bioplastics MAGAZINE 01-2010

ISSN 1862-5258

01 | 2010

Basics Cellulosics | 44 Highlights: Automotive | 10

bioplastics

magazine

Vol. 5

Foam | 22

5 countries

... is read in 8

FKuR plastics - made by nature!® ica!

r Ame n i now R u FK

Bio-Flex® resins ... taking PLA further!

Net Bag made from Bio-Flex®

Deep Freeze Packaging made from Bio-Flex®

Mulch Film made from Bio-Flex®

Sustainable • Compostable • Renewable FKuR Plastics Corp. | 921 W New Hope Drive | Building 605 | Cedar Park, TX 78613 | USA Phone: +1 512-971-3581 | Fax: +1 512-986-5346 | sales.usa@fkur.com

www.fkur.com

Guest Editorial Dr. Harald Kaeb, Secretary General of European Bioplastics

Building a Green Century Oh! What a year! From ‘Apocalypse Now!’ to ‘Business As Usual’? Actually there is no business as usual any more! Wherever you look there are enormous pressures that will lead to far-reaching changes. The last decade was the one in which we finally noticed this. Yes, it‘s true, raw materials can become very expansive - because they are not used in a sustainable way. And emissions caused by humans will lead to environmental changes that can destroy our quality of life. We have been regularly warned since the 1960‘s, but now we know it‘s true!

In this coming decade the shape of the new century will be set. It will be - and must be - a green one. 2020 is a deadline, and not only for the maximum 2°C increase commitment. Cars must go ‘electric‘, energy supplies and fuels from renewable resources will grow, but total consumption will also heavily decrease, food and feedstocks must be sourced from sustainable agriculture and forestry. Not everything will be perfect by then, but those who do not seriously start will see their businesses effectively annihilated in the long run. The frontrunners and risk-takers of today will be the real business leaders.

And be aware that sustainability claims must be substantiated. Standards, indicators, measurements and labels will be most important tools for providing proof. Some of them are already in place, others need updating or are still to be developed. Each and every product category will be impacted by measurement tools such as LCA or carbon footprint, and the derived policies. If you want to shape these standards and tools then do ensure that you are represented in branch associations.

I hope you enjoy this first issue of bioplastics MAGAZINE in the new decade. In addition to my own ‘wise’ comments it features editorial highlights such as foamed bioplastics and bioplastics in automotive applications. It explains the basics of cellulosics, and the article of Professor Narayan offers a good closing word in this issue for the oxoepisode.

A Happy New Year, and a Great Decade!

Harald Kaeb

bioplastics MAGAZINE [01/10] Vol. 5

bioplastics MAGAZINE [06/09] Vol. 4

Hyundai Blue-Will Concept to feature PLA and PA 11 16

From Science & Research

Tires Made from Trees 17 Disposal of Bio-Polymers via Energy Recovery

Ontario BioAuto Council 18

Basics

PSA Peugeot Citroën Applies Green Materials 19 Basics of Cellulosics

Concept Tyres Made with BioIsoprene™ 20

Bioplastics Situation in Brazil

26

Bio-Based Biodegradable PHA Foam 28

Heat-Resistant PLA Bead Foam 29

A large number of copies of this issue of bioplastics MAGAZINE is wrapped in a compostable film manufactured and sponsored by FKuR (www.fkur.com) Horn & Bauer (www.horn-bauer.de)

Cellulose Acetate Foams

Envelope

Editorial News Application News Event Calendar Glossary Suppliers Guide

Editorial contributions are always welcome.

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

24

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

‘Cradle to Cradle‘ Certified PLA Foam

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.

22

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

Foam

bioplastics MAGAZINE is read in 85 countries.

Automotive

bioplastics MAGAZINE is printed on chlorine-free FSC certified paper.

January/February

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

This publication is sent to qualified subscribers (149 Euro for 6 issues).

Foaming Agents and Chain Extenders for PLA Foam

bioplastics magazine

Tölkes Druck + Medien GmbH 47807 Krefeld, Germany Total Print run: 4,200 copies

Print

Elke Hoffmann phone: +49(0)2351-67100-0 fax: +49(0)2351-67100-10 eh@bioplasticsmagazine.com

Media Adviser

Dammer Str. 112 41066 Mönchengladbach, Germany phone: +49 (0)2161 664864 fax: +49 (0)2161 631045 info@bioplasticsmagazine.com www.bioplasticsmagazine.com

Polymedia Publisher GmbH

Head Office

Mark Speckenbach

Layout/Production

Samuel Brangenberg

Dr. Michael Thielen

Publisher / Editorial

Impressum Content 03

05

34

52

54

56

01|2010 Materials

Bio-Polyamides for Automotive Applications 10 High Heat Injection Molding PLA 33

Wheat Straw for New Ford Flex 12 A Novel, Lightweight, Heat-resistant PLA 33

BioConcept-Car – with Biomaterials on the Passing Lane 14 OXO 38

42

44

Politics

48

PLA Foam Trays 30

A True Compostable Foam 32

News

www.natureworksllc.com www.sommernp.com www.loopla.org

NatureWorks Products at and after UN Climate Conference The exposition-grade carpet used during the UN Conference on Climate Change, enough to cover nearly five soccer fields, will not be disposed of in a landfill but instead is being taken to Belgium, where a new process will recycle the NatureWorks Ingeo® PLA fibers, into the building blocks of a second generation of products.

At the Bella Center where the United Nations global conference on climate change was held, December 7-18, more than 20,000 square meters (215,000 square feet) of ultra low carbon footprint Eco2punch® carpet manufactured by Sommer Needlepunch was used. Galactic, one of the largest lactic acid producers in the world, will now use its new LOOPLA® process to convert the carpet back to virgin lactic acid, a value added industrial feedstock and the building block for Ingeo biopolymer.

Galactic is also recycling the Eco2punch carpet and all the NatureWorks Ingeo food service items used during the NICE Fashion Summit held in Copenhagen on December 9. Those food service items included cutlery by CDS, plates by I.L.P.A. Srl, and cold cups by Ecozema, respectively.

“NatureWorks and dozens of its customers showcased in Copenhagen a compelling set of innovations that are making a difference to climate change and energy usage every day by using renewably sourced, low carbon Ingeo”, said Marc Verbruggen, president and chief executive officer of NatureWorks LLC. “Galactic is instituting a true cradle-to-cradle reuse of Ingeo and leveraging those benefits for future users of a second generation of products. This is truly a milestone in the bioplastics industry because we are not talking about what will happen in the future, but experiencing that reality today.”

Zelfo fibre – a multi dimensional solution.

