI sent us copies of old scientific papers by Chiellini et. al and Wiles & Scott.

Coverphoto courtesy Du Po

s MAG bioplastic

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I hope you enjoy reading this issue of bioplastics comments, opinions or contributions.

MAGAZINE

and look forward to your

Yours Michael Thielen

bioplastics MAGAZINE [05/09] Vol. 4

bioplastics MAGAZINE [05/09] Vol. 4

Meltblown PLA Nonwovens 10 A new Cradle-to-Cradle Approach for PLA 30

PLA Floor Mat 11

Report

New carpet made from PLA fibres 11

Innovative Tea-Bags From PLA Fibres 12

Plant-Based Materials for Automobile Interiors 13

Fibers of PTT Receive New U.S. Generic, ‘Triexta’ 14

Injection Moldable High Temperature Bioplastic

27

Versatile Precursor Made From Cashew Nuts

28

Coverphoto courtesy DuPont

Basics of Starch-Based Materials

A large number of copies of this issue of bioplastics MAGAZINE is wrapped in a compostable film manufactured and sponsored by alesco (www.alesco.net)

26

Envelope

Biobased Engineering Plastic

Editorial contributions are always welcome.

Please contact the editorial office via mt@bioplasticsmagazine.com.

20

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

Editorial News Application News Event Calendar Suppliers Guide

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.

Sustainable Cups from Georgia-Pacific

Not to be reproduced in any form without permission from the publisher.

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bioplastics MAGAZINE is read in 85 countries.

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ISSN 1862-5258 bioplastics magazine is published 6 times a year.

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Fiber Applications

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Impressum Content 03

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46

05|2009

End of Life

Fraunhofer IAP 32

Basics

Raw Materials and Arable Land for Biopolymers 34

Position Paper ‘Oxo-Biodegradable‘ Plastics 38

Twin-Screw Extruders for Biopolymer Compounding 17 42

Paper Coating

Materials

News

Comprehensive biopolymer database with new features Certification of Bio-Based Content The content of renewable resources of products, which can be measured by 14C determination as the fraction of ‘bio-based carbon content’, enjoys much attention in the environmental and resource discussion. It is also the focus of several political initiatives like for example in the U.S.A. (USDA’s ‘biopreferred’ program) Japan (Biomass Nippon Plan) and the EU Lead Markets Initiative (LMI). One of the core activities within the LMI focuses on the development of suitable standards for defining ‘bio-based products’ and for the determination of the bio-based content – similar to ASTM D-6866. Industry is involved in a dialogue with the European Commission about the LMI and participates actively in the respective working groups, also at the CEN level. Based on the future standards, it is intended to develop independent certification and market surveillance of claims concerning the bio-based content. So far however, the LMI working groups have not arrived yet at the certification part, so independent certification is not available yet.

European Bioplastics (EuBP) has now started to coordinate with partners along the bioplastic value chain for a joint approach towards the development of a ‘bio-based content’ certification system. Says Joeran Reske of EuBP, coordinator of the project within the association: “We are aiming at a system as simple as possible, on the other hand we think that independent certification is a must, so that users have a both transparent and reliable basis for their product-related communication. We consider the bio-based content only one out of several parameters influencing the environmental performance of a product.” Consequently, labelling is seen as a very sensitive topic which needs a careful and well balanced approach to be trustworthy. “Therefore we thought we ought to deliver our contribution to the discussion about the criteria of bio-based content certification”, adds EuBPChairman Andy Sweetman.

The Biopolymer Database includes more than 100 biopolymer manufactures and more than 370 material types. Until now the data from the material suppliers have been reported against many different test standards and it has not been possible to make a fair comparison between different grades. Therefore the materials are now tested under uniform and comparable conditions in the University of Applied Science and Arts (Hannover, Germany). The results of these tests are to be made available in October 2009.

Through the biopolymer database customers, converters and end users will be connected with the bioplastic manufacturers. With the biopolymer database it will also be much easier to find information. At the first stage the users can indicate whether their interest is pellets or film.

The biopolymer database allows extensive search options for both variants, e.g. manufacturers, including contact addresses, polymer types, trade names, mechanical and thermal properties, barrier properties, information about certifications, biobased material content etc.

Furthermore the opportunity of comparing functions is also given, i.e. a comparison of the properties of different biopolymers. It is also possible to search in the published literature.

All data are printable as datasheets. Datasheets from the manufacturers are also available.

The database is available via the Internet in German and English. Access is free of charge. www.materialdatacenter.com

European Bioplastics is seeking cooperation along the whole product value chain, with the European Commission and with other (national) authorities. It is intended to develop a system that could be used finally also in policy making. The association is in a dialogue with test laboratories, certification institutes and other partners in and beyond Europe to include the best available knowledge. - MT biobased@european-bioplastics.org

bioplastics MAGAZINE [05/09] Vol. 4

News

from left: Patrick Gerritsen, Frank Eijkman, Jhon Bollen, Oliver Fraaije.

Bio4Pack offers One-Stop Shopping Two Dutch thermoforming companies, Nedupak Thermoforming BV (of Rheden, NL) and Plastics2Pack (of Uden, NL), recently announced the forming of ‘Bio4Pack‘ as a new packaging supply company. The new company is headed by Managing Director Patrick Gerritsen, who brings with him several years of know-how and expertise in the area of biobased and biodegradable packaging.

Bio4Pack not only offers thermoformed packaging but also all other kinds of packaging made from biobased and/or biodegradable materials, including films, bags and netting, and through to sugar cane trays made from the bagasse, a by-product from the sugar cane industry.

“We want to offer our customers a total packaging solution,“ says Oliver Fraajie, Commercial Director of Nedupack, “not just a thermoformed tray or bulk pack.“ And thus the portfolio of Bio4Pack comprises the traditional thermoformed packaging made from bioplastics such as PLA or new thermoformable materials.

The range also includes films and bags for all kinds of purposes, e.g shopping bags or flow wrap packaging made from starch based bioplastics such as Biolice®, Materbi® or Bioflex® from FKUR, and also nets for onions, potatoes or fruit and, of course, the labelling on the packaging.

“We also offer meat packaging consisting of a thermoformed PLA tray with peelable SiOx coated PLA film, having the same properties as conventional packing“ adds Frank Eijkman, Managing Director of Plastics2Pack.

“And for bakery goods such as cakes and cookies we have thermoformed trays and folded boxes from a more rigid PLA sheet. This kind of box is also available for the packaging of bio-chocolate for example.“

Blisters for liquor gift packs or batteries round off the list of examples. “In a nutshell: We are a trading company that offers all types of packaging made from biobased or biodegradable materials,“ says Patrick Gerritsen, “Those that we don‘t produce ourselves at Nedupack or Plastics2pack, we get from partners who I know from the past“.

Of course all products are certified according to EN 13432 and Patrick goes even one step further: “We are investigating the possibility of having our products certified and labeled with ‘Climate Neutral‘ (www.climatepartner.de)“.

Bio4Pack started operations in early August and is proud of the first orders from leading companies in the fresh produce and supermarket businesses. Even if the company initially targets the European market, clients from all over the world can be served via Nedupack‘s partners in many countries.

“Another big advantage is that Nedupack Thermoforming have their own design and tool-making department, so we are more flexible and can react much quicker than many other suppliers,“ says Jhon Bollen, Technical Director of Nedupack.

Although this new company was founded in a generally difficult economic situation, the entrepreneurs have full confidence in the development of this market. “We are looking forward to convincing more and more supermarkets and other suppliers to switch to bioplastic products - and not only because the traditional resources are finite,“ says Patrick Gerritsen. Oliver Fraaije is convinced that “the customers who buy bio-food are also willing to buy biopackaging.“ - MT www.bio4pack.com

Erratum: In the last issue (04/2009) bioplastics MAGAZINE published an article on the NIR sorting field test of NatureWorks Ingeo PLA bottles from a clear PET recycling stream. In table 1 on page 25 the removal efficiency was listed as 3 percent, when it should have been 93 percent.

To be clear, 93 percent of the PLA bottles were removed from the clear PET stream. The resulting clear PET bail contained just 453 ppm (parts per million) PLA. The bails were 99.95 percent PET and plastics other than PLA following the storing test.

We apologize for this error.

bioplastics MAGAZINE [05/09] Vol. 4

News

Completely Biodegradable Food Service for Dallas Convention Center Centerplate (Stamford, Connecticut, USA), the hospitality partner to North America‘s premier convention centers and sports stadiums, recently announced the introduction of a completely biodegradable food service solution for the Dallas Convention Center. All of the facility‘s disposable food service items from cups to flatware to napkins will be 100 % biodegradable, dramatically reducing the environmental impact of the site‘s menu operations.

The initiative taps Centerplate‘s deep expertise in implementing eco-friendly food service programs for major convention centers and stadiums across North America following its recent work helping the University of Colorado at Boulder transform its 53,750 seat Folsom Field football stadium into a zero-waste facility. For the Dallas Convention Center, the biodegradable program augments the site‘s position as one of the most environmentally sound convention venues in the nation and one of the few to achieve the elite ISO 14001:2004 certification, an international environmental standard which helps organizations limit the negative impact of their operations on the environment.

“When a two-million square foot plus operation like the Dallas Convention Center commits to this level of change,

the benefits to the overall environment and to the health of the immediate community are substantial,“ said Des Hague, president and CEO of Centerplate. “As part of our commitment to becoming the number one in hospitality and a leader in sustainability, we intend to extend this biodegradable food service solution to all our clients.“ Among the new biodegradable products being introduced are cutlery made from potato starch; clear colored, cornbased cups for beer and soda; and plates, bowls and togo containers made from sugarcane pulp; hot cups that are lined with plant-based plastic; and compostable lines for trash receptacles.”It‘s a point of pride for us to be able to operate a world class venue offering a world class experience while simultaneously maintaining one of the most environmentally responsible facilities in the country,“ said Frank Poe, the director of convention and event services at the Dallas Convention Center. “Centerplate has been a key partner of ours for several years and their ability to successfully implement major changes such as this new biodegradable food service program has played a key role in our overall success.“ - PRNewswire - MT www.centerplate.com.

PLA Based Masterbatches At FAKUMA 2009, to be held in Friedrichshafen, Germany in mid October, Austrian Gabriel-Chemie from Gumpoldskirchen is presenting its new MAXITHEN® BIOL range of colour- and additive masterbatches based on Polylactide (PLA).

At a dosage rate up to 5% MAXITHEN BIOL colour masterbatches comply with the composting regulations and the normative standard EN13432. The colour masterbatches are characterised by transparency and high colour strength and can be well processed on existing machines. All PLA based colour- and additive masterbatches are compatible with a lot of other biogenic as well as petrochemical (conventional) polymers and offer a wide range of applications.

MAXITHEN BIOL masterbatches can be used for the production of films, form parts, boxes, cups, bottles and other commodities. This new product range is mainly recommended for the colouring of short-dated packaging or thermoformed products (e.g. beverage- or yoghurt cups, trays for meat, fruits and vegetables); but also for the colouring and dressing of agricultural films (mulch and protective films) and auxiliary gardening articles (seedling trays, plant holders, single-use plant pots).

www.gabriel-chemie.com

bioplastics MAGAZINE [05/09] Vol. 4

Event Review

2nd PLA Bottle Conference

T

he 2nd PLA Bottle Conference hosted by bioplastics MAGAZINE (September 14-15, Munich, Germany) attracted almost 80 experts from 18 different countries.

Delegates from the beverage industry as well as bioplastics experts came from all over Europe, North America and from countries as far away from the event venue as South Africa, Kuwait and Syria. Organizers, speakers and delegates were all well satisfied with the conference, as all presentations as well as the discussions were considered to be “very substantial“, “very much state-of-the-art“ and offered “many opportunities for making valuable contacts“.

In an extremely well received keynote speech on ‘Land use for Bioplastics‘ Michael Carus from the nova Institut gave a comprehensive overview of the situation regarding the need to use available arable land to feed humans and animals, and its use for the production of biofuels and bioplastics.

The conference itself followed a central theme from renewable feedstock to end-of-life. Starting with the basics on how starch or sugar is converted into lactic acid and then into PLA, the speakers addressed topics such as preform making and bottle blowing. Special focuses were on certain challenges such as barrier improvement (e.g. by SiOx coating) or enhanced thermal stability. Here special processing techniques were discussed as well as blending or stereocomplexing L and D lactides. Colorants and additives were introduced in order to achieve effects such as antiyellowing or anti-slip.

Once a bottle has been produced and filled the next steps are capping (with ongoing efforts being made in the field of bioplastic caps and closures) and labelling. Shrink sleeves made of PLA represent a viable solution that neither compromises automated sorting nor compostability (where desired). A world premier was the introduction of a bioplastics shrink film (see page 24 for more details).

Reports on their experiences by PLA bottle pioneers as well as brand new entrepreneurs gave an inspiring impression of the possibilities and challenges. As a surprise for all participants a Greek dairy company, together with their consultant, gave an almost spontaneous presentation about

bioplastics MAGAZINE [05/09] Vol. 4

a very recently launched milk bottle in Greece, accompanied by a goat‘s milk tasting experience for everybody.