Omodo GmbH a bio based materials development company from Germany is the owner and developer of the patented ‘Zelfo’ material process. Zelfo, a cellulosic micro fibre material featuring nano scale fibrils, offers three-dimensional strengthening properties rarely found in the world of ‘bio-fibre’ additives. Outside of the plastics world Zelfo is principally known for it’s ability to self-bind and is essentially a bio-plastic matrix in a category of its own. The resulting material in its standard application has a density range of 0.5 to up to an outstanding 1.5 g/cm3 when dried.

Omodo are now venturing into the world of plastics where their fibre is being introduced to various materials as a bioadditive. Using a new form of Zelfo the first product tests, carried out together with AMCO Plastic Materials Inc from the USA using both standard and bio based plastics have proved successful, further developments are now underway. A new partner, DSM of the Netherlands is also now involved and is investigating the material for use within their portfolio of materials. “First trials at DSM led to very satisfactory results,“ says Omodo‘s managing director Richard Hurding.

As a result of a joint venture project over the last 3 years, Zelfo production has undergone optimisation resulting in significantly improved economic viability. Omodo together with selected partners plans to offer access to the world of Zelfo technology and related end products via a new business named Omodo Europe, with a primary base in Paris, France. www.omodo.org

bioplastics MAGAZINE [01/10] Vol. 5

News

Public Relations Exercise for Biobased Materials As part of this year‘s ‘Green Week’ in Berlin, Germany the subject of biopolymers was brought closer to the attention of the end consumer. Working in association with the German Federal Ministry of Food, Agriculture and Consumer Protection the Hanover University of Applied Sciences and Arts gave a presentation of bioplastics at the ‘nature.tec’ special technical exhibition on renewable resources.

To show the visitors where bioplastics are currently in widespread use, a display of various items of catering cutlery and plates etc, through to office and sports equipment based on different biopolymers was presented.

In addition different biopolymers and colour systems from BASF, FKuR and Sukano were processed right there on the stand using a Dr. Boy high precision injection moulding machine.

The exhibition was a successful opportunity to discuss directly with consumers and to make them more aware of these new materials.

Futerro Starts up PLA Demo Unit End of last year, Futerro, a 50/50 joint venture established in September 2007 by Galactic and Total Petrochemicals, announced the start up of its demo unit in Escanaffles, Belgium. The purpose of the unit is to test a state-of-the-art technology for the production of PolyLactic Acid (PLA) bioplastics of renewable vegetable origin, developed by the two partners.

This clean, innovative and competitive technology, based on a research and development program launched at the creation of the joint venture, entails two main phases. The first is the preparation of the monomer – the lactide – and its purification from lactic acid, as part of the fermentation of sugar from beet (note: Lactic acid can be extracted from other plants, including cane, maize (corn) and wheat.

Renewable resources like biomass (forest waste) are also envisaged in the future). The second is the polymerisation of the monomer to produce biodegradable plastic granules of vegetable origin.

The demo unit, which has a capacity of 1,500 tonnes per year, will be used to test and improve the successive steps in this process during an internal evaluation, which is expected to last around six months. By that time, Futerro will be able to offer a full range of products made from lactic acid, including lactide, oligomers and PLA polymers for the packaging market, especially food packaging, on the one hand, and sustainable applications, on the other. www.futerro.com

FKuR expands into North America FKuR Kunststoff GmbH, leading developer and supplier of sustainable plastic compounds headquartered in Willich, Germany, is now expanding its activities into USA and Canada. Since the beginning of this year, FKuR Plastics Corp. with a four member team around President Patrick Zimmermann is marketing the Bio-Flex®, Biograde® and Fibrolon® products lines from Cedar Park, Texas, USA. FKuR started its activities in the field of bioplastics in 2003. “Green plastics are the inevitable future and on our way out of the oil dependence, we are scientifically supported by Fraunhofer UMSICHT when developing our sustainable products“, says Patrick Zimmermann. During the last four years the company saw an annual increase in turnover of 50 percent. Now FKuR wants to expand this success story to North America. After thoroughly watching and evaluating the market, as a strategic milestone FKuR participated in NPE 2009 in Chicago, and “was positively surprised about the dynamic market development in USA and Canada“, as Patrick put it. This confirmed all strategic evaluations and convinced FKuR to now start up a branch establishment in Texas.

In the beginning, with Bio-Flex blends made from PLA for e.g. pouches, mulch film, waste bags or diapers, FKuR‘s main focus was on compostable packaging (ASTM 6400, EN 13432). Now they also increase their activities in the field of durable applications. The cellulose based Biograde injection molding grades and natural fiber reinforced compounds Fibrolon are very well suited for injection molding of durable and even technical applications such as automotive, household appliances or consumer electronics.

“Depending on the future development and before the background that a part of our raw materials are being produced in USA anyway, it is projected to expand our US-activities into building a production facility within the next three years“, closes Patrick. www.fkur.com

bioplastics MAGAZINE [01/10] Vol. 5

News

Note to the Editor Berlin, January 25, 201

0: European Bioplastics would make the follow ing comments regard statements made in the ing the article on oxo-fragmenta ble, so called ‘oxo-biod plastics by Professor Sc eg radable‘, ott published in the No v./Dec. edition of biopla 06/2009: stics magazine This article, written on behalf of Symphony En vironmental Technologie absolutely no experime s (UK), contains ntal data based on the ASTM D6954-04 Stand ard Guide.

The ASTM Guide is quote d several times in the art icle , bu t no laboratory results plastics whatsoever are for the oxo-fragmenta stated. The article the ble refore still lacks scien (timeframe, final level tific data about biode and pre-conditions ne gradation eded to reach it).

Furthermore, the article contains some inaccu racies that could lead believe that ASTM D6 a non specialist reade 954 is establishing ‘pa r to wrongly ss/ fail ‘ criteria on biodegrada criteria are only to deter tion. In reality, these mine when to stop the ‘pass/fail‘ biodegradation test an biodegradability. d are not at all thresh olds that prove European Bioplastics considers standards an d scientific data based transparent and sustai on standards as the nable market. pillars of a On the other hand, Eu ropean Bioplastics ack nowledges and apprecia that oxo-fragmentable tes the clear statemen plastics are not compo t of Prof. Scott stable, which sweeps aw on that subject. ay some precedent misun derstandings For up to date informati on as to the nature of oxo-fragmentable plastic reader to the following s, European Bioplastic links on its website: s refers the

http://www.european-b

ioplastics.org/media/fi

les/docs/en-pub/Europ ean_Bioplastics_OxoPo sitionPaper.pdf ioplastics.org/index.php ?id=1078

http://www.european-b

Hasso von Pogrell

Braskem and Novozymes to Make Green Plastic Braskem, the largest petrochemical company in Latin America, and Novozymes, the world’s leading producer of industrial enzymes, today announced a research partnership to develop large-scale production of polypropylene (PP) from sugarcane.