The conference ended with a session on end-of-life or better end-of-use options for PLA. The delegates learned that NIR (= Near Infrared) is a technology that works well for automated sorting but that, on the other hand, still has some limitations. As at the previous two PLA conferences organised by bioplastics MAGAZINE, almost all of the attendees agreed that composting is not necessarily the best option. However, in closed loop systems such as stadiums, big events or similar, collection and composting may be a viable solution, provided that composting facilities are available. Elsewhere, where perhaps the volumes of collected PLA do not reach a critical mass for sorting and recycling, incineration with energy recovery seems to be a good solution. As one fairly new option the chemical recycling of PLA back into lactic acid was presented and can be reviewed in more detail on page 30.

After the second day of the conference the delegates were invited to visit drinktec, the world‘s number one trade fair for beverage and liquid food technology in Munich.

And on Wednesday an encouraging number of lime-green backpacks could be observed at the fairgrounds … www.pla-bottle-conference.com

4

th

Next Generation: Green

SAVE THE DATE !

10 / 11 November, 2009 The Ritz-Carlton, Berlin Conference Contact:

www.conference.european-bioplastics.org

conference@european-bioplastics.org Phone: +49 30 284 82 358

Fiber Applications

Melt Blown Line (Photo Courtesy Biax-Fiberfilm)

Meltblown PLA Nonwovens

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wo grades of NatureWorks‘ Ingeo™ PLA resin are now commercially available for the production of meltblown nonwovens, fabrics widely used in such products as wipes and filters.

“As interest grows in polymers made from renewable resources, equipment manufacturers, process developers, and researchers have been exploring solutions that offer meltblown nonwoven fabrics that both perform well and achieve a lower carbon footprint than the existing petroleum-based incumbents,” said Robert Green, director of fibers and nonwovens, NatureWorks, at the recent 2009 International Nonwovens Technical Conference (INTC) in Denver, Colorado, USA. Green was referring to meltblown fiber equipment manufacturer Biax-FiberFilm, Greenville, Wisconsin, USA, which earlier this year conducted meltblown tests of Ingeo PLA. Researchers at the University of Tennessee Nonwovens Research Lab (UTNRL) also evaluated Ingeo for its suitability for meltblown fabric substrates using conventional meltblowing equipment.

“Our development of an Ingeo meltblown substrate significantly broadens the variety of applications in which this material can be used,” said Doug Brown, president, Biax-FiberFilm. “An Ingeo meltblown nonwoven offers an estimated 30 to 50 percent cost savings over conventional fiber-based nonwoven roll goods and a significant advantage in price stability compared to petroleum-based products.” Brown also noted that mixing the meltblown fiber with wood pulp or viscose greatly enhanced the material’s absorption, making it suitable for a broad range of performance wipes products.

In its development work, Biax-FiberFilm demonstrated excellent performance of two Ingeo grades in their meltblown process. The grades 6252D and 6201D each provided broad processing windows and quality fabrics that meet requirements for a range of applications. The high pressure die design unique to Biax FiberFilm meltblown lines allow processing of higher viscosity grades, such as 6201D, offering even higher fabric strength than seen on conventional meltblowing equipment.

These recent advances provide the nonwoven market with a full range of Ingeo fabrics that can now be produced with all major fabric forming technologies from spunmelt to conventional carded nonwovens, offering the ability to meet consumers’ convenience needs with an annually renewable low environmental impact material. The attached graphic shows the significant environmental advantage Ingeo offers over conventional petroleum based products.

NatureWorks and Biax FiberFilm presented the results of this work in separate sessions at the INTC. Also at the conference, Fiber Innovation Technologies presented a paper on thermal bonding with Ingeo, and the University of Tennessee as well as Oklahoma University reviewed research into Ingeo mulch fabrics and fiber production. MT

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www.natureworksllc.com www.biax-fiberfilm.com

bioplastics MAGAZINE [05/09] Vol. 4

Fiber Applications

New carpet made from PLA fibres PLA Floor Mat

A

special floor mat available for the fully remodeled third-generation Toyota Prius uses an advanced Ingeo™ based PLA fiber. Known as the world’s most eco-conscious car, Toyota Prius features world-leading mileage (2.6 L/100 km or 89 Miles per Gallon), a solar powered ventilation system, and environmentally friendly plant-derived plastics for seat cushion foam, cowl side trim, inner and outer scuff plates, and deck trim cover. Now, the new Prius adds to these biobased materials by offering optional floor mats (deluxe type) using an advanced Ingeo fiber system.

As a result of reducing the use of fossil resource as much as possible in its manufacturing process from feedstock to factory shipment, Ingeo reduces the fossil fuel use by 65% and cuts by 90% the CO2 emission when compared to the petroleum-derived nylon resin used in traditional floor mats. By adopting the PLA mat products, Toyota benefits from the unique environmental advantages of a fiber made from plants, not oil. This adoption of new floor mats exemplifies Toyota’s belief that the use of environmentally friendly materials is as equally important as design and product performance.

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ommer Needlepunch, Baisieux, France, is specialised in floor covering solutions: carpet for events, domestic and contract use and more recently artificial grass. Its more than 50 years of know-how and experience is recognised throughout the world.

The care for the environment has always been an important consideration for the company, especially for the issues related to the consumption of raw materials and energy and the development of new products. During the last five years they proved to be a trendsetter in the development of sustainable eco-friendly solutions, believing strongly that economy and ecology can go together.

An important investment program made it possible for Sommer Needlepunch to switch almost completely to the use of biobased and recycled raw materials and the plan to supply energy from wind turbines is scheduled to be in place by 2010.

The launch of Ecopunch®, the first carpet collection made from 100% PLA fibres derived from NatureWorks‘Ingeo™ is a result of the important R&D efforts made in the area of the development of biodegradable products. “Ecopunch is a real natural alternative to the conventional oilbased products that offers the same performance and quality,“ says a press release of Sommer Needlepunch.

“This new product is an environmentally friendly carpet as its process reduces the CO2 emissions by up to 60 % compared to the traditional PP and PA products and extends the economical life time of the raw materials.“- MT www.sommernp.com

“We have long looked at Japan as an ‘innovation engine’ for our Ingeo business,” noted Marc Verbruggen, NatureWorks CEO. “With Toyota’s latest development, we recognize their achievement in leading the automotive industry’s efforts with excellence in biobased product performance and innovation”.

NatureWorks in Japan supplied Ingeo to Toyota Tsusho Corporation, who developed the new environmentally friendly floor mats. www.natureworksllc.com

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Fiber Applications

Innovative Tea-Bag Material Made From PLA Fibres

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hlstrom Corporation, headquartered in Helsinki, Finland is a global leader in the development and manufacture of high performance fiber-based materials. Last June the company presented its innovative, biodegradable nonwoven for infusion applications at the Tea & Coffee World Cup exhibition in Seville, Spain.

Thanks to an innovative, ahead of the curve investment at the Chirnside, Scotland operations, Ahlstrom introduced a world premier to the infusion market: a lightweight, fine filament web based on NatureWorks‘ Ingeo™ PLA. It is designed to deliver functional benefits to converters and consumers of tea-bags, while featuring unique environmental characteristics. Now commercially available, it was presented for the first time at a European exhibition.

“The raw material and the fine filament webs are fully biodegradable and compostable. An independent LCA (life cycle assessment) carried out to ISO 14040 standards demonstrated that these webs have a lower carbon footprint compared to similar products made of oil-based polymers“ says Mike Black, Ahlstrom‘s General Manager, Food Nonwovens. The principal ingredient is PLA. This also means that the raw material for this product is based on 100% annually renewable resources.

While responding to the growing demand for sustainable food packaging solutions, the new product also delivers remarkable functional benefits.

The extra fine webs highlight the contents while maintaining shape and easily accommodating tea-bag strings and tags. The resulting tea-bags look different and feel different to the touch: they represent the ideal choice for brand owners wanting to highlight quality infusions and to differentiate their premium blends, the fastest growing segment in the market.

Suitable for conversion on tea-packing machines that use ultrasonic sealing technology, the new materials complement Ahlstrom‘s wide range of traditional heatsealable and non-heatsealable filter webs for tea and coffee. Ahlstrom now offers the broadest range of beverage filtration materials available on the market, with manufacturing both in Europe and North America.

Ahlstrom infusion materials are part of the company‘s Advanced Nonwovens business area and can be found worldwide in numerous everyday applications. These include tea-bag materials manufactured primarily in the UK and USA and used by leading tea packers such as Tetley, Typhoo or Unilever. The products are sold globally through the Ahlstrom sales network. - MT www.ahlstrom.com

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Fiber Applications

Plant-Based Materials for Automobile Interiors

Materials to be used in different automobile interior parts have to clear tough and varied physical property requirements.

Generally, environment-friendly materials such as PLA used to be believed to lack in heat and wear resistance properties in comparison to regular polyester. Though various efforts were being made to address those weaknesses, the adoption of such materials in automobile applications had so far been limited to a few models due to a number of shortcomings.

This time Toray developed various technologies for compounding environment-friendly materials with petroleum-based products, including a proprietary hydrolysis control technology to modify polymer and techniques for compounding using polymer alloys and in the process of fiber spinning as well as mixed fiber compounding during higher processing. By making full use of these technologies, Toray succeeded in achieving the significantly high levels of durability sought by automobile interior applications, enabling actual adoption by mass-produced vehicles.

Having cleared the tough physical property benchmarks for automobile interiors, Toray will focus on further development of materials with higher plant-derived biomass

percentage and expand the materials’ applications into wideranging applications such as general apparel and industrial materials.

In this age of growing importance for environmentconsciousness, automobile manufacturers are striving to develop advanced technologies and aiming for a motorized society that can co-exist with the environment. The companies are actively considering a shift from the existing petroleumbased materials to products made from plant-derived materials for interior components which make up about 5 to 10% of a vehicle’s body weight. The use of plant-derived materials is expected to explode in the future, given the fact that it has low CO2 emissions in its lifecycle from production to disposal and it helps in curbing the use of the limited fossil fuel resources.

Under its Innovation by Chemistry slogan, Toray is actively pursuing the development of environment-friendly products and aims to contribute to the development of a sustainable, recycling-oriented society through its sales of environmentfriendly automobile parts. www.toray.com

Photos: Lexus / Toyota

T

oray Industries, Inc. with headquarters in Chuo-ku, Tokyo, Japan has started full-fledged mass production of its environment-friendly fiber materials based on PLA and plant-derived polyesters for automobile applications.

Toray has already been supplying the materials for the trunk and floor carpeting to Toyota Motor Corp. in its latest hybrid model of Lexus, the HS 250h, launched in July this year. At the same time, Toray is promoting the products to other automakers. Toray aims to have annual sales of 200 tons for the first year for products including ceiling upholstery and door trim materials, and expects them to grow to 5,000 tons per year by 2015.

bioplastics MAGAZINE [05/09] Vol. 4

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Fiber Applications

Fibers of PTT Receive New U.S. Generic, ‘Triexta’ Article contributed by Dawson E. Winch Global Brand Manager DuPont Applied BioSciences Wilmington, Delaware, USA

T

his year is a significant year in fiber history for several reasons.

Seventy years ago, at the 1939 World’s Fair, nylon was introduced and women began wearing stockings made with nylon from DuPont. In 1959, 50 years ago this year, the Textile Identification Act was passed to create standards for fiber identification in apparel, carpet and other fiber markets. And most recently, in March of 2009, the U.S. Federal Trade Commission (FTC) issued a new subgeneric – ‘triexta’ – for fibers made from PTT (polytrimethylene terephthalate) polymer. Sorona® is the brand name for renewably sourced PTT polymer from DuPont.

In addition to its legacy of fiber innovation, DuPont has also led in the establishment of environmental goals. DuPont established its first environmental goals more than 19 years ago and as recently as 2006, set aggressive sustainability goals to meet or exceed by 2015. In addition to the operational goals of reducing its environmental footprint, for the first time DuPont established market facing goals. Sorona addresses one of these goals in particular, to reduce dependency on depletable (petrochemical) resources. DuPont™ Sorona® renewably sourced polymer was created at the intersection where sustainability and fiber innovation meet.

Sorona is just one product that utilizes Bio-PDO™, the key and ‘green’ ingredient made using a fermentation process. And it is only one of many products in the DuPont Renewable Materials Program (DRSM). DRSM was developed to help DuPont customers identify those products that perform as well as or better than traditional petrochemical-based products AND contain a minimum of 20% renewably sourced ingredients by weight.

By creating base monomers or building block molecules like BioPDO, using renewable resources instead of petrochemicals, DuPont has introduced a variety of materials for diverse markets and end uses from personal care products to industrial antifreeze to fibers for textiles and carpet. It is in these last two categories – textiles and carpet – where Sorona can be found.

Apparel as well as residential and commercial interior markets can enjoy and benefit from the unique combination of attributes provided

by Sorona, that led to the new generic, ‘triexta.’

APPAREL The versatility and adaptability of fibers made with Sorona compliment the needs by a wide variety of apparel applications. Since it can easily be blended with other fibers, both synthetic and natural,

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fibers from Sorona, with its features and benefits, allows designers to take designs to new heights.

The benefits of Sorona compliment the demands of swimwear manufacturers and consumers. Swimwear remains looking newer longer due to the chlorine and UV resistance, meaning prints and colors won’t fade or wash out due to repeated exposure to bright sun and harsh chlorine. And one swimsuit will last the whole season (at least) since it resists pilling. Speedo has adopted Sorona for swimwear in the United Kingdom.

Intimate apparel designers and consumers appreciate the exceptional and luxurious softness and flattering drape provided by Sorona. Unlike other synthetics, these -fibers reach a bright white and a deep, rich black – both very popular colors in the intimate apparel market.

And, due to its colorfastness and fade resistance blacks and whites won’t fade or yellow over time. Best of all for consumers is the easy care attribute of Sorona - no special washing instructions to follow.

Activewear also benefits from the unique attributes and benefits of Sorona. As a polymer, it can be extruded in an odd cross section to increase the wicking ability of the fiber. Moisture management is enhanced with these fibers since the moisture transporting channels remain more clearly defined. And, fleece takes on a new level of softness since a microdenier feel can be obtained with fibers of greater than one denier. And, fiber and fabric is fade resistant from repeated washings, activewear colors remain bold and vivid through many work-outs and adventures.

In blended fabrics popular in ready to wear, Sorona continues to provide wonderful benefits. Wool/Sorona blends offer softness and drape along with resistance to wrinkles – perfect for the business traveler who goes from plane to meeting. Cotton/Sorona blends offer softness and a comfort stretch and recovery to provide freedom of movement through the shoulders and elbows where consumers need it most. And, baggy, saggy knees and elbows are virtually eliminated since it also provides permanent recovery. This stretch and recovery leads to freedom of movement improving comfort and wearability in clothing. In other words, such blends enhance and maximize the fabric’s benefits.

Spun Bamboo® has incorporated blends of Sorona and bamboo into it’s lines of t-shirts and polo shirts.

Timberland and Izod have also adopted Sorona into a line of fishing shirts and polo shirts respectively.

Designers and apparel manufacturers appreciate the easy dyability of fibers made with Sorona since it reaches full color absorption at the boiling point of water. Unlike some other synthetic fibers, it doesn’t require additional heat, pressure or chemical carriers to dye. Fabrics print beautifully too – and prints remain sharp, vivid and

New Book!

Order now!

Hans-Josef Endres, Andrea Siebert-Raths Technische Biopolymere

Rahmenbedingungen, Marktsituation, Herstellung, Aufbau und Eigenschaften 628 Seiten, Hardcover

Engineering Biopolymers

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       

Order your english copy now and benefit from a prepub discount of EUR 50.00.

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

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Fiber Applications

crisp since fabrics are fade resistant from both sunlight and repeated washings.

The most unique attribute of Sorona, however, lies in the fact that this fiber is also an environmentally smart choice for textile and carpet markets. The performance of Sorona contributes to the overall sustainability since the performance keeps products look newer longer.

Since one of the ingredients is made with renewable resources instead of petrochemicals, Sorona is 37% renewably sourced by weight. Energy savings and reduced greenhouse gas emissions are added to the environmental benefits since the production requires 30% less energy and reduces CO2 emissions 63% over nylon 6 on a pound for pound basis.

Durability and performance also contribute to the sustainable aspects since products perform and look better, longer.

CARPET The ‘Performance PLUS Environmental‘ story of Sorona continues in carpet fibers for both residential and commercial applications. In carpeting, it offers a unique combination of benefits that customers’ value. In addition to providing durability and crush resistance, carpets with Sorona are permanently, naturally stain resistance. Since the stain resistance is an inherent attribute of the fiber, it will never wash or wear off and therefore never has to be reapplied.

Triexta, the new generic, also pertains to Sorona as a fiber for residential and commercial carpets. In test after test, carpets with Sorona outperformed both premium stain treated nylon and polyester carpet in both durability and stain resistance.

And the energy equivalent of 1 gallon of gasoline is saved for approximately every 7 square yards (1 liter per 1.55 m²) of residential carpet. Leaders in the carpet industry state that Sorona is the newest innovation to positively impact the carpet industry in over 20 years.

The benefits of Sorona in commercial carpet continue in green building design for commercial interiors. It’s permanent natural stain resistance and durability attributes delight both building residents and maintenance teams alike. Architects and designers appreciate the three ways that carpeting with Sorona can contribute to LEED’s points: 1) As a ‘Rapidly Renewable Material’ MR Credit 6; 2) as a ‘Regional Material’ MR Credit 5; and 3) ‘Low-Emitting Materials,’ IEQ Credit 3. The LEED program was established by the U. S. Green Building Council as guidelines for the design and construction industries.

Sorona is evidence of the innovation that results from intersections – the intersection of biology, chemistry and polymer science as well as the intersection of performance and environmental benefits.

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www.sorona.dupont.com www.renewable.dupont.com

Processing

Twin-Screw Extruders for Biopolymer Compounding

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NTEK Manufacturing, Inc., headquartered in Lebanon, Oregon, USA, the leading U.S. based manufacturer of twin-screw extruders and replacement wear parts, recently introduced customized twin-screw extruders specifically designed for bio-based compounding.

At NPE in Chicago in June, ENTEK showed a specially outfitted E-MAX™ 27mm twin-screw extruder designed for processing bio-based blends. It includes two dry feeders and a liquid feeder for processing a combination of thermoplastics and a bioresin or starch material.

The use of ENTEK twin-screw extruders for biopolymer processing is not new; in fact, the company’s machinery is currently being used by several processors worldwide in commercially successful bio-based applications. However, because of the ever-increasing number of biopolymer materials, additives and fillers being used in the industry, ENTEK has developed new machine configurations specifically designed for compounding materials in the following three areas:  Reactive bio-based materials (starch-based materials and plasticizers)  Bioresin materials (PLA, PHA, PSM, etc.)  Bio-based blends (Bioresins or Starches blended with Thermoplastics) “Our development lab has seen a real spike in the number of bio-based material and product trials,” said John Effmann, ENTEK Director of Sales and Marketing. “The experience we’ve gained from these trials, as well as our in-field bio experience, has helped us understand what’s

needed to successfully compound the many types of biobased materials on the market.”

ENTEK 27mm, 40mm, and 53mm twin-screw extruders are the most popular models for bio-based applications, but larger models such as the 73mm and 103mm machines are also in use for commercial applications. “Typically a customer will use our in-house development lab for material trials, then start with a 27mm or 40mm machine,” said Effmann.

“Once the bio-based compound makes it to market, the customer ramps up for production by purchasing our larger machines,” he said.

ENTEK was an early participant in biopolymer processing.

Back in 2004, Australian customer Plantic, a pioneer in biopolymer compounding, successfully processed their patented packaging products on ENTEK machinery before the term ‘biopolymers’ was common in the industry. The first Plantic products got their start in the ENTEK lab in Lebanon, Oregon, and the two companies continue a strong business relationship today.

While still a young industry, today biopolymers are a fastgrowing field. In 2008, bio-based material trials made up 36% of all trials run in ENTEK’s in-house development lab.

Several new players have emerged in the industry in this area, and ENTEK is working with many of them. New materials of all types are arriving at the company weekly, and ENTEK welcomes the opportunity to lend its lab and processing expertise for the next breakthrough biopolymer application. www.next-step.com

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Paper Coating

Improved Paper Coatings Article contributed by John T. Moore, Vice President- Business Development, DaniMer Scientific, Bainbridge, Georgia, USA

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any companies are building the value of their brands and growing their business by investing in development of product offerings that utilize renewable-based biopolymer materials. DaniMer Scientific, LLC is enabling brand owners and converters who focus on environmental stewardship to grow their market share by offering biopolymers for extrusion coating of paper and paperboard. Extrusion coating is an excellent application for biopolymers, and there is no current opposition concerning contamination of the existing recycle stream for paper articles when biopolymers are present. Further enhancing its appeal, DaniMer’s extrusion coating resin provides additional value by enabling coated articles to be repulpable. DaniMer’s advances in the use of biopolymers led to the introduction in 2006 of the world’s first commercial extrusion coating resin that meets global standards for compostability while utilizing renewable resources. This new DaniMer technology enabled International Paper to launch the Ecotainer product in a partnership with Green Mountain Coffee. Since that launch, DaniMer’s extrusion coating product has continued to enjoy the market’s embrace and steady growth. In fact, International Paper recently announced it has crossed the one billion cup milestone and is expanding their product line to include cold cups for a certain large global brand owner; further demonstrating that biopolymer coated paper substrates are more than just a fad. DaniMer has expanded its customer base and is working with key customers on a global basis in various stages of commercialization for new products.

DaniMer’s proprietary extrusion coating resin is based on NatureWorks Ingeo™ Biopolymer. Ingeo biopolymer is an excellent material, but requires modification for melt strength, melt curtain stability, and adhesion to paper in extrusion coating applications.

In most cases, DaniMer’s extrusion coating resin can be run on existing equipment with minimal adjustments relative to the

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Paper Coating setup typically used for low density polyethylene. One challenge encountered with the use of biopolymers is the need to process the material at lower moisture content than that typically acceptable for polyethylene. Like PET and other polyesters, biopolymers (which are typically bio-polyesters) can gain moisture when exposed to ambient conditions. Moisture management is often a new area of focus to most converters of LDPE. Another difference often noted with biopolymer materials such as the DaniMer extrusion coating resin is the lower processing temperatures than those used when processing traditional polyolefin materials such as LDPE. The ability to process at much lower temperatures enables an additional cost savings when using biopolymers. With proper training and instruction, most processing changes are recognized as minor and require only slight adjustment in procedure.

The market success that DaniMer has enabled its customers to experience with the first generation renewable-based, compostable extrusion coating biopolymer has led to development of a second generation formulation. Development of this second generation material is in the final stages of commercial-scale validation with cost reduction and broader operating parameters as the primary new characteristics. Increased efficiencies in manufacturing of the next generation material will translate into cost savings, which along with broader processing and converting parameters are expected to enable converters and brand owners to gain and retain greater market share for coated paper articles that are intended for single-use and short-term-use applications.

In response to requests from key market leaders, DaniMer has recently developed a wax replacement coating. This proprietary material is also made from renewable resources and is both compostable and repulpable. Traditional wax coatings are losing favor with paper companies and converters, due to large fluctuations in consistency and price. Utilizing their Seluma technology platform, the Danimer R&D staff has developed a wax replacement material using renewable based monomers to create a coating resin that can be used as a ‘drop in’ for existing wax coatings of paper and other substrates. Early customer evaluations confirmed that because the DaniMer material has a higher stiffness vs. wax, a reduction in part weight or paper thickness is possible resulting in significant overall package savings.

Photos: International Paper

DaniMer continues to focus on cost-effective innovation in order to serve brand owners and converters with a broad product portfolio of biopolymer materials. DaniMer recently acquired the Procter & Gamble intellectual property portfolio for a new type of biopolymer known as polyhydroxyalcanoate (PHA) and is commercializing the technology via a new company identified as Meredian, Inc. It is expected that Meredina PHA (scheduled for commercial-scale production in 2010) will provide additional innovations in the area of biopolymer technologies suitable for paper and paperboard coatings as well as for other unique combinations of biopolymers that will be offered through Meredian’s sister company DaniMer Scientific. www.danimer.com

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Paper Coating

Sustainable Cups from Georgia-Pacific Article contributed by John Mulcahy Vice President – Category Georgia-Pacific Professional Food Services Solutions Atlanta, Georgia, USA

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n August, Georgia-Pacific Professional Food Services Solutions launched a complete line of Dixie beverage solutions, which are part of the company’s EcoSmart product line that demonstrates the company’s commitment to innovative products that support sustainability goals.

The EcoSmart products includes two collections: A PLA-lined single wall paper hot cups made from at least 95 percent renewable resources; and the Insulair® line of insulated cups, available in 12 and 25 percent post-consumer recycled fiber.

The products are designed to allow operators to enhance their environmental stewardship position. These EcoSmart products can be processed successfully in commercial composting operations, where they exist. The PLA hot cup is 100 percent compostable because both the fiber portion and the coating are fully compostable.

This coating is supplied by NatureWorks. The Insulair collection contains a fiber portion which is fully compostable in commercial facilities. While the Insulair coating is not inherently compostable, it will separate from the fibers and can be screened out at the end of the composting operation.

“This is a tremendous step forward in the approach we take to responsible manufacturing,” notes John Mulcahy, vice president – category, Georgia-Pacific Professional Food Services Solutions.

“The EcoSmart line represents some of the most groundbreaking products available to operators and is just one example of our dedication to providing sustainable solutions that create a positive impact on the world around us.”

New from Georgia-Pacific Food Services Solutions, the PLA coated cup collection is printed with a green foliage stock design, Viridian™, and available immediately in 8-, 10-, 12-, 16- and 20ounce sizes.

The Insulair insulated hot cup collection features 12 and 25 percent post-consumer recycled fiber options. Both feature triple-wall construction and an insulative middle layer that keeps beverages hot while staying cool to the touch. The corrugated middle layer is comprised of 99 percent post-consumer recycled fiber.

Insulair is available in attractive stock designs, including Viridian™, Aroma™ and Interlude™, and in 8-, 12-, 16-, 20- and 24-ounce sizes. The cup also boasts custom graphic capabilities with sharp resolution and rich colors, which have won Bronze, Silver and Gold at the 2008 Flexography Awards international design competition. www.gppro.com

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Polylactic Acid

Uhde Inventa-Fischer extended its portfolio to technology and production plants for PLA, based on its long-term experience with PA and PET. The feedstock for our PLA process is lactic acid which can be produced from local agricultural products containing starch or sugar.

The application range is similar to that of polymers based on fossil resources. Physical properties of PLA can be tailored to meet the requirements of packaging, textile and other applications.

Think. Invest. Earn.