“Braskem was the first company in the world to produce a 100% certified green polypropylene on an experimental basis. The partnership with Novozymes will further boost Braskem’s technology development and be a key step in the company’s path to consolidate its worldwide leadership in green polymers, all leveraged by Brazil’s competitive advantages within renewable resources,” says Bernardo Gradin, CEO of Braskem.

Today, the commodity plastic PP is primarily derived from oil, but Braskem and Novozymes will develop a green alternative based on Novozymes’ core fermentation technology and Braskem’s expertise in chemical technology and thermoplastics.

Initial development will run for at least five years.

“We live in a world where oil is limited and expensive, and the chemical industry is looking for alternatives to its petroleumbased products. Novozymes’ partnership with Braskem is a move toward a green, bio-based economy, in which sugar will be the new oil,” says Steen Riisgaard, CEO of Novozymes.

Both companies have ongoing interests in a bio-based economy: Braskem is currently building a 200,000-tons-per-year green polyethylene plant in Brazil with ethanol from sugarcane as the raw material. Novozymes is producing enzymes to turn agricultural waste into advanced biofuels and has partnered to convert renewable raw materials into acrylic acid.

www.braskem.com www.novozymes.com

bioplastics MAGAZINE [01/10] Vol. 5

News

3rd WPC Congress Even in the current economic crisis international sales figures of Wood Plastic Composites (WPC) are increasing. The 3rd German WPC Congress in Cologne in early December wasn’t exactly a German congress as about 300 delegates from 26 countries met for this international industry get-together. The audience acted as the judging panel in deciding to give the WPC Innovation Award to STAEDTLER for a new sustainable pencil. The second and third places went to Hiendl for an assembly profile system and Qingdao HuaSheng for a thermally insulated siding (cladding) system for buildings.

Today more than 1.5 million tonnes per annum of WPC are produced globally, mainly in North America (approx. 1 millon tonnes), China (200,000 tonnes), Europe (170,000 tonnes) and Japan (100,000 tonnes). In Europe Germany is the leading country with more than 70,000 tonnes of WPC, as well as being the most significant machinery manufacturers. The most important applications are found in the automotive sector as well as in deckings, i.e. outdoor floor coverings for patios or public places. WPC is establishing itself more and more as an alternative for tropical wood solutions.

Award winning assembly profile system made with Hiendl NFC® (photo nova Institut)

However, although WPC incorporates up to 70% wood as a natural ingredient bioplastics MAGAZINE asked about the steps being taken towards using bioplastics as matrices. Helmut Hiendl, owner and CEO of the award-winning company Hiendl, firstly wanted to make a product that functioned properly. After this first, and successful, step of replacing 70% of the fossil based material by renewables (wood) they of course are now seriously looking at the remaining 30% - the matrix. Helmut Hiendl indeed sees that some of what he called ‘green plastics’ could be used in his products. Dr. Matthias Schulte of WPC converter Werzalit tempered this view a little by commenting that feasibility and marketability must be checked, but basically WPC with biobased polymers will come. Extrusion and compounding machinery maker Reifenhäuser, represented by Dieter Thewes, Head of Business Area Extrusion Center, sees an increasing use of biopolymers, now that more production capacity is being installed. Finally conference organizer and MD of the nova Institute Michael Carus added that WPC with biobased matrices will open up new potential applications. MT www.nachwachsende-rohstoffe.info

SPI Bioplastics Council Position Paper on Oxo- and Other Degradable Additives The Bioplastics Council, a special interest group of SPI: the Plastics Industry Trade Association, recently announced the release of a position paper that questions the scientific validity of biodegradability claims made by producers of ‘oxo-degradable’ and ‘oxo-biodegradable’ products. The Council’s paper formally supports the point of view put forth by European Bioplastics in a July 2009 publication. Download the complete Position Paper from www.bioplasticsmagazine.de/201001 Producers of pro-oxidant and biological additives use the term ‘oxo- biodegradable’ to describe the resulting products made using the additives. This term suggests that the products can undergo rapid biodegradation under many different end-of-life conditions. However, the main effect of oxidation is fragmentation, not biodegradation, into small particles which remain in the environment for an undetermined amount of time. These results do not meet the internationally established and acknowledged standards and certifications that effectively substantiate claims on biodegradation under certain specific endof-life conditions.

“In 2010 we made a pointed decision to insist on bringing clarity to the bioplastics market,” said Bioplastics Council Chair Frederic Scheer, CEO of Cereplast, Inc. “Allowing the brand owner, retailer or ultimately the consumer to decide what they consider a biodegradable product to be is risky, as they may lack the scientific knowledge to make an accurate decision. The Bioplastics Council supports legitimate scientific data as recommended by state and federal agencies and stresses the need for all companies, when making product claims, to work along guidelines defined by the Federal Trade Commission.” MT

bioplastics MAGAZINE [01/10] Vol. 5

Order now!

Hans-Josef Endres, Andrea Siebert-Raths

Rainer Höfer (Editor)

Technische Biopolymere

Sustainable Solutions for Modern Economies

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.

New Book!

Order now!

ISBN: 978-1-84755-905-0 Copyright: 2009 / Format: Hardcover / 497 pages

Sustainable Solutions for Modern Economies is an essay to reflect the aspects of sustainability in the different sectors of national and global economies, to draft a roadmap for public and corporate sustainability strategies, and to outline the current status of markets, applications, use and research and development for renewable resources.

The book brings up philosophical aspects of the relationship between man and nature and highlights the key sustainability initiatives of the chemical industry.

The position and the systemic role of the financial market in the economic circuit is depicted in one chapter as well as recently developed key performance indicators for the sustainability rating of companies.

The eco-efficiency analysis is described as a management tool incorporating economic and environmental aspects for the comprehensive evaluation of products over their entire life-cycle.

Another chapter describes a holistic approach to define sustainability as a guiding principle for modern logistics.

Consumer behaviour and expectations, indeed, are crucial aspects to be considered in this book when dealing with further development of the sustainability concept.

The achievements of food security are specified at a global level as a key element of sustainable development.

Energy economy and alternative energies are key challenges for society today, dealt with in a separate chapter. Tens of millions of years ago, biomass provided the basis for what we actually call fossil resources and biomass again is by far the most important resource for renewable energies today.

The efficient complementation and eventual substitution of fossil raw materials by biomass is the subject matter of green chemistry and is comprehensively described. The chapter „Biomass for Green Chemistry“ in particular highlights the potential of sucrose, starch, fats and oils, wood or natural fibres as building blocks and in composites of bio-based plastics and resins.

Reduction in greenhouse gas emissions, energy and water usage are examples of the benefits brought about by greener, cleaner and simpler biotechnology processes, comprehensively dealt with in the last chapter „ White Biotechnology“. This includes PLA as one bioplastics example for White Biotechnology.