Uhde Inventa-Fischer GmbH Holzhauser Strasse 157–159 13509 Berlin Germany Tel. +49 30 43 567 5 Fax +49 30 43 567 699 Uhde Inventa-Fischer AG Reichenauerstrasse 7013 Domat/Ems Switzerland 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

Application-News

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n conjunction with the new 62N BioTAK™ contact adhesive, German company Herma is offering a unique adhesive material that is 100 % biodegradable. Located in Filderstadt near Stuttgart, Herma GmbH is a leading European specialist in self-adhesive technology. The new contact adhesive satisfies the European standard DIN EN 13432 which certifies products made from compostable materials. A white, lightweight coated paper and three different films are available as the label material. The patented 62N BioTAK contact adhesive is used on all of them. “Biodegradable materials based on renewable raw materials have already had a huge impact on the packaging materials sector,“ explains Herma managing director Dr. Thomas Baumgärtner. “Consumers are already showing a growing interest in where packagings come from, and whether they can be reused; natural cosmetics, fruit and vegetable packagings and all the products in the burgeoning organic sector are good examples of this trend.“

Fully Compostable Self-Adhesive Labels HERMAnaturefilms – films made from wood In the certification procedure, the HERMAnaturefilms widely exceeded the requirements. To comply with EN 13432, 90 % of the material must have biodegraded after 45 days. The HERMAnaturefilms achieved this value after only 31 days and were fully degraded after 39 days. The special films are obtained from cellulose supplied by FSC-certified companies (from sustainable forestry). The films can be printed using solvent-free and water and UV-based inks by all conventional printing methods; they are antistatic and repel oil and grease. Paper converters also benefit from the high moisture and oxygen barrier. “The film is already used as a packaging material by a large number of major food manufacturers and packaging companies. With labels made from our HERMAnaturefilms, these packaging materials are now fully compostable,“ stresses Baumgärtner. Thanks to the high gloss level, they even meet the sophisticated needs of cosmetics packagings.

The biodegradable adhesive material is a further addition to HERMA‘s ‘GreenLine’ product range. Just recently the company included PEFC-certified paper adhesives and label papers in its offering. “In this way label manufacturers will now be able to take even greater advantage of the growing demand for environmentally friendly packagings and marking systems,“ states Baumgärtner.

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Labels using BioTAK adhesive (Photo: courtesy BioTAK)

Application News

Biobased and Compostable Shrink Film

Sustainable and compostable, metallised NatureFlex™ NM wraps Dr Vie Inc’s nutritional products

Nutritional Canadian Products Canadian company, Dr Vie Inc, is wrapping its entire range of nutritional ‘superfood’ products in metalized NatureFlex™ NM film from Innovia Films, Wigton, Cumbria, UK. Based in Montréal, Québec, Dr Vie Inc is a family-owned business managed by a mother and daughter team. A family history of ill health inspired their mission to create powerful low-allergenic superfoods that stimulate wellness, enhance a feeling of well-being and prevent illness.

The company’s 100% all-natural products are lowglycemic, high in antioxidants, essential omegas and fatty acids. The product line includes a variety of pure cacao products, antioxidant-rich goji berry and acai berry raw chocolate bars, sports nutrition bars and frozen desserts.

Dr Vie Inc has recently partnered with a global team of elite sports, IronMan and Olympic team coaches and their products are now available worldwide online to athletes, in addition to Canadian health food, sports, wellness centres and speciality stores.

At the recent 2nd PLA Bottle Conference, hosted by bioplastics MAGAZINE within the supporting programme of drinktec in Munich, Germany, alesco presented as a World premier a compostable shrink wrap film manufactured from renewable raw materials. This film makes the company, which is based in Langerwehe, Germany one of the first packaging film manufacturers in the world to offer such a product. The film has been named BIOSHRINK and will initially be available to wrap 6 x 0.5 litre PET and PLA drinks containers, with additional sizes to follow. The film has already been successfully tested by the soft drinks bottler SDI. SDI produces mineral water and about 180 different fruit juices and soft drinks and supplies major German discounters. As with all other compostable biofilms produced by alesco in accordance with EN 13432, the new bio shrink film will be produced carbon neutrally and with the exclusive use of green electricity, and it will be printed with water colours upon customer request for impressive advertising.

The development of compostable shrink film from renewable raw materials has been one of the great challenges that processors of plastics have faced in recent years. “When we introduced our first alesco biofilm two years ago, we didn’t think it would be possible to present a readyfor- market compostable shrink film within such a short space of time,” comments a proud alesco Managing Director Philipp Depiereux.

The key issue was developing a formula that allowed for reliable shrinking as well as surface properties for optimal gliding behaviour and printing with solventfree, water-based inks. The development engineers at alesco successfully solved this issue. www.alesco.com

Dr Vie Inc individually cuts and shapes the roll of NatureFlex film to wrap each product at their factory.

According to company founder, Dr Vie, NatureFlex is an ideal packaging choice: “Our company’s goal is to promote wellness, optimise individual performance and protect the planet in the process. NatureFlex is fully sustainable and aligns beautifully with our core values”.

The high barrier against water vapour (WVTR <10g/m²/ day @ 38degC, 90% RH) of NatureFlex NM keeps the Dr Vie products in premium condition.

www.innoviafilms.com www.drvieinc.com

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Application News

Green Packaging Line A new ‘Green Packaging Line‘ of products has been recently developed by Smurfit Kappa, Orsenigo, Italy, a leading company specialised in the sector of innovative cardboard based packaging.

It has adopted a new technology offered by Novamont, Italy and Iggesund Paperboard, a leading company active in the sector of high quality coated boards, headquartered in Iggesund, Sweden.

World’s First Bioplastic Eyeglasses Japanese Companies Teijin Limited and Teijin Chemicals Limited announced the development of eyeglass frames made from plant-based, heat-resistant PLA BIOFRONT™, the world’s first bioplastic to be used for all plastic parts of eyeglass frames, including the temples. The frames were developed in collaboration with Tanaka Foresight Inc., Higashi-Sabae City, Japan, which manufactures and sells approximately 60% of all plastic eyeglass parts in Japan.

The new Biofront frames will be exhibited at the Tanaka Foresight booth during the International Optical Fair Tokyo (IOFT 2009) at Tokyo Big Sight from October 27 to 29. Tanaka Foresight eventually expects to sell between 50,000 and 100,000 pairs of PLA eyeglasses per year.

Although acetate is commonly used for the plastic parts of eyeglasses, contact with cosmetics or hairstyling products can result in bleaching. Acetate also tends to warp under high heat and can cause skin rashes.

PLA (polylactide) has been used for eyeglass nose pads because its antibacterial properties help to avoid rashes, but conventional PLA has not been used for other parts such as frames and temples because of insufficient heat resistance.

Biofront, however, is an advanced polylactide that offers enhanced heat resistance. Its melting point of 210 °C puts it on par with PBT, a leading engineering plastic. Biofront also is highly resistant to bleaching and bacteria, making it ideal for the plastic parts of eyeglasses. www.teijin.co.jp

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This new rigid packaging line, which comprises trays, punnets and containers for fresh and frozen food, bakery, confectionary and others, is based on the virgin fibre paperboard Invercote, coated through extrusion coating technology with a compostable Mater-Bi polymer.

This special coating brings various technical properties to the cardboard, like an excellent sealability, good thermal stability and water, oil and fat protection.

Given these properties, Smurfit Kappa Orsenigo is able to supply a wide range of products for cold and hot, dry and wet food packaging applications, in the retail, catering and Ho.Re.Ca. (=Hotel/Restaurant/Café) areas, like: Deep frozen packaging, trays and punnets for ready cut salad or fresh fruits or vegetables, ready meals and take away containers, fresh cheese and dairy products, sweets, chocolate, bakery.

Moreover, several non food applications can be taken into consideration, like agro-floricultural ones, customised gifts, wear packaging.

Besides being food contact approved, biodegradable and compostable (according to EN13432), the ‘Green Packaging Line’ products may also be disposed in the paper stream, because the Mater-Bi coating has been designed as well in order to meet the paper and cardboard recycling requirements.

The result is an extremely versatile and sustainable range of products, because of its multiple end of life options.

www.smurfitkappa.it www.novamont.com www.iggesund.com

Application News

The ‘Green‘ Shaver Established in 1945, the Société BIC is a Clichy, France based, well recognized one-time-use products manufacturer. The company specialises in ballpoint pens, cigarette lighters, razors and many more such products. The BIC Group is committed to a pragmatic approach when it comes to materials which have a better environment performance: to experiment them. This is why the company started to implement different material alternatives in their products and packaging recycled or coming from renewable resources.

This is the case for example for the new BIC ECOLUTIONS triple blade shaver with its bioplastic handle and its 100% recycled cardboard packaging. After 5 years of research, BIC succeeded to develop a handle made with Ingeo T PLA and other additives that resists to the constraints of shaving. In addition bio-pigments of vegetable origin give this shaver a distinct green color and the recycled pack is printed with bio inks made of vegetable based pigments (soy).

Consumers usually perceive ‘green‘ products as expensive. However with a suggested retail price of €3.20 per pack of four shavers, BIC® ecolutions™ remains affordable to everyone. - MT www.bicecolutions.com

Eco-Conscious Parenting Solutions

Dorel Juvenile Group, Inc, Columbus, Indiana, USA, the largest juvenile products manufacturer in the USA, recently launched its Safety 1st® Nature Next collection as part of its ongoing initiative to focus on the environment. The special collection addresses a growing concern among parents who want to provide quality products for their children that incorporate eco-conscious materials.

“We recognize the need – and our customers’ desire – to make products that help keep children safe and healthy,“ said Vinnie D’Alleva, EVP Business Development at Dorel, “but with a view to maximizing the environmental benefits.

We are also pleased to bring the collection to retail at an accessible price point that all parents can appreciate.”

The Nature Next collection features the following ecoconscious materials, such as bamboo, a quick-growing and renewable resource. It is able to rapidly replenish itself, making it a great alternative to traditional woods. In addition, bamboo can thrive with little water and does not require the use of fertilizers or pesticides, further reducing its environmental impact.Bioplastics: The starches used in the Nature Next collection’s items are all plant byproducts, not crops that could otherwise be used as a food source.

Dorel also applies recycled plastics.

The line currently includes a Bamboo Booster Seat (photo), Bamboo Gate, Bio-Plastic Infant-to-Toddler Bathtub, BioPlastic Booster and Bio-Plastic 3-in-1 Potty. http://naturenext.safety1st.com

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Materials

Biobased Engineering Plastic

www.dsm.com

Castor beans

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SM Engineering Plastics from Sittard, The Netherlands, has expanded further its Green Portfolio with the introduction of EcoPaXX™, a bio-based, high performance engineering plastic. The new material, which is based on polyamide (PA) 410 (or PA 4.10), has been developed by DSM in recent years, and is now set to be commercialized.

High performance Polyamide 410 is a ‘long-chain polyamide’. Thus EcoPaXX is a high-performance polyamide with excellent mechanical properties. It combines typical long-chain polyamide properties such as low moisture absorption with high melting point of 250°C (the highest of all bio-plastics) and high crystallization rate enabling short cycle times and thus high productivity. The material has excellent chemical and hydrolysis resistance, which makes it highly suitable for various demanding applications, for instance in the automotive and electrical markets. A good example is its very good resistance to salts, such as calcium chloride.

Because of its low moisture absorption, EcoPaXX will also keep good strength and stiffness after conditioning.

Zero carbon footprint Newly-introduced EcoPaXX is a green, bio-based material: The polyamide 4.10 consists of the ‘4‘-component (fossil oil based diaminobutane) and the ‘10‘-component (approximately 70% of the polymer) derived from castor

oil as a renewable resource. Castor oil is a unique natural material and is obtained from the Ricinus Communis plant, which grows in tropical regions. It is grown in relatively poor soil conditions, and its production does not compete with the food-chain.

As not all carbon of the castor beans (or even of the castor plants) is being used for making the building blocks of the PA 4.10 there is still a certain amount of carbon sequestered by the castor plant that is being used as an energy source for the PA production or as fertilizer. Thus EcoPaXX can be seen as to be 100 % carbon neutral from cradle to gate, as per DSM, which means that the carbon dioxide which is generated during the production process of the polymer, is fully compensated by the amount of carbon dioxide absorbed in the growth phase of the castor beans. According to Kees Tintel, project manager EcoPaXX “the carbon footprint of plastics is rapidly becoming a hot issue for Customers, therefore they really appreciate EcoPaXX being carbon neutral!”

Market introduction phase “DSM Engineering Plastics is proud to have EcoPaXX, the ‘Green Performer’ , in a market introduction phase.

Combining unique DSM knowledge with the skills of Mother Nature allows our Customers to benefit from a new step towards a more sustainable world” says Roelof Westerbeek, President of DSM Engineering Plastics. - MT

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Materials

Injection Moldable High Temperature Bioplastic

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aunched in March 2009 by Colombes (France) based Arkema, RilsanÂŽ HT for extrusion is the first flexible high-temperature thermoplastic to replace metal in high-temperature applications. Now, the company unveiled Rilsan HT injection resins. The Rilsan HT range is now the first complete polyphtalamide (PPA)-based product line suitable for all process technologies, ranging from extrusion to blow or injection molding. Rilsan HT resins are up to 70% bio-based (according to ASTM D6866-06, biobased carbon) and match the increasing environmental commitment of many industries.

PPA-based injection resins in automotive applications have increasingly replaced metal parts as a way to optimize costs, reduce emissions and weight, improve fuel economy and extend car life. Until now, PPA-based injection resins were more difficult and costly to process when compared to aliphatic high-performance polyamides.