Order now

for just EUR 99.00 plus shipping & handling (please ask for shipping cost into your country)

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

order at www.bioplasticsmagazine.de/books, by phone +49 2161 664864 or by e-mail books@bioplasticsmagazine.com

Automotive

Bio-Polyamides for Automotive Applications

A

joint development project, which is partly funded by the German Federal Ministry of Education and Research (BMBF) and partly supported by the so-called BIOPRO Baden-Württemberg ‘cluster‘, focuses its activities on biobased polyamides for automotive applications and received two awards in 2009. In April, during the world renowned Hanover Fair, a group of scientists from companies such as Daimler, BASF, Bosch, MANN + HUMMEL and Fischerwerke, as well as the University of Braunschweig, received the ‘2009 VDI award for the innovative application of plastics‘.

This award acknowledges the first successful manufacture of an air filter system for Daimler, made from bio-polyamide and ready for series production. The air cleaner in question is supplied by MANN+HUMMEL. The partly (60%) biobased polyamide 6.10 used for the filter was supplied by BASF. Another award was presented to the team at MATERIALICA in October 2009 in Munich, Germany. Within the ‘MATERIALICA Design and Technology Awards 2009‘ the group received the special ‘Best of Material’ prize for the same air cleaner. In addition to this achievement companies in the group succeeded in developing further automotive applications suitable for series production using 100% bio-based polyamide 5.10.

performance plastics produced from fossil raw materials.

To drive forward this integrated project the air filter, for the new Mercedes Benz engine, was for the first time produced from polyamide 6.10 and polyamide 5.10, establishing new milestones in future-oriented and ecologically friendly material applications technology. As in other branches of industry, market launches in the automotive industry will depend very much not only on the technological development of this innovative material but also on the way that the prices of bio-polyamides develop.

In the future biopolymers will also be able to be used for automotive components that are currently made from high

Based on this biotechnical development, as opposed to the conventional methods of chemical conversion,

The air filter housing consists largely of three polyamide parts. The air intake tube and the clean air hood are screwed together. A top cover is bonded to the housing by vibration welding. The polyamide 6.10 which is used for the parts is produced from hexamethylenediamine and 60 percent by weight of bio-based sebacinic acid (from castor oil), and reinforced with 10% glass fibre and 20% mineral substances.

Alternatively a totally bio-based polyamide 5.10 can be used. With this material both monomers are produced from renewable resources. In addition to the sebacinic acid a diaminopentane is used which can be obtained, for example, from a sugar-based material by a fermentation process.

Fig 1 and 2: Air Filter Housing

(Photo: MANN + HUMMEL)

10

bioplastics MAGAZINE [01/10] Vol. 5

(Picture: Daimler)

Automotive

(both photos: Philipp Thielen)

A B Fig 3 and 4: acceleration Pedal

The biobased PA 5.10 version (B) shows a much better visual surface quality

researchers at BASF have succeeded in developing an effective manufacturing process that ensures a high purity product. PA 5.10 is a polyamide based on 100% renewable resources and exhibits a particularly robust and technically relevant performance. However, as stated by BASF, currently the PA 5.10 is a rather expensive specialty PA. Thus a broad application in the cost sensitive automotive industry is not to be expected too soon.

The technical reasons for the selection and development of the PA 6.10 and PA 5.10 polyamide materials include their weight saving of about 6%, their low water absorption, their better dimensional stability and improved flow characteristics compared with conventional fossil-based PA 6 compounds.

Where internal and external visible components made from bio-polyamide 5.10 are involved the material exhibits clearly superior visual (Fig. 4) and tactile properties that lend the parts a quality look. The first trial components (coloured trim parts for inside the vehicle) have proven very positive.

Using the example of the air filter housing, the table below demonstrates the advantages of the PA 6.10 and PA 5.10 biopolymers.

In addition to the award-winning air filter housing made from PA 6.10 the group of collaborating companies has produced, analysed and tested other Mercedes parts made

Material / Property

PA 6 (material from series application)

PA 6.10

PA 5.10

Biobased content [by weight]

0

63

100

Melting point [°C]

220

220

215

Glass transition temperature [°C]

54

46

50

Density [g/cm³]

1.14

1.07

1.07

Notched impact after 700 hrs ageing [kJ/m²]

22*

30**

-

Water absorption [%] (at 23°C / 50% RH)

3

1.4

1.8

*: PA 6 GF30, **: PA6.10 GF30 Ultramid Balance, BASF

from PA 5.10 bio-polyamide. These include an accelerator pedal module, a cogwheel for the steering angle sensor, and a cooling fan and housing module.

The biopolymer components, given the medium and long term increases expected in oil prices, offer the potential for use at less volatile cost but with technical, and (because of the use of renewable resources) ecological advantages.

Furthermore when using bio-polyamides, rather than the standard PA 6, the eco-balance is significantly helped in a positive way by the lower component weight.

In addition the market opportunities will be enhanced by an increased desire on the part of the consumer for resource saving products. In the future increased use will be made of innovative biobased materials. Daimler intends to use innovative materials in the production of vehicles with the aim of protecting the planet‘s finite fossil hydrocarbon resources.

As part of the joint project outlined above the PA 5.10 and PA 6.10 polyamides have been qualified and characterised.

Sample components are being produced from bio-polyamides that are suitable for mass production processes and extensive functional trials are being carried out. In the case of Daimler for a product such as the air filter housing a series production is projected for 2010. MT

www.basf.com www.bio-pro.de www.bosch.com www.daimler.com www.fischerwerke.de www.mann-hummel.com www.tu-braunschweig.de www.vdi.de

This article is (partly) based on an article previously published in the June 2009 issue of KONSTRUKTION, Springer VDI Publishing House, Düsseldorf, Germany

Table: comparison of the properties of polyamides

bioplastics MAGAZINE [01/10] Vol. 5

11

Automotive

Wheat Straw for New Ford Flex

F

ord Motor Company, working with academic researchers and one of its suppliers, is the first automaker to develop and use environmentally friendly wheat straw-reinforced plastic in a vehicle.

The first application of the natural fiber-based plastic that contains 20 % wheat straw bio-filler is on the 2010 Ford Flex‘s third-row interior storage bins. This application alone reduces petroleum usage by some 9,000 kg per year, reduces CO2 emissions by 14,000 kg per year, and represents a smart, sustainable usage for wheat straw, the waste byproduct of wheat.

“Ford continues to explore and open doors for greener materials that positively impact the environment and work well for customers,“ said Patrick Berryman, a Ford engineering manager who develops interior trim. “We seized the opportunity to add wheat strawreinforced plastic as our next sustainable material on the production line, and the storage bin for the Flex was the ideal first application.“

Collaborative effort Ford researchers were approached with the wheat straw-based plastics formulation by the University of Waterloo in Ontario, Canada, as part of the Ontario BioCar Initiative – a multi-university effort between Waterloo, the University of Guelph, University of Toronto and University of Windsor. Ford works closely with the Ontario government-funded project, which is seeking to advance the use of more plant-based materials in the auto and agricultural industries.

The University of Waterloo already had been working with plastics supplier A. Schulman of Akron, Ohio, to perfect the lab formula for use in auto parts, ensuring the material is not only odorless, but also meets industry standards for thermal expansion and degradation, rigidity, moisture absorption and fogging. Less than 18 months after the initial presentation was made to Ford‘s Biomaterials Group, the wheat straw-reinforced plastic was refined and approved for Flex, which is produced at Ford‘s Oakville (Ontario) Assembly Complex.

The wheat straw-reinforced resin is the BioCar Initiative‘s first production-ready application. It demonstrates better dimensional integrity than a non-reinforced plastic and weighs up to 10% less than a plastic reinforced with talc or glass. “Without Ford‘s driving force and contribution, we would have never been able to move from academia to industry in such lightning speed,“ said Leonardo Simon, associate professor of chemical engineering at the University of Waterloo. “Seeing this go into production on the Ford Flex is a major accomplishment for the University of Waterloo and the BioCar Initiative.“ An interior storage bin may seem like a small start, but it opens the door for more applications, said Dr. Ellen Lee, technical expert, Ford‘s Plastics Research. “We see a

12

bioplastics MAGAZINE [01/10] Vol. 5

Automotive

great deal of potential for other applications since wheat straw has good mechanical properties, can meet our performance and durability specifications, and can further reduce our carbon footprint – all without compromise to the customer.“ Already under consideration by the Ford team: center console bins and trays, interior air register and door trim panel components, and armrest liners.

Abundant waste material put to good use The case for using wheat straw to reinforce plastics in higher-volume, higher-content applications is strong across many industries. In Ontario alone, where Flex is built, more than 28,000 farmers grow wheat, along with corn and soybeans. Typically, wheat straw, the byproduct of growing and processing wheat, is discarded. Ontario, for example, has some 30 million tonnes of available wheat straw waste at any given time.

Wheat straw bio-filled polypropylene.

Industry and world-first usage in quarter trim bins on 2010 Ford-Flex

“Wheat is everywhere and the straw is in excess,“ said Lee. “We have found a practical automotive usage for a renewable resource that helps reduce our dependence on petroleum, uses less energy to manufacture, and reduces our carbon footprint. More importantly, it doesn‘t jeopardize an essential food source.“ To date, Ford and its suppliers are working with four southern Ontario farmers for the wheat straw needed to mold the Flex‘s two interior storage bins.

History in the making Ford‘s interest in wheat dates back to the 1920s, when company founder Henry Ford developed a product called Fordite – a mixture of wheat straw, rubber, sulphur, silica and other ingredients – that was used to make steering wheels for Ford cars and trucks. Much of the straw used to produce Fordite came from Henry Ford‘s Dearborn-area farm.

The company‘s new-age application for wheat straw joins other bio-based, reclaimed and recycled materials that are in Ford, Lincoln and Mercury vehicles today, including soy-based polyurethane foams on the seat cushions and seatbacks, now in production on the Ford Mustang, Expedition, F-150, Focus, Escape, Escape Hybrid, Mercury Mariner and Lincoln Navigator and Lincoln MKS. More than 1.5 million Ford, Lincoln and Mercury vehicles on the road today have soy-foam seats, which equates to a reduction in petroleum oil usage of approximately 1.5 million pounds. Last year, Ford has expanded its soy-foam portfolio to include the industry‘s first application of a soy-foam headliner on the 2010 Ford Escape and Mercury Mariner for a 25 % weight savings over a traditional glass-mat headliner.

COMPOSTABLE PACKAGING TECHNOLOGIES

EcoWorks

ÂŽ

• 100% BIODEGRADABLE • 100% COMPOSTABLE • RENEWABLE CONTENT (5-70%) • CONTAINS NO POLYETHYLENE

Q U A EXCELLENCE I T Y

w w w. C o r t e c V C I . c o m

ÂŽ

info@CortecVCI.com

C O R P O R AT I O N Environmentally Safe VpCI ÂŽ/MCI ÂŽ Technologies

1-800-4-CORTEC St. Paul, MN 55110 USA EN

www.ford.com

SY

BioPlastics 2010.indd 1

ST

VIRO

NMENT

AL

EM REGISTER

ED

( & ) ( , - %

8D >AB +:<>HIG6I>DC 'D ) 8D0DG@H +:<>HIG6I>DC 'D )

2/1/10 9:11:30 AM

bioplastics MAGAZINE [01/10] Vol. 5

13

Automotive BioConcept Car 2, the Megane Trohpy (photo: Four Motors)

BioConcept-Car – with Biomaterials on the Passing Lane I

n the first ‘automotive issue‘ of bioplastics MAGAZINE in early 2007 we reported on the BioConcept-Car. The Ford Mustang GT RTD features the world‘s most powerful biodiesel engine and bodywork made of flax-fibre reinforced linseed-acrylate, i.e. a high performance composite made of natural fibres embedded in a resin from the same plant (flax and linseed).

At the end of October 2009 the ‘BioConcept-Car‘ project by Four Motors, Reutlingen, Germany, received the COMPOSITES Pioneer Award 2009 for the groundbreaking achievements in using natural fibres in automotive applications. The award was given to team leader and former DTM driver Thomas von Löwis of Menar (photo) within the framework of the COMPOSITES EUROPE 2009 exhibition. The trophy itself also lived up to its name, as its basic body is made entirely from renewable materials. Industrial designer Rolf Bender, who has already designed a large number of awards, created a monolithic shape made from the biopolymer PLA and bamboo grass. Its special feature: the two PLA sheets are welded, not glued, to the layer in between.

During Composites Europe 2009 in Stuttgart, Germany, the Ford Mustang was presented, as well as the new generation BioConceptCar, a green Renault Mégane Trophy. Both racing models show that even with biofuels and materials from renewable resources, trophies

14

bioplastics MAGAZINE [01/10] Vol. 5

Automotive

in long term races, such as the BFGoodrich long-distance championship and the 24-hour races on the Nürburgring, can be successfully achieved. Advantages of the bio-composites are their lower weight compared to glass-fibre composites, they do not splinter in crashes and, most importantly, they are better for the environment.