According to Arkema, Rilsan HT is the only PPA-based injection resin that offers processing characteristics similar to those of aliphatic high-performance polyamides. With mold temperatures close to those of PA12 and PA11, it can be easily processed on standard injection-molding equipment using conventional water-cooled temperature control. Moreover, the material can be processed in injection molds designed for PA12 and PA11 thanks to similar mold shrinkage properties.

Unlike conventional PPA-based resins, Rilsan HT has very low moisture uptake, which provides multiple benefits in manufacture and applications. Low moisture pickup means that the resin is easily stored and requires no supplemental steps before processing. Low moisture absorption makes the resin easy to process and handle, and imparts reliable uniformity to the finished partsâ&#x20AC;&#x2122; properties, which avoids further downstream processing and limits waste. The finished parts exhibit excellent dimensional stability.

Rilsan HT injection grades have exceptional ductility not found in typical semi-aromatic injection resins. Thus the resins deliver a designer-friendly balance of toughness, strength and elongation and reduce the risk of failures that can occur with brittle plastics, such as conventional PPAbased injection materials or PPS. Conductivity combined with ductility make it the first conductive PPA-based injection resin that perfectly balances high temperature resistance and excellent mechanical properties with conductivity â&#x20AC;&#x201C; making it well suited for fuel system applications where conductivity is specifically required, as it is for example in the North American market.

As stated by Arkema, this new PPA-based injection resin is the only one that can be easily spin-welded with aliphatic high performance polyamides, a completely new processing feature for this material group. This offers further component integration and addresses the enhanced safety and emission standards of pipe connections in fuel-conducting systems.

Rilsan HT injection grades - glass-fiber reinforced or formulated for conductivity - are ideally suited for metal replacement in fuel system applications requiring low permeation, low swelling and high thermal resistance. And the suitability of the injection grade for quick-connectors and other temperature resistant parts extends to powertrain components including those integrated with Rilsan HT flexible tubing.

Largely derived from renewable non-food-crop vegetable feedstock, the polyamide material is a durable high-temperature thermoplastic containing up to 70% renewable carbon. It offers a significant reduction in CO2 emissions compared to conventional petroleum-based high-temperature plastics, a reduced dependence on oil resources and a perfect fit with the eco-design concepts of many vehicle manufacturers. www.arkema.com

bioplastics MAGAZINE [05/09] Vol. 4

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Materials

C

omposite Technical Services Inc. (CTS), based in Kettering (Dayton), Ohio, USA, have recently established manufacturing and research and development operations. Combining innovation with environmental sustainability, CTS is providing high performance, cost effective materials and technology that include unique bio-resins and flame retardant additives. Housed in the National Composite Center (NCC), CTS is initially targeting the composites and plastics industries.

Versatile Precursor Made From Cashew Nuts Cardanol from Cashew One versatile precursor for a variety of polymers is cardanol, a phenol derivative having a C15 unsaturated hydrocarbon chain with one to three double bonds in meta position. It has interesting structural features for chemical modification and polymerization. Cardanol can be obtained from anarcadic acid, the main component of Cashew (Anacardium occidentale L.) Nut Shell Liquid (CNSL) by double vaccum destillation.

CNSL is a renewable natural resource obtained as a by-product of the mechanical processes used to render the cashew kernel edible. Its total production approaches one million tons annually. If not used as a widely available and low cost renewable raw material, CNSL would represent a dangerous pollutant source.

Cardanol-phenol resins were developed in the 1920s by a student of the Columbia University (New York) named Mortimer T. Harvey.

The name â&#x20AC;&#x2DC;cardanolâ&#x20AC;&#x2DC; comes from the word Anarcadium, which includes the cashew tree, Anarcadium occidentale. The name Anarcadium itself is based on the Greek word for heart.

Cardanol-based resins Based on this, CTS is currently working on a breakthrough brand called Exaphen. Exaphen products use a process that extracts (exa) phenolic (phen) resins from agricultural by-products such as CNSL while retaining the special properties nature has already engineered. A unique chemical structure gives phenolic-type resins the capability to fight fire and delay the spread of flames combined while providing resistance to aggressive environments.

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Photo: Barnabà

Materials

CTS offers a series of products based on the phenolic structure derived from cashew nut shells.  Cardanol-based phenolic resins (novolacs) as curing agents of commercial epoxy resins;  Cardanol-based polyols (POLYCARD XFN™) for the preparation of polyurethanes;  Cardanol-based epoxy-novolacs (NOVOCARD XFN™);  Saturated and unsaturated polyester resins prepared using cardanol derivatives;  Cardanol-based aminoalcohols to be used in polymeric matrices with a polyurea scaffold;  Cardanol-based acrylic and methacrylic monomers as additives for coating or varnishes;  Cardanol-based benzoxazines as either coupling agents for glass and natural fibres or as reticulating agents for epoxy resins.

Cardanol based polyols for poluyrethanes Polycard XFN product line is a family of earth-friendly polyols derived from cardanol for the formulation of both high and low density rigid polyurethane foams, flexible polyurethane foams for use in insulating foams, mattresses and couches, elastomers and coatings. The high percentage of primary hydroxyl groups give these polyols a relatively high rate of reactivity with isocyanates. In addition to classic polyols an aminolachol monomer, AMINOLCARD XFN-AM120, is available.

References: CTS-Materials Divison Brochure wikipedia Tullo, Alexander H.: (September 8, 2008). „A Nutty Chemical“. Chemical and Engineering News 86 (36): 26–27.

Senning, Alexander: (2006). Elsevier‘s Dictionary of Chemoetymology. Elsevier.

ISBN 0444522395 Ikeda, Ryohei et. al.: (2000). „A new crosslinkable polyphenol from a renewable resource“. Macromolecular Rapid Communications 21 (8): 496–499.

Cardanol based epoxy hardeners Novocard XFN products are liquid cardanol/formaldehyde novolacs designed to be used as curing agent in formulating heat cured bisphenolA and bisphenol-F epoxy resins. Their long alkenyl side chains impart flexibility in cured epoxy resins. The intrinsic properties of the phenolic structure are chemical resistance, heat and flame resistance. Novocard XFN can also be used as polyols for polyurethane formulations.

Cardanol based epoxy monomer and resins Epocard XFN™ are epoxy monomers and resins suitable for composite manufacture and coating applications which are available in a wide range of viscosities. The alkyl side chain of the phenolic ring enhances the final product flexibility, while the phenolic structure enhances chemical resistance, heat and flame durability. Epoxy Equivalent Weight and their formulation can be tailored for any end-use. - MT www.ctsusa.us

bioplastics MAGAZINE [05/09] Vol. 4

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End of Life Sales Finished product producers

EEnd nd users users

CCollection o llection P artners Partners Sorting recovery S orting &&reco very entities entities Loopla

PLA pellets

Shipment of used P LA lot Partners PLA producers

Loopla Lactic acid

Patented technology

A new Cradle-to-Cradle

G

alactic is a Belgian company involved in the world of green chemistry with its lactic acid being produced by fermentation of a biomass such as beet or cane sugar. Lactic acid is used in different applications such as foodstuffs, cosmetics and pharmaceuticals, as well as in industrial applications.

Chemical Recycling vs. other ‘end-of-life‘ options

Lactic acid is also used as the starting material for the production of polylactic acid or PLA, an eco-friendly, renewable biopolymer with attractive characteristics for packaging and other convenience applications.

 Low chemicals needed

Introduction to LOOPLA® Although PLA is derived from renewable resources, Galactic has conceived the LOOPLA process to provide the best ‘end-of-life‘ option for PLA waste and contribute to the development of a sustainable environment.

The LOOPLA concept is a closed loop where the used PLA is recovered and recycled back into its original form: lactic acid. This lactic acid can easily be polymerised again to make PLA with exactly the same characteristics as the original material.

Carbon footprint The patented technology is a chemical recycling process that goes back from PLA to lactic acid by depolymerisation through hydrolysis. The process does not need harmful chemicals and is optimised to create a minimum CO2 footprint.

Currently there are several ‘end-of-life‘ options available: mechanical recycling, incineration, composting, anaerobic digestion and land filling.

All energy and raw materials invested in the original PLA are recovered as the recycling rate with LOOPLA is close to 100% and provides a low carbon footprint.

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bioplastics MAGAZINE [05/09] Vol. 4

With this concept, GALACTIC is proud to contribute to a more sustainable solution for the ‘end-of-life‘ management of PLA waste:  Less energy consumption

 Recycling rate close to 100%  Recycling process is endless  Less agricultural land needed  shorter recycling loop means: - lower CO2 foot-print - Cheaper process

End-users The success of LOOPLA is related to the contribution of the different parties involved in the recycling process.

The sorting and recovery of the used PLA is key in the efficiency of the process: PLA is used in a wide range of applications including food packaging, beverage containers, cars, electronic, housing etc. Two types of material are identified: the nearly 100% PLA, and material combinations such as blends, compounds and composites. LOOPLA not only recovers close to 100% of the lactic acid used for the production of PLA, it also takes care of possible contamination of the used PLA.

All PLA waste can be put into one of three different categories:  ‘Post-industrial‘ waste or production waste that consists of out-of-specification material or objects produced during trial runs, production start-up procedures or as trimmings or runners and sprue in injection moulding.

End of Life

ECO-Benefits (points) 200 160

180 160 140 120 100 80 60 40 20

3

10

20

0

Composting

Incineration

Anaerobic digestion

LOOPLA

Approach for PLA The material flow is generally very clean and does not need specific sorting.  ‘Short-loop‘ or ‚closed-loop‘ waste that is locally generated during a defined period: cups during a music-festival, catering in aeroplanes etc… and even non-woven carpets, combining a wide range of colours and patterns as used during an exhibition, can be sorted out and recycled.

Indeed, the flow of waste generally does contain other materials. A creative effort has to be realised in order optimise the process and efficiently sort PLA from other materials.  And finally, ‘post-consumer‘ waste. The process for this kind of waste is the most complex one. For example, bottles made of PLA and PET are mixed together. It is important to sort PLA from PET to avoid a negative impact on the recycling of PET (yield and quality) and also to be able to recover a single stream of PLA in order to recycle it.

Technical solutions are available on the market, including NIR installations or a green chemical treatment able to separate PLA (more than 99%) from PET.

LOOPLA technology According to the origin of the used PLA, the process will be adjusted: the treatment is not the same if the stream is clean or dirty, pure or contaminated. The contamination can arise from a problem of sorting or when the product is made from different materials. In case of contamination, the process can be easily adjusted in order to remove the contaminant(s) with no consequence on the quality of the final lactic acid.

At the end of the cycle, the lactic acid obtained by depolymerisation will be purified according to the targeted applications (industrial applications or polymer production).

Article contributed by Johnathan Willocq, Project Engineer Developments n.v. Galactic s.a., Escanaffles, Belgium

A little chemistry Lactic acid is a chiral molecule and has two optical isomers. One is known as L-(+)-lactic acid and the other, its mirror image, is D-(−)-Lactic. L-(+)-Lactic acid is the biologically important isomer.

During the polymerisation and the production of the original product, the treatments generate a racemization of the lactic acid. If PLA is made of L-(+)-Lactic acid, only a small quantity of D-(−)-Lactic will remain in the final product.

Then, lactic acid coming from the LOOPLA technology contains a low amount of D-(−)-Lactic but the production of PLA is feasible.

The research and development team has developed a process in order to reach a high L polymer grade of lactic acid.

Galactic has acquired a deep knowledge of the PLA market with its involvement in Futerro, a joint venture created between Total Petrochemicals and Galactic. The project entails the construction of a demonstration plant able to produce 1,500 tonnes of PLA per year using a clean, innovative and competitive technology, developed by both partners.

Thanks to the LOOPLA concept, PLA can be then depolymerised back into lactic acid which also could be the raw material for a wide range of products including solvents, detergents, textiles, food and beverages containers...

PLA is a renewable and sustainable resource with countless possibilities! www.loopla.lactic.com

bioplastics MAGAZINE [05/09] Vol. 4

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Report

I

n a new series bioplastics MAGAZINE plans to introduce, in no particular order, research institutes that work on bioplastics, whether it be the synthesis, the analysis, processing or application of bioplastics. The first article introduces the Fraunhofer Institut für Angewandte Polymerforschung in Potsdam-Golm, Germany The Fraunhofer Institut für Angewandte Polymerforschung IAP (The Fraunhofer Institute for Applied Polymer Research) is one of about 60 Institutes within the Fraunhofer Gesellschaft e.V., a non-profit organization headquartered in Munich, Germany.

The institute‘s budget in 2008 was about € 12 million, 30% of which was government funded and 70% acquired from other sources (35% by way of publicly funded research projects and 35% directly from industry projects)

Fraunhofer IAP

In the preface to the institute‘s 2008 Annual Report, Professor Hans Peter Fink, director of the institute writes: “We are living in the age of plastics. Polymers are everywhere, found in plastics and in many other applications like fibers and films, foam plastics, synthetic rubber products, varnishes, adhesives, and additives for construction materials, paper, detergents, cosmetic and pharmaceutical industries. In addition to innovative developments in polymer functional materials, research is now focusing on the sustainability of the polymer industry. Environmentally friendly and energy efficient production processes and the utilisation of bio-based resources, which are not dependent on petroleum, are playing a vital role. The Fraunhofer IAP is well positioned in this regard with its unique competencies in the area of synthetic and bio-based polymers…“

PLA In the area of biopolymers, the Fraunhofer IAP is active in particular in the field of synthesis and material development of bio-based polylactide (PLA) in connection with the establishment of production facilities in Guben (on the German/Polish border).