The globally unique project with the Mustang featuring doors, fenders, engine hood, bumpers, spoilers and trunk lid made completely from bio-composites is now being further developed with a Renault Mégane Trophy 09. Its multi-part glass fibre reinforced body will be replaced step-by-step by natural fibre reinforced linseed-acrylate. This is happening in close cooperation with the German government‘s FNR (Agency for Renewable Resources) and the German Aerospace Center (DLR). “One important goal after the 2007 Mustang was to reduce weight and increase stability,“ says Thomas (Tom) von Löwis. “The new unpainted door of the Ford (that can be seen in the picture) is already 40% lighter than the previous one. This was achieved by reducing the number of fibre layers in some areas while maintaining a rigid structure in the areas of the hinges or the windows.“ The weight of the engine hood was reduced by 45%, and so on. “And there is still room for further improvement,“ says Tom. All of the experts from the FNR and DLR, as well as the racing team, are confident that with the Mégane even loadbearing parts can be realised. “This will really take us a huge step further,“ Tom points out.

COMPOSITES Pioneer Award: from left: Markus Jessberger (Director COMPOSITES EUROPE), Amanda Jocob (Editor in Chief ‘Reinforced Plastics‘) and Thomas von Löwis, Crew Chief ‘Four Motors‘ (photo bioplastics MAGAZINE)

The project is based on a concept with a scope far beyond motor sports. With the application of bio-materials and biofuels Thomas von Löwis and racing driver Smudo (by the way, he‘s a well-known Hip-Hop Star in Germany too) want to show and prove the capabilities of renewable resources. Further goals in the BioConcept Car 2 project are for example a solar panel roof to support the on-board electronics. “This will not lead to reduced lap times - that is the job of our drivers - but it will help to go longer distances on just one tankful,“ says Tom von Löwis. And he begins to dream … but it is a dream with the potential to come true: “One day, I hope we can drive a racing car around the Nürburgring powered by an electric motor, the batteries charged by a block power station - solar panels during daylight and a biodiesel generator at night. Emobility is definitely coming,“ he says.

But this BioConcept Car project does not want to be restricted to motor racing. On the contrary, the supporting partners FNR and others are very interested in transferring the project‘s findings to serial applications, starting for example with rear view mirror housings or tank lids. “Potential partners from industry that are interested in participating and transferring these results into ‚real‘ products are more than welcome,“ says Simone Falk of Four Motors. The first talks with seat manufacturers, for example, have already started. MT www.fourmotors.com

Covergirl Theresia worked with Reed Exhibitions, organizers of COMPOSITES EUROPE. She says: “The whole week in Stuttgart was quite interesting, but the two BioConcept Cars were definitely among the highlights“.

bioplastics MAGAZINE [01/10] Vol. 5

15

(Pictures: Hyundai)

Hyundai Blue-Will Concept to feature PLA and PA 11

Automotive

A

t the 2010 North American International Auto Show in Detroit (January 2010) Korean automaker Hyundai for the first time presented its Blue-Will Plug-in Hybrid concept car. Besides other environmental goodies such as a panoramic glass roof with solar cells for recharging batteries and a thermal generator that converts hot exhaust gases into electricity the Blue-Will serves as a test bed of new ideas that range from drive-by-wire steering to lithium polymer batteries and touch-screen controls, and foreshadows future focused hybrid production vehicles from Hyundai. Blue-Will promises an electric-only driving distance of up to 40 miles on a single charge and (in the so-called plug-in HEV mode) a fuel economy rating of more than 100 miles per gallon (less than 2.3 liters/100 km).

While the headlamp bezel for example is made of recycled PET bioplastics from renewable resources such as PLA or PA 11 have been used on interior and exterior parts.

The Blue-Will concept is powered by an all-aluminum 152-horsepower Gasoline Direct Injected (GDI) 1.6-liter engine mated to a Continuously Variable Transmission (CVT). A 100kw electric motor is at the heart of Hyundaiâ&#x20AC;&#x2122;s proprietary parallel hybrid drive architecture. This parallel hybrid drive architecture serves as the foundation for future Hyundai hybrids, starting with the Sonata hybrid coming later this year in the USA. www.hyundai.com

16

bioplastics MAGAZINE [01/10] Vol. 5

Tires Made from Trees

Automotive

A

utomobile owners around the world may someday soon be driving on tires that are partly made out of trees – which could cost less, perform better and save on fuel and energy.

Wood science researchers at Oregon State University (Corvallis, Oregon, USA) have made some surprising findings about the potential of microcrystalline cellulose – a product that can be made easily from almost any type of plant fibers – to partially replace silica as a reinforcing filler in the manufacture of rubber tires.

A new study suggests that this approach might decrease the energy required to produce the tire, reduce costs, and better resist heat buildup.

Early tests indicate that such products would have comparable traction on cold or wet pavement, be just as strong, and provide even higher fuel efficiency than traditional tires in hot weather.

“We were surprised at how favorable the results were for the use of this material,” said Kaichang Li, an associate professor of wood science and engineering in the OSU College of Forestry, who conducted this research with graduate student Wen Bai. “This could lead to a new generation of automotive tire technology, one of the first fundamental changes to come around in a long time,” Li said.

Cellulose fiber has been used for some time as reinforcement in some types of rubber and automotive products, such as belts, hoses and insulation – but never in tires, where the preferred fillers are carbon black and silica. Carbon black, however, is made from increasingly expensive oil, and the processing of silica is energy-intensive. Both products are very dense and reduce the fuel efficiency of automobiles.

In the search for new types of reinforcing fillers that are inexpensive, easily available, light and renewable, OSU experts turned to microcrystalline cellulose – a micrometer-sized type of crystalline cellulose with an extremely well-organized structure. It is produced in a low-cost process of acid hydrolysis using nature’s most abundant and sustainable natural polymer – cellulose – that comprises about 40-50 % of wood.

In this study, OSU researchers replaced up to about 12 % of the silica used in conventional tire manufacture. This decreased the amount of energy needed to compound the rubber composite, improved the heat resistance of the product, and retained tensile strength.

Traction is always a key issue with tire performance, and the study showed that the traction of the new product was comparable to existing rubber tire technology in a wet, rainy environment. However, at high temperatures such as in summer, the partial replacement of silica decreased the rolling resistance of the product, which would improve fuel efficiency of rubber tires made with the new approach.

source: iStockphoto

This advance is another in a series of significant discoveries in Li’s research program at OSU in recent years. He developed a non-toxic adhesive for production of wood composite panels that has dramatically changed that industry, and in 2007 received a Presidential Green Chemistry Challenge Award at the National Academy of Sciences for his work on new, sustainable and environmentally friendly wood products. http://oregonstate.edu

bioplastics MAGAZINE [01/10] Vol. 5

17

Automotive GreenCore Composites - Structural and nonstructural components made from pulp mill micro fibres

Ontario BioAuto Council

T

he Ontario BioAuto Council, headquartered in Guelph Ontario, is an industry-led, not-for-profit organization established in 2007 to link chemicals, plastics, manufacturing, auto-parts and automotive assemblers with agriculture and forestry.

The Council’s membership includes large Canadian auto-parts companies like Magna, Woodbridge Group and Canadian General Tower who manufacture and sell products around the world.

The Council has attracted foreign membership from multinational industrial biotechnology, chemical and agri-business companies wanting to partner with Ontario’s manufacturing sector to develop global markets for biobased products.

Examples include DuPont, Dow, and Cargill in the US; DSM in the Netherlands; and Braskem in Brazil.

The Council also links industry with leading universities and provincial and international centres of research excellence in bioplastics and biocomposites. Auto21, The National Research Council of Canada and FP Innovations are a few of the important research links.

The Ontario BioAuto Council established a Commercialization Fund in 2007 with initial start-up funding of $6 million (€4 mio) from the Province of Ontario. The fund helps to diminish the risk for companies commercializing biobased products and processes using emerging green technologies (e.g. biotechnology, nanotechnology, green chemistry and material science). Funding is eligible to Ontario-based startups, small and medium enterprises and multi-national companies who typically partner with international biopolymer and biochemical suppliers in the product and market development process.

18

bioplastics MAGAZINE [01/10] Vol. 5

The Council has demonstrated that an industry-led board can successfully use relatively small, strategically targeted incentives for manufacturing companies to kick start new markets for biobased products.

The Commercialization Fund has focused on four major priorities:  Improving the global competitiveness of Ontario’s manufacturing sector – by developing new products that can better compete on price, performance and environmental footprint.  Reducing greenhouse gas emissions - by using renewablebased bioplastics, biochemicals, and high performance natural fibre composite materials that can reduce vehicle weight and improve recyclability.  Reducing the use of toxic chemicals in production processes and consumer products.  Increase market demand for bioplastics and biochemicals across industry sectors.

The Council is now focusing on establishing partnerships between Ontario’s global automotive and manufacturing sectors and similar sectors in the US, Europe, Brazil and Japan. Through these partnerships it hopes to accelerate the commercialization of new technologies and build global market demand.

The Ontario BioAuto Council’s vision is to make Ontario a global leader in the use of renewable biobased materials. It is well on its way to achieving this vision because of its support of global product and market development partnerships. www.bioautocouncil.com

Automotive Picture courtesy Peugeot Citroën

Natural Fibers Biopolymers

PSA Peugeot Citroën Applies Green Materials

www.psa-peugeot-citroen.com www.sustainability.psa-peugeot-citroen.com

L

ast October French automotive group PSA Peugeot Citroën presented the latest developments in its green materials plan, set up to limit the eco-footprint of Group vehicles during their service life.

also concerns existing vehicles, with green materials being integrated during their production life. Engineering teams are working in close cooperation with suppliers in order to select these new materials.

The Group has set an ambitious target in eco-design: to include 20% of green materials in the polymers used to build its cars by 2011. A car is made up of 70% metal, already largely recycled, 5% miscellaneous materials (glass, etc.) and 5% fluids. The rest (20%) is plastics (polymers).

This effort also gives new impetus to the recycled materials industry. The subject of biomaterials is still at the research stage in the automotive industry. To address the issue, scientific partnerships have been set up as part of research clusters bringing together public laboratories, chemical firms and parts suppliers. The aim of these partnerships is to accelerate the application of these materials in the automotive industry. Suppliers of biomaterials are new to the automotive industry. Therefore specifications must cover the basics from a technical and functional standpoint. The materials for example need to be suitable to be converted in an industrial process and must be available in sufficient quantity.

At PSA the term ‘green materials‘ covers natural fibres, such as linen and hemp, non-metallic recycled materials and biomaterials, which are produced using renewable resources rather than petrochemicals. The aim is to use fewer fossil fuel plastics and to increase the use of raw materials from renewable sources to make parts lighter, in some cases, to cut CO2 emissions from plastics production and to promote plastics recycling.

The Earth’s resources are dwindling, so it is important to optimise the way in which they are used. End-of-life processing is therefore factored in from the design stage.

The aim is to boost recyclability and thus reduce the potential impact of end-of-life vehicles. As a minimum, 85% of a vehicle by weight can be reused or recycled, and a further 10% be used for energy recovery.

The key feature of the action plan set up by PSA Peugeot Citroën in 2008 is that it concerns all Group vehicles and the three families of green materials. The green material content of each vehicle project must be increased. This approach

Examples of applications include foam for seating, armrests, headrests, from vegetable polyols (castor oil, soy oil) or fuel pipes from bio-polyamide.

The target of a project named MATORIA (with MOV’EO, AXELERA, PLASTIPOLIS) which is steered by PSA is the development of injectable plastics from renewable resources.

14 partners in this project include ROQUETTE and ARKEMA for the supply of bio-sourced polymers, and VISTEON, VALEO, PLASTIC OMNIUM and MECAPLAST for approval for automotive use. The project looks at 18 different applications which represent a total of about 50kg per vehicle.

bioplastics MAGAZINE [01/10] Vol. 5

19

Automotive

Concept Tyres Made with BioIsoprene™

www.genencor.com/bioisoprene www.goodyear.com

T

he world’s first concept demonstration tyres made with BioIsoprene™ technology, a breakthrough alternative to replace a petrochemically produced ingredient in the manufacture of synthetic rubber with renewable biomass, made their debut at the United Nations Climate Change Conference in Copenhagen, Denmark, last December.

The tyres made with BioIsoprene are the result of a collaboration between Genencor, a division of Danisco, and Goodyear, one of the world’s largest and most innovative tyre companies.

“Goodyear’s collaboration with Genencor to develop BioIsoprene, which will be ultimately converted by Goodyear to BioNatsyn polymers, is another example of open innovation,“ says Jesse Roeck, Director, Global Materials Science at Goodyear. “BioNatsyn polymers made from BioIsoprene are a renewable resource that offers promise as a ‘green‘ alternative to petroleumbased isoprene. It will ultimately give manufacturers, who use isoprene to produce synthetic rubber, the choice to use a raw material made with renewable feedstocks therefore reducing the dependency on oil.“

Picture courtesy Goodyear

“We are literally rolling out an important milestone in our collaboration with Goodyear on a breakthrough biochemical,” says Tom Knutzen, CEO of Danisco.

“BioIsoprene is an excellent example of Danisco’s leadership in industrial biotechnology through our Genencor division. As we deliver enzymes to existing markets, we are also investing in future bio-innovations with extraordinary potential to address the world’s most urgent business and environmental challenges.“

BioIsoprene is derived from renewable raw materials. Genecor is testing wide range of renewable feedstocks, including sugars from corn and sugar cane and a variety of biomass substrates: It represents a significant development within the biochemical and rubber industries. Aside from synthetic rubber for tyre production, traditional isoprene is used for the production of a variety of copolymers that are used in the elastomer-, adhesives- and performance polymer markets. Application examples range from surgical gloves to golf balls and thus, the potential for BioIsoprene product is substantial.