A biopolymer application center is being planned at the site in collaboration with the investor Pyramid Bioplastics Guben GmbH. Here, a project group from IAP will develop PLA grades, blends and composites for different fields of application such as films, fibers, bottles, injection moulded or extruded products and many more. The research and development of blends and copolymers of L- and D-lactides is also part of the planned activities.

Bead cellulose with porous and smooth surface

Further research activities concentrate on naturally synthesized polysaccharides such as cellulose, hemicellulose, starch and chitin, which are available in almost unlimited quantities.

The opportunities for using cellulose and starch biopolymers, which have been available in almost unlimited quantities for a long time, are far from being exhausted. One focus of the research and development at the Fraunhofer IAP is on these versatile raw materials. New products and environmentally friendly production methods are being developed at the IAP thanks to the growing amount of knowledge concerning the exploration, characterization and modification of these polymers.

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Report Cellulose Cellulose is the most frequently occurring biopolymer, and as dissolving pulp it is an important industrial raw material. It is processed into regenerated cellulose products such as fibers, non-wovens, films, sponges and membranes. It can also be processed into versatile cellulose derivatives, thermoplastics, fibers, cigarette filters, adhesives, building additives, bore oils, hygiene products, pharmaceutical components, etc.

Charpy, un-notched [kJ/m²] 50

- 23 °C - 18 °C 40

30

20

Composites Cellulose-based man-made fibers (rayon tyre cord yarn) are a serious alternative to short glass fibers for reinforcing even biopolymers such as PLA or PHA. Rayon fibers have advantages over short glass fibers in terms of their low density and abrasiveness. Furthermore, they do not pierce the skin as do glass fibers, which makes them much easier to handle.

When rayon fibers are combined with PLA, a completely biobased and biodegradable material is formed. One of the crucial disadvantages of PLA is its low impact strength. In composites, rayon fibers can increase impact strength significantly, as they act as impact modifiers.

By reinforcing a polyhydroxyalkonoate (PHA) polymer with cellulose-based spun fibers, biogenic and biodegradable composites were obtained with substantially improved (in some cases double) mechanical properties as compared with the unreinforced matrix material. bioplastics MAGAZINE will publish more comprehensive articles about these findings in future issues.

Starch Starch is another indispensable resource with a long tradition.

The substance’s many functional properties make it suitable for use in the food sector and for technical applications. Nonfood applications include additives for paper manufacture, construction materials, fiber sizes, adhesives, fermentation, bioplastics, detergents, and cosmetic and pharmaceutical products.

10

native

15%

25%

30%

Fiber content

Un-notched Charpy impact strenght of rayon reinforced polylactic acid vs. fibert content.

Charpy, notched [kJ/m²] 10

- 23 °C - 18 °C 8

6

4

2

native

15%

25%

30%

Fiber content

Notched Charpy impact strenght of rayon reinforced polylactid vs. fiber content.

To further their aim of comprehensive utilization of biomass for such materials, scientists at Fraunhofer IAP have developed strong lignin competencies in recent years. They have also investigated the use of sugar beet pulp for polyurethane production.

The use and optimization of biotechnology with the aim of directly applying the biomass by extraction and plant material processing is a further focus of Fraunhofer IAP‘s biopolymer research. With its comprehensive expertise in the field of biopolymers and long-standing experience and knowledge of polymer synthesis, the institute is highly qualified to develop products and processes in various areas of biopolymers, ranging from applied basic research in the laboratory to pilot plant operation. - MT

SEM micrograph of a cellulose melt blown nonwoven

www.iap.fraunhofer.de

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Basics

Raw materials and required for

I

n the last issue of bioplastics MAGAZINE we looked at the basic principles of ‘Land use for Bioplastics’. Following this general introduction we now put forward some more concrete facts concerning the specific biopolymers. The following article is an edited extract from the new book entitled ‘Technical Biopoymers’, written by Hans-Josef Endres and Andrea Siebert-Raths. The book has already been published in German and will be available in English at the beginning of next year (see also page 15).

To evaluate the land area required for biopolymer production the annual yield from different renewable raw materials is illustrated below.

In Fig. 1 the raw materials have been grouped into sugars, starches, plant oils and cellulose or fibrous materials to facilitate comparison. It can be seen that the sugars offer the highest yield. Starches too deliver relatively high yields, whilst the yield from renewable plant sources of oils or cellulose is, in comparison, significantly less. Among the oils it is only palm oil and perhaps jatropha oil that offer yields approaching that of the starches.

In order to determine the annual amount of biopolymer that can be produced per unit of land area (the biopolymer yield per area) it is also necessary to take into account the data in Fig. 2, i.e. the various biobased percentage of each biopolymer. With the blends in particular there is a wide range of bio-based content because petrochemical components and additives are often also used in the blend.

Furthermore, consideration must be given to the efficiency of converting the biobased materials listed, i.e. the initial amount of the raw material required to produce the particular bio-based component.

Based on the respective percentage of bio-based material and the amount of renewable raw material required for this, Fig. 3 shows the representative relationship of the amount of bio-based input material to the total amount of material output. When ethanol is used as an intermediate step almost 0.5 tonnes of ethanol per tonne of sugar is output. But it must be noted that almost no biopolymers are 100% bio-based. At times the bio-based element of the material is below 25% by weight, i.e. in such a case 75 % of the weight of the material is in no way to be considered when calculating the necessary amount of land because it is not based on renewable raw materials. Basically the lower the percentage of bio-based material the higher the relationship of the absolute quantity of bio-polymer to the area under cultivation. This also shows the direct comparison of the data in figures 2 and 3, each of which represents a basically inverted proportionality. A statement of the biopolymer output per unit of arable land without taking into consideration the percentage of bio-based material in that polymer is therefore not sufficient.

When calculating the outputs of biopolymer materials and the input of renewable raw material required, as shown in Fig. 3, the following assumptions were made:

1: Cellulose acetate (CA): Percentage of cellulose based material 40 – 50 percent by weight Since even with partially biodegradable cellulose acetate at least about 2/3 of the hydroxyl groups in the glucose element unit are replaced by acetal groups (for details please see the respective section in the book), i.e. the degree of substitution is as a rule greater than 2.0, and in addition non-bio-based softeners of up to a maximum of 30 % by weight are used, for cellulose acetate an initial input amount of between 40 and 50 %

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bioplastics MAGAZINE [05/09] Vol. 4

5

Flax

Cotton

Hemp

Wheat straw

Soy oil

Wood fibres

Rapeseed oil

Sunflower oil

Cocoa oil

Castor oil

Jatropha oil

Palm oil

Rice starch

Wheat starch

Potato starch

Sugar (beet)

Maize starch

Sugar (cane)

0

Fig 1: Absolute yield of various renewable raw materials per hectare per annum

100%

80%

60%

40%

20%

Biopolyesters9

Biopolyethylene (BIO-PE)10

Biopolyesters9

Biopolyethylene (BIO-PE)10

Bioenthanol8

Polylactide blends

Polyhydroxyalkcanoates (PHA)

7

6

Polylactides (PLA)5

Starch blends4

Thermoplastic starches (TPS)3

Cellulose acetates1

0%

6 5 4 3 2 1

Bioenthanol8

Polylactide blends6

Polylacticdes (PLA)5

0

Starch blends4

Output: tonnes of biopolymer or bioethanol / Input: tonnes of regenerating raw materials

Fig 2: Percentage of renewable raw materials by weight in various biopolymers

Polyhydroxyalkcanoates (PHA)7

To optimise the properties in the processing and use of thermoplastic processable starch polymers it is necessary for native starch - as already

Cellulose (fibres)

10

Thermoplastic starches (TPS)3

4: Starch blends: Starch-based percentage 25 - 70 percent by weight

Plant oils

15

3: Thermoplastic starch (TPS): Starch based percentage of the material 70 - 80 percent by weight To optimise the performance of thermoplastic starch in processing and use, native starches must be modified and/or in particular be added with a softener such as glycerine or sorbitol (for details please see the respective section in the book).

To calculate the average starch content, a total conversion of 100 % of the unmodified starch to a biopolymer was assumed. For starch acetate on the other hand, similar to cellulose acetate with a high degree of substitution, a starch requirement of only 600 kg per tonne is required. For the remaining additives or softeners raw materials of petrochemical origin were assumed. We can therefore assume on average that thermoplastic starch materials require an input of 70 to 80 % by weight of starch itself.

Starches

Cellulose acetates1

Cellulose regenerates are used in the biopolymer sector mainly as coated film (e.g. with a barrier coating or sealing layer). From the point of view of the weight of the dominant material a cellulose percentage of near enough 100 % can be assumed.

For the coating, a percentage by weight of at the most 10 % is assumed. Normally the coating will account for a much smaller percenatge.

Sugars

20

Cellulose regenerates2

2: Cellulose regenerate: Percentage of cellulose based material 90 - 99 percent by weight

25

Cellulose regenerates2

by weight is required. This means that under certain circumstances up to 60 % of the material is not cellulose at all but is based on acetic acid (largely produced under pressure by catalytic conversion of petrochemical methanol with carbon monoxide), and other petrochemical softeners.

With an assumed minimum degree of substitution of 2 the acetate content alone represents 30 and the plasticizer 20 % by weight.

The percentage of material in biopolymers that is biobased, i.e. obtained from renewable resources (% by weight)

arable land biopolymers

Raw material yield [t/(hectare*annum)]

Basics

Fig 3: Total Biopolymer output in relation to the input of renewable raw materials

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Basics explained - to be modified or blended with other polymers. The second component of the blend usually represents the continuous phase in the resultant 2-phase blend (for details please see the respective section in the book). The assumption is made that in starch blends there is 30 to 85 % by weight of material coming directly from the starch.

For this figure the values of thermoplastic starch from the above assumption 3 have been used. For the remaining 15 to 70 % of the starch blends it is assumed that a petrochemical-based material is used.

35 30 25 20 15 10 5

Fig 4: Minimum and maximum possible biopolymer yields per hectare per annum

Biopolyethylene (BIO-PE)10

Biopolyesters9

Bioenthanol8

Polyhydroxyalkcanoates (PHA)7

Polylactic acid blends6

Polylactic acid (PLA)5

Starch blends4

Thermoplastic starch (TPS)3

Cellulose acetates1

0

Cellulose regenerates2

[tonnes of bioplymer /(ha*annum)]

Theoretical minimum and maximum biopolymer yield per unit of land area

5: PLA: PLA-based percentage 90 - 97 percent by weight With the PLA polymers produced from lactic acid the assumption is made that only functional additives (nucleating agents, colour batches, stabilisers etc) in amounts from maximum 3 to 10 % by weight, are added to the PLA. It is assumed that maize starch is used as the raw material for PLA. Around 0.7 tonnes of PLA are obtained from 1 tonne of maize starch.

6: PLA blends: PLA-based material percentage 30 - 65 percent by weight For these suitably ductile PLA blends, used overwhelmingly for film applications, it can be assumed a percentage of PLA-based material of between a maximum of 65 % and a minimum of 30 % by weight. For the PLA components the PLA values from the previous assumption 5 were used.

The second component of the blend is mainly a bio-polyster. For the bio-polyester (30 to 65 % by weight) the assumptions described under point 9 were made. Also, for PLA blends, the addition of 5 % by weight of a petrochemical-based additive is assumed, for example processing aids or components to improve the interaction of the two basic materials.

7: Polyhydroxyalcanoate: PLA-based material percentage 30 - 65 percent by weight With the Polyhydroxyalcanoates (PHA), produced by fermentation, there is a very small amount of additive used and thus an average bio-based material content of 90 to 98 % by weight can be assumed. To produce one tonne of PHA about 4 to 5 tonnes of sugar are required.

8: Bioethanol To produce bioethanol as an intermediate, particularly for bio-polyethylene and various bio-polyesters, it is assumed that 100% of the bio-alcohol is sugar-based. In addition it can be assumed that in the most favourable case about 1.7 (and in the least favourable case 2.7) tonnes of sugar are required per tonne of bioethanol.

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Basics 9: Bio-polyester: Bioalcohol content 30 - 40 percent by weight, remainder based on petrochemical raw materials With bio-polyesters a bioalcohol-based input of 30 - 40% was assumed to calculate the conversion efficiency, i.e. viewed from the opposite perspective 60 - 70% of the so-called bio-polyester is not based on renewable raw materials. For the bioalcohol content the raw material requirement for bioethanol, as specified in point 8, is assumed.

10: Bio-polyethylene (bio-PE): Bioalcohol-based content 95 - 98 percent by weight As with conventional PE, bio-polyethylene also requires between 2 and 5% by weight of other additives, which means that a bioalcohol-based material content of 95 to 98% by weight can be assumed. Furthermore it is assumed that 2.3 - 2.5 tonnes of ethanol are required per tonne of polyethylene. For the bioethanol content the same assumptions are made as in point 8.

Finally, to define the annual output of various biopolymers per unit of land area working from the bio-based material content of each of the biopolymers (cf. Fig 2), the required input amount of renewable raw material for each biopolymer (cf. Fig 3) and the related annual yield per unit of land area for each of the renewable raw materials (cf. Fig 1) the theoretical achievable annual amount of each of the biopolymers per unit of land area can be calculated and is shown in Fig. 4.

Because of the wide range of yields from renewable resources, and the possibility of using different renewable raw materials to produce the same biopolymer (e.g. starch instead of sugar), plus the, at times, very different bio-based material content, there is ultimately a very wide range of the theoretical biopolymer yields per unit of arable land.

Because, in biopolymer manufacture, there is pressure on economic grounds for maximum material usage and the maximum possible yield per hectare, a comparison of the values detailed above is more representative of the effective trends in biopolymer yield per hectare.

Accordingly to these considerations a bio-PE for example, despite the high sugar yield available per hectare, exhibits the lowest land use efficiency because of the high demand for sugar at the bioethanol stage and the high ethanol demand for polymerisation of the polyethylene. The relatively low land-use efficiency of the PHAs can, as with cellulose regenerates, also be traced back to the high bio-based material input and the lack of a petrochemical component not related to land use or to another bio-based material.

By contrast the high percentage of non bio-based material components in particular with bio-polyesters, starch blends, PLA blends and cellulose acetate, leads to what seems to be a high land-use efficiency that is, however, traced back to the addition of significant amounts of non landdependent substances of petrochemical origin.

However, what is important at the end of the analysis is the fact that, in comparison with bio-fuels, to achieve a perceptible share of the plastics market biopolymers would require a significantly smaller land area in absolute terms (see article on Land Use for Bioplastics in issue bM 04/2009), as well as exhibiting a higher land use efficiency.

With a cautious estimate of the average yield per unit of land area of at least 2.5 tonnes per hectare the current global biopolymer output (about 0.4 million tonnes per annum) would need only 0.01 % of the worldâ&#x20AC;&#x2DC;s agricultural land. www.fakultaet2.fh-hannover.de

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Basics

Position Paper ‘Oxo-Biodegradable‘ Plastics

I

n this issue bioplastics MAGAZINE publishes an extract of the recently published Position Paper of European Bioplastics. The complete document can be downloaded from www.bioplasticsmagazine.de/200904.

Introduction Bioplastics are either biobased or biodegradable or both. European Bioplastics, as the industry association for such materials is distancing itself from the so-called ‘oxobiodegradables‘ industry.

Terms such as ‘degradable‘, ‘biodegradable‘, ‘oxodegradable‘, ‘oxo-biodegradable‘ are used to promote products made with traditional plastics supplemented with specific additives.

Products made with this technology and available on the market include film applications such as shopping bags, agricultural mulch films and most recently certain plastic bottles. There are serious concerns amongst many plastics, composting and waste management experts that these products do not meet their claimed environmental promises.

In this position paper, European Bioplastics, the international organisation representing the certified Bioplastics and Biopolymer industries outlines the issues and questions concerned in order to support consumers, retailers and the plastics industry in identifying unsubstantiated and misleading product claims.

Terminology Producers of pro-oxidant additives use the term ‘oxobiodegradable’ for their products. This term suggests that the products can undergo (complete) biodegradation.

However, main effect of oxidation is fragmentation into small particles, which remain in the environment. Therefore the term ‘oxo-fragmentation’ does better describe the typical degradation process, which can occur to these products, under some specific environmental conditions.

European Bioplastics considers the use of terms such as biodegradable, oxo-biodegradable etc. without reference to existing standards as misleading and as such not reproducible and verifiable. Under these conditions the term ‘oxo-biodegradable‘ is free of substance. (...)

On the other hand, the terms ‘biodegradable and compostable‘ enjoy a different status. There are internationally established and acknowledged standards that effectively substantiate claims on biodegradation and compostability such as ISO 17088. (...) The specification of time needed for the ultimate biodegradation is an essential requirement for any serious claim on biodegradability.

Therefore, the U.S. Federal Trade Commission has advised companies “that unqualified biodegradable claims are acceptable only if they have scientific evidence that their product will completely decompose within a reasonably short period of time under customary methods of disposal” [1]. (...)

The Degradation Process behind the So-called ‘Oxobiodegradable‘ Plastics The ‘oxo-biodegradable‘ additives are typically incorporated in conventional plastics (...) at the moment of conversion into final products.

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â&#x20AC;˘ Job Market for Specialists and Executive Staff in the Plastics Industry

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These additives are based on chemical catalysts, containing transition metals such as cobalt, manganese, nickel, zinc, etc., which cause fragmentation as a result of a chemical oxidation of the plasticsâ&#x20AC;&#x2122; polymer chains triggered by UV irradiation or heat exposure. In a second phase, the resulting fragments are claimed to eventually undergo biodegradation. (...)

l ssiona â&#x20AC;˘ Profe t s a F date â&#x20AC;˘ Up-to-

Fragmentation Is Not the Same as Biodegradation Fragmentation of â&#x20AC;&#x2DC;oxo-biodegradableâ&#x20AC;&#x2DC; plastics is not the result of a biodegradation process but rather the result of a chemical reaction. The resulting fragments will remain in the environment [2]. The fragmentation is not a solution to the waste problem, but rather the conversion of visible contaminants (the plastic waste) into invisible contaminants (the fragments).

This is generally not considered as a feasible manner of solving the problem of plastic waste, as the behavioural problem of pollution by discarding waste in the environment could be even stimulated by these kinds of products.

An Answer to Littering or the Promotion of Littering ?

Oxo-fragmentable plastic products have been described as a solution to littering problems, whereby they supposedly fragment in the natural environment.

In fact, such a concept risks increasing littering instead of reducing it. (...)

Accumulation of Plastic Fragments Bears Risks for the Environment If oxo-fragmentable plastics are littered and end up in the landscape they are supposed to start to disintegrate due to the effect of the additives that trigger breakdown. Consequently, plastic fragments would be spread around the surrounding area. As ultimate biodegradability has not been demonstrated for these fragments [3], there is substantial risk of

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accumulation of persistent substances in the environment.

Through the impact of wind or precipitation the plastic fragments can drift into aquatic or marine habitat where they affect organisms and pose the risk of bioaccumulation. In addition, studies, amongst others by the US National Oceanic and Atmospheric Administration, have shown that degraded plastics can accumulate toxic chemicals such as PCB, DDE and others from the environment and act as transport medium in marine environments [4]. Such persistant organic pollutants in the marine environment were found to have negative effects on marine resources [5].

Organic Recovery Is Not Feasible Collection and recovery schemes for organic waste are liable to suffer from the use of oxo-fragmentable materials, as these materials are reported not to meet the requirements of organic recovery [6].

Unfortunately, sometimes the oxo-fragmentable products have been publicised as ‘biodegradable‘ and ‘compostable‘, despite not meeting the standards of suitability for organic recovery. Besides, the terms oxo-biodegradable, oxo-degradable and the like can be taken by the consumers as synonym of ‘biodegradable and compostable‘ and erroneously recovered via organic recovery. (...) Therefore, well-developed and broadly accepted certification schemes according to EN 13432, EN 14995 or equivalent standards should be used invariably.

This is also why, in the interest of the best recovery of organic fractions and biowaste, the involvement of ‘oxo-fragmentable’ materials in such recovery schemes should be avoided.

Plastic Recycling Schemes Are Disturbed A further environmentally feasible option for the handling of used plastics is that of recycling. Oxo-fragmentable products can hamper recycling of post consumer plastics.

In practice, the ‚oxo-biodegradable‘ plastics are traditional plastics. The only difference is that they incorporate additives which affect their chemical stability. Thus, they are identified and classified according to their chemical structure and finish together with the other plastic waste in the recycling streams. In this way, they bring their degradation additives to the recyclate feedstock. As a consequence the recyclates may be destabilised, which will hinder acceptance and lead to reduced value. The European Plastics Recyclers Association (EuPR) and the Association of Postconsumer Plastic Recyclers (APR) therefore warn against oxo-degradable additives [7, 8]. www.european-bioplastics.org

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References [1] Federal Trade Commission Announces Actions Against Kmart, Tender and DynaE Alleging Deceptive ‚Biodegradable‘ Claims. www.ftc.gov/opa/2009/06/kmart. shtm. Accessed on June 19, 2009 [2] Narayan, Ramani, Biodegradability - Sorting Facts and Claims, in bioplastics magazine, 01/2009, pp 29.

[3] Koutny et al. (2006) [4] Moore C. (2008). Synthetic polymers in the marine environment: A rapidly increasing, long-term threat.

Environmental Research 108(2), pp.

131-139 [5] Yuki Mato et.al. (2001), Plastic Resin pallets as a transport medium for toxic chemicals in the Marine Environment, Environmental Science and Technology, 35(2), pp. 318-324 .

[6] California State University, Chico Research Foundation (2008).

Performance Evaluation of Environmentally Degradable Plastic Packaging and Disposable Food Service Ware – Final Report. www.ciwmb. ca.gov/Publications. Publication Date: November, 8, 2008. Accessed on June 19, 2009 [7] Association of Postconsumer Plastic Recyclers (APR) and the National Association for Plastic Container Resources (NAPCOR) express concerns about degradable additives. www. plasticsrecycling.org/article.asp?id=50.

Publication Date: February 12, 2009.

Accessed on June 19, 2009 [8] European Plastics Recyclers, OXO degradables incompatibility with plastics recycling. www.plasticsrecyclers.eu/ press. Publication Date: June 10, 2009.

Accessed on June 19, 2009

Basics

Basics of Starch-Based Materials

S

tarch is a reserve of energy for plants and is widely available in cereals, tubers and beans all over the planet. The present annual production of starch worldwide is about 44 million tonnes and comes mainly from corn, where worldwide production is about 700 million tonnes, as well as from wheat, tapioca, potatoes etc.. Today the main uses of starch available annually from corn and other crops, produced in excess of current market needs in the United States and Europe, are in the pharmaceutical and paper industries. Starch is totally biodegradable in a wide variety of environments and can permit the development of totally biodegradable products for specific market demands.

Biodegradation or incineration of starch products recycles atmospheric CO2 sequestered by starch-producing plants and does not increase potential global warming.

All of these reasons aroused a renewed interest in starch-based plastics over the last 20 years. Starch graft copolymers, starch plastic composites, starch itself, and starch derivatives have been proposed as plastic materials.

Starch consists of two major components: amylose (Fig. 1), a mostly linear a-D-(1,4)-glucan; and amylopectine (Fig. 2), an a-D-(1,4) glucan that has a-D-(1,6) linkages at the branch point. The linear amylose molecules of starch have a molecular weight of 0.2–2 million, while the branched amylopectine molecules have molecular weights as high as 100–400 million.

In nature starch is found as crystalline beads of about 15–100 mm in diameter, in three crystalline design modifications: A (cereal), B (tuber), and C (smooth pea and various beans), all characterised by double helices - almost perfect left-handed, six-fold structures, as elucidated by Xray-diffraction studies.

Starch as a filler Crystalline starch beads can be used as a natural filler in traditional plastics [1]; they have been used particularly in polyolefines. When blended with starch beads, polyethylene films biodeteriorate on exposure to a soil environment. The microbial consumption of the starch component, in fact, leads to increased porosity, void formation, and loss of integrity of the plastic matrix. Generally, starch is added at fairly low concentrations (6–15%); the overall disintegration

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of these materials is obtained, however, by transition metal compounds, soluble in the thermoplastic matrix, used as pro-oxidant additives to catalyse the photo and thermooxidative processes [2].

Starch-filled polyethylenes containing pro-oxidants have been used in the past in agricultural mulch film, in bags, and in six-pack yoke packaging. According to St. Lawrence Starch Technology, regular cornstarch is treated with a silane coupling agent to make it compatible with hydrophobic polymers, and dried to less than 1% of water content. It is then mixed with the other additives such as an unsaturated fat or fatty-acid autoxidant to form a masterbatch that is added to a commodity polymer.

The polymer can then be processed by convenient methods, including film blowing, injection molding, and blow molding. The non compliance of these materials with the international standards of biodegradability in different environments and the increasing concern for micropollution that can be enhanced by their fragmentability, together with the potential negative impact on recyclability of traditional plastics, and their limited performances with time, have not permitted serious consideration of this technology as a real industrial and environmental option.

Thermoplastic starch There are two different conditions for loss of crystallinity of starch: at high water volume fractions (>0.9) described as gelatinization; and at low water volume, fractions (<0.45) with a real melting of starch [3,4]. This second condition can only apply to thermoplastic starch [5,6].

Starch can be made thermoplastic using extrusion technologies under specific conditions. Sufficient work, heat and time have to be applied to a cereal-based product in the presence of plasticizers to destructurise the starch.

The best plasticizer for starch is water in quantities lower than 45%. Other plasticizers are glycols such as glycerol, sorbitol etc. Starch becomes fully destructurised through a thermoplastic transformation which destroys the granular structure and the original crystallinity of native starch.

After having undergone a thermoplastic transformation, thermoplastic starch has lost its native crystallinity, characterised by left-handed double helixes, as reported

Article contributed by Catia Bastioli, CEO, Novamont S.p.A., Novara, Italy

Fig. 3: Droplet-like structure of thermoplastic starch / EVOH blend above. It can show other forms of crystallinity, different from the native ones, induced by the interaction of the amylose component with specific molecules. These types of crystallinity are characterised by single helical structures and are known as V complexes [7]. Moreover thermoplastic starch is characterised by a melt viscosity comparable with that of traditional polymers [8]. This aspect makes possible the transformation of destructurised starch in finished products through the use of traditional manufacturing technologies for plastics.

Thermoplastic starch alone can be processed as a traditional plastic; its sensitivity to humidity, however, makes it unsuitable for most applications.

Thermoplastic starch composites Starch can be destructurised in combination with different synthetic polymers to satisfy a broad spectrum of market needs. Thermoplastic starch composites can reach starch contents higher than 50%.

EAA (ethylene-acrylic acid copolymer) / thermoplastic starch composites EAA/thermoplastic starch composites have been studied since 1977 [9]. The addition of ammonium hydroxide to EAA makes it compatible with starch. The sensitivity to environmental changes and mainly the susceptibility to tear propagation precluded their use in most of the packaging applications; moreover, EAA is not at all biodegradable.

Starch / vinyl alcohol copolymers Starch/vinyl alcohol copolymer systems, depending on the processing conditions, starch type, and copolymer composition, can generate a wide variety of morphologies and properties. Different microstructures were observed: from a droplet-like (Fig. 3, 4) to a layered (Fig. 5) one [10], as a function of different hydrophilicity of the synthetic copolymer.

Furthermore, for this type of composite, materials containing starch with an amylose/amylopectine weight ratio of >20/80 do not dissolve even under stirring in boiling water. Under these conditions a microdispersion, constituted by microsphere aggregates, is produced, whose individual particle diameter is <1 mm.

Fig.1: Amylose (source wikipedia)

The morphology of materials in film form, containing starch with an amylose/amylopectine weight ratio of <20/80, gradually loses the droplet-like form, generating layered structures. In this case the starch component becomes partially soluble.

The biodegradation rate of starch in these materials is inversely proportional to the content of amylose/vinyl alcohol complex.

Fig. 2: Amylopectine (source wikipedia)

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Fig.3: Mater-Bi technology: droplike structure

The products based on starch/EVOH show mechanical properties good enough to meet the needs of specific industrial applications.

Their moldability in film blowing, injection molding, blow-molding, thermoforming, foaming, etc is comparable with that of traditional plastics such as PS, ABS, and LDPE [11]. The main limits of these materials are in their high sensitivity to low humidities, with consequent enbrittlement. The biodegradation of these composites has been demonstrated in different environments [12].

A substantially different biodegradation mechanism for the two components has been observed: Fig. 5: Foamed loose fill

 The natural component, even if significantly shielded by an ‘interpenetrated‘ structure of vinyl alcohol, seems, first, hydrolysed by extracellular enzymes.  The synthetic component seems biodegraded through a superficial adsorption of micro-organisms, made easier by the increase of available surface that occurred during the hydrolysis of the natural component.

Bibliography [1] G. J. L. Griffin, U.S. Pat. 4016117 (1977).

[2] G. Scott, U.K. Pat. 1,356,107 (1971).

[3] J. W. Donovan, Biopolymers 18, 263 (1979).

[4] P. Colonna and C. Mercier, Phytochemistry 24(8), 1667–1674 (1985).

[5] J. Silbiger, J. P. Sacchetto, and D. J. Lentz, Eur. Pat. Appl. 0 404 728 (1990).

[6] C. Bastioli, V. Bellotti, and G. F. Del Tredici, Eur. Pat. Appl. WO 91/02025 (1991).

[7] P. Le Bail, C. Rondeau, and A. Buléon,, Int. Journal of Biological Macromolecules 35 (2005), 1-7 [8] J.L:Willett, B.K: Jasberg, C.L: Swanson,, Polymer Engineering and Science 35 (2), 202210 (2004) [9] F. H. Otey, U.S. Pat. 4133784 (1979).

[10] C. Bastioli, V. Bellotti, M. Camia, L. Del Giudice, and A. Rallis “Biodegradable Plastics and Polymers” in Y. Doi, K. Fukuda, Ed., Elsevier, 1994, pp. 200–213.

[11] C. Bastioli, V. Bellotti, and A. Rallis, “Microstructure and Melt Flow Behaviour of a Starch-based Polymer,” Rheologica Acta 33, 307–316 (1994).

[12] C. Bastioli, V. Bellotti, L. Del Giudice, and G. Gilli, J. Environ. Polym. Degradation 1(3), 181–191 (1993).

[13] C. Bastioli, V. Bellotti, G. F. Del Tredici, R. Lombi, A. Montino, and R. Ponti, Internatl.

Pat. Appl. WO 92/19680, (1992).

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The degradation rate of 2–3 years in watery environments remains too slow to consider these materials as compostable.

Aliphatic polyesters/thermoplastic starch Starch can also be destructurised in the presence of more hydrophobic polymers, totally incompatible with starch, such as aliphatic polyesters [13].

It is known that aliphatic polyesters having a low melting point are difficult to process by conventional techniques for thermoplastic materials, such as film blowing and blow molding. It has been found that the blending of starch with aliphatic polyesters allows an improvement of their processability and their biodegradability.

Particularly suitable polyesters considered in the past have been poly-e-caprolactone and its copolymers, or polymers at higher melting point formed by the reaction of glycols as 1,4-butandiol with succinic acid or with sebacic acid, adipic acid, azelaic acid, dodecanoic acid, or brassilic acid. The presence of compatibilizers between starch and aliphatic polyesters such as amylose/EVOH Vtype complexes [10], starch grafted polyesters, and chain extenders such as diisocyanates, and epoxydes is preferred. Such materials are characterised by excellent compostability, excellent mechanical properties, and reduced sensitivity to water.

Thermoplastic starch can also be blended with polyolefines, possibly in the presence of a compatibilizer. Starch/cellulose derivative systems are also reported in the literature [12]. The combination of starch with a soluble polymer such as polyvinyl

Fig.4: Mater-Bi technology: layered structure

alcohol (PVOH) and/or polyalkylene glycols has been widely considered since 1970. In recent years the thermoplastic starch/PVOH system has been studied, mainly for producing starch-based loose fillers as a replacement for expanded polystyrene.

Micro- and Nanostructured Composites The most important achievement of recent years in the sector of starch technology is seen in the creation of micro and nanostructured composites of starch with polyesters of different types and particularly with aliphatic-aromatic polyesters and with rubber. This technology has been developed and patented by Novamont. In these families of products starch gives a technical contribution to the mechanical performance of the finished products in terms of increased toughness and excellent stability at different humidities and temperatures. With this generation of products it is possible to cover a wide range of demanding applications in the film sector and to meet the different needs of end-of-life conditions up to home compostability and soil biodegradation. Moreover, it is possible to obtain low hysteresis rubber for low rolling-resistance treads in tyres. The last developments in this sector have been achieved within the EU Biotyres project which has led Goodyear to produce the tyres used in the new BMW 1-series models.

The development of aliphatic and aliphatic-aromatic copolyesters containing monomers from vegetable oils, covered by a new range of Novamontâ&#x20AC;&#x2122;s patents, has further improved and widened the performances of these products from an environmental and technical point of view. Such development has justified the significant industrial investment made by Novamont to build the first local biorefinery of this type in Europe, which comprises plants for the production of nanostructured starch and polyesters from vegetable oils. Moreover new investments in monomers from vegetable oils from local crops will permit a further up-stream integration of the biorefinery.

This family of tailor-made products has permitted Novamont to work on many case studies aimed at demonstrating the opportunity offered by biodegradable and bio-based plastics to rethink entire application sectors, thereby affecting not only the manner in which raw materials are produced, but also permitting verticalisation of entire agro-industrial non-food chains, or which are synergistic with food, and the way in which products are used and disposed of, expanding the scope of experimentation to local areas. This is the way Novamont believes bio-plastics may become a powerful, largescale case study for sustainable development and cultural growth - a real example of transition from a product-based to a system-based economy.

Fig. 6: Biotyre

www.novamont.com

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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 PolyOne Avenue Melville Wilson, 2 Zoning de la Fagne 5330 Assesse Belgium Tel. + 32 83 660 211 info.color@polyone.com www.polyone.com

180

190

200

210

BIOTEC Biologische Naturverpackungen GmbH & Co. KG Werner-Heisenberg-Straße 32 46446 Emmerich Germany Tel. +49 2822 92510 Fax +49 2822 51840 info@biotec.de www.biotec.de

220

230

240

250

Cereplast Inc. Tel: +1 310-676-5000 / Fax: -5003 pravera@cereplast.com www.cereplast.com European distributor A.Schulman : Tel +49 (2273) 561 236 christophe_cario@de.aschulman.com

260

270

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BIOTEC Biologische Naturverpackungen GmbH & Co. KG Werner-Heisenberg-Straße 32 46446 Emmerich Germany Tel. +49 2822 92510 Fax +49 2822 51840 info@biotec.de Sukano Products Ltd. www.biotec.de Chaltenbodenstrasse 23 CH-8834 Schindellegi Tel. +41 44 787 57 77 Fax +41 44 787 57 78 www.sukano.com

Limagrain Céréales Ingrédients ZAC „Les Portes de Riom“ - BP 173 63204 Riom Cedex - France Tel. +33 (0)4 73 67 17 00 Fax +33 (0)4 73 67 17 10 www.biolice.com

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

130

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

Suppliers Guide

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

Postbus 26 7480 AA Haaksbergen The Netherlands Tel.: +31 616 121 843 info@bio4pack.com www.bio4pack.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

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 6.2 Laboratory Equipment

MODA : Biodegradability Analyzer Saida FDS Incorporated 3-6-6 Sakae-cho, Yaizu, Shizuoka, Japan Tel : +81-90-6803-4041 info@saidagroup.jp www.saidagroup.jp 7. Plant engineering

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

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 8. Ancillary equipment 9. Services

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

9. Services Wiedmer AG - PLASTIC SOLUTIONS 8752 Näfels - Am Linthli 2 SWITZERLAND Tel. +41 55 618 44 99 Fax +41 55 618 44 98 www.wiedmer-plastic.com

Siemensring 79 47877 Willich, Germany Tel.: +49 2154 9251-0 , Fax: -51 carmen.michels@umsicht.fhg.de www.umsicht.fraunhofer.de

4.1 trays 5. Traders 5.1 wholesale 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

6. Equipment

Bioplastics Consulting Tel. +49 2161 664864 info@polymediaconsult.com www.polymediaconsult.com

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

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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

6.1 Machinery & Molds

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

Marketing - Exhibition - Event Tel. +49 2359-2996-0 info@teamburg.de www.teamburg.de 10. Institutions

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

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

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

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

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

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Companies in this issue Company A&O Filmpac Ahlstrom Corporation Alesco Arkema Arkhe Will Bamboo BASF Biax-FiberFilm BIC BIO4PACK bioplastics 24 BioTAK Biotec BPI Centerplate Cereplast Composite technical Services Dallas Convention Center DaniMer Dorel Juvenile Dr Vie DSM Engineering Plastics DuPont Entek EPI European Bioplastics Fachhochschule Hannover FAS Converting Machinery FKuR Forapack Fraunhofer IAP Fraunhofer UMSICHT Futerro Gabriel Chemie Galactic Georgia Pacific Green Mountain Coffee Hallink Herma Labels Huhtamaki Innovia Films International Paper Izod Lexus Limagrain

12 23 27

Advert 46 47 47

15 46 10 25 5

47 39

22 46 47 7 46 28 7 18 25 23 26 14 17 3 3, 5, 38 5, 34 6

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32 47 31 7 30 20 18 47 22 23 18 15 13 6

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Company Maag Mann + Hummel Protech Michigan State University Minima Technology natura Verpackung Naturally Iowa NatureWorks NaturTec Nedupack Neue Messe M端nchen (drinktec) nova Institut Novamont Plantic Plastick2Pack Plasticker Polymediaconsult Polyone President Packaging PSM Purac Pyramid Bioplastics Saida Sidaplax Smurfit Kappa Sommer Needlepunch Speedo Sukano Symphony Tanaka Foresight Teijin Telles Tetly Tianan Timberland Toray Total Petrochemicals Toyota Toyota Transmare Typhoo Uhde Inventa-Fischer Unilever University of Tennessee Wei Mon Wiedmer

Next Issue

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

Nov/Dec 30.11.2009

Editorial Focus:

Basics:

Films / Flexibles / Bags Consumer Electronics

Anaerobic Digestion

Publ.-Date

Editorial Focus (1)

Editorial Focus (2)

Basics

Jan/Feb

01.02.2010

Automotive Applications

Foam

Basics of Cellulosics

Mar/Apr

05.04.2010

Rigid Packaging

Material Combinations

Polyamides

Injection Moulding

Natural Fibre Composites

t.b.d.

bioplastics MAGAZINE [04/09] Vol. 4

Editorial

Advert 46 47 47 47 47

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47, 52 46 39 47 46 47 46 46

32 47 46 24 11 15 46 3 24 24 9 12

51, 46 46

15 13 31 11 13 46 12 21, 47 12 10 41, 47 47

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48

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Fair Specials

Events

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

October 7-10, 2009 Plastics Philippines SMX Convention Center, Seashell Drive, Mall of Asia Complex, Pasay City, Phillipines www.globallinkph.com

October 22, 2009 Timeproof biopolymers: durability of biobased materials PEP (Pôle Européen de Plasturgie) Bellignat, Franceopéen de Plasturgie)

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 www.wpc-kongress.de

www.biowerkstoff-kongress.de

October 27-28, 2009 Biofoams 2009 Sheraton Fallsview Hotel & Conference Centre Niagara Falls, Canada http://mpml.mie.utoronto.ca/biofoams/

March 16-17, 2010 EnviroPlas 2010 Brussels, Belgium 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!

October 26-27, 2009 Biowerkstoff Kongress 2009 within framework of AVK and COMPOSITES EUROPE Neue Messe Stuttgart, Germany

Please contact us in advance by e-mail.

jt.pep@poleplasturgie.com

bioplastics MAGAZINE [05/09] Vol. 4

49

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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