According to experts the market for high purity isoprene was 0.75 million tonnes/year in 2007. Genencor plans to bring the technology to pilot stage within two years, followed by commercial production.

Since 2001, Goodyear has already used the BioTRED Technology, which allows to partly replace the carbon black, diatomite and silica fillers by a starch based (MaterBi) reinforcement. BioTRED, is a special patented formula. The starch is here treated to obtain nano-droplets of a complexed starch. In a next step, these nano droplets are added to the rubber compound to be transformed into a biopolymeric filler. The so called Bio-Tyres require less energy in their production, the cultivation of corn absorbs CO2, and in addition the tyre offers a reduced rolling resistance leading to up to 5% saving in fuel consumption (bM 01/2007). MT

20

bioplastics MAGAZINE [01/10] Vol. 5

Foam Fig. 3: Magnified view of the cell structure of PLA foamed with HYDROCEROL 1% CT 3108 shows a coarse cell structure, resulting in a poor surface quality with many collapsed cells

A

s biopolymers have found applications in food packaging, medical and many other applications, there is increasing interest in foaming these materials. The green image of biodegradable polymers like polylactidacid (PLA), starch-based polymers or copolyesters make them attractive to supermarkets and consumers. High raw-material cost have been one of the limitations of these materials and so PLA foaming – and hence weight and material-cost savings – offers an option to push these polymers further into the market.

Foaming Agents and Chain Extenders for PLA Foam Article contributed by Jan-Erik Wegner and Mirco Gröseling, Clariant Masterbatches (Deutschland) GmbH, Ahrensburg, Germany

Although foaming can be accomplished using direct-gas injection, Clariant’s chemical foaming agents (CFAs) in masterbatch form are increasingly preferred, particularly in food packaging applications. The benefits of this technology include  Solid decomposition residue acts as a nucleator creating a finer cell structure and a better solubility of the gas in the polymer melt;  Decomposition reaction takes place in a defined temperature range;  Easy mixing and uniform dispersion;  High gas yield;  Approved for food-contact applications.

Fig. 4: Photo shows smaller and more uniform cells in PLA foamed with 2% Hydrocerol CT 3108 in and with 1% CESA-extend BLA0025505

In general, there are two kinds of chemical foaming agents characterized by whether they generate heat during decomposition (exothermic) or absorb heat during the reaction (endothermic). Exothermic foaming agents can cause odor during production and in the finished product, and their solid byproducts often are undesirable and even toxic. Therefore the exothermic CFAs are banned from use in products that must have food approval. The endothermic CFAs offered by Clariant, on the other hand, are acceptable in food packaging materials, but they have one important limitation when used in ester-based polymers like PET, polycarbonate and PLA – moisture.

A byproduct of most endothermic chemical foaming agents is water, which is generated during the converting process at high temperatures.

The resulting hydrolytic reaction can destroy a part of the polymer chains, resulting in a lower viscosity (increased melt flow rate, MFR), which makes the process difficult to handle. Specifically, proper die pressure, vital for foaming, cannot be maintained and the foaming process runs out of control. The melt strength drops and the film starts sagging. The dispersion of gas in the polymer is not optimized and will create surface

22

bioplastics MAGAZINE [01/10] Vol. 5

Foam

30

1,2

25

1,0

20

0,8

15

0,6

10

0,4

5

0,2

0

0

PLA Nature

MFR (210°C/2,16 kg) [g/10 min]

1% CT3108

1,5% CT3108

Density [g/10 min]

30

1,4

25

1,2 1,0

20

0,8

15

0,6 10

0,4

5 0

0,2 PLA Nature

1% CT3108 1,5% CT3108 2% CT3108 + 1% CESA exend + 1% CESA exend + 1% CESA exend BLA0025505 BLA0025505 BLA0025505

MFR (210°C/2,16 kg) [g/10 min]

Fig. 1: Weight reduction and melt flow ratio (MFR) of PLA foam are plotted as a function of the addition of HYDROCEROL CT 3108 chemical foaming agent

defects when extruded sheets are thermoformed. Due to the lower melt index the finished articles, like food-trays, can become brittle.

Fortunately, certain additives, when used in combination with CFAs, can reconnect short or broken polylactid acid chains and restore them to a higher level. These additive masterbatches (tradenamed CESA®-extend) are based, for instance, on multifunctional additives that react with the functional groups of the polymer. There are two types: chain extenders, which are designed for linear chain extension only; and chain branchers, which achieve both linear extension and cross-chain branching.

Of the two, the cross-chain branching type – which actually accomplishes both chain extension and chain branching – are preferred for use in PLA along with endothermic chemical foaming agents. First, they are less sensitive to water because they do not react as fast and thus have free functional groups available to react with the polymer. Another advantage of the multifunctional additives is that the partial chain branching enhances the melt strength, therefore stabilizes the extrusion conditions and leads to a better dispersion of the blowing gas, which yields a finer and more homogeneous foam structure.

Recently, lab trials were conducted to investigate the potential for density reduction in cast PLA film (NatureWorks® 2002D) and to confirm how chain-branching additives can improve the extrusion process and the quality of the end product. HYDROCEROL® CT 3108 was the chemical foaming agent used and the chain-branching additive masterbatch was Cesa-extend BLA0025505. Both products are manufactured

by Clariant Masterbatches.

Density [g/cm3]

1,4 MFR (210°c/2,16 kg) [g/10 min]

MFR and Density of PLA in relation to the let down rate

35

Density [g/cm3]

MFR (210°c/2,16 kg) [g/10 min]

MFR and Density of PLA in relation to the let down rate

0

Density [g/10 min]

Fig. 2: Weight reduction and melt flow ratio (MFR) of PLA foam are plotted as a function of the addition of HYDROCEROL CT 3108 chemical foaming agent together with1% chain brancher CESA-extend BLA0025505

The first trial extruded PLA with Hydrocerol at let down rates of 0%, 1% and 1.5% and the density reduction and melt flow rate were measured. As shown in fig. 1, density of the PLA extruded without CFA was 1.25 g/cm3. Adding CFA at 1% reduced the density to 1.08 g/cm3 and a let down rate of 1.5% reduced it further to 0.94 g/cm3, effectively reducing material weight by 25%. At the same time, however, meltflow rate (g/10 min @ 210°C/2.16 kg) increased dramatically from 6.0 without CFA to almost 30 with 1% Hydrocerol and to almost 27 with 1.5% CFA. The foamed film had a coarse cell structure (see fig 3), and poor surface quality with many collapsed cells.

Next, the PLA was foamed with Hydrocerol CT 3108 at 1%, 1.5% and 2% let down rates, and Cesa-extend BLA0025505 chain-branching agent added at a rate of 1% in all three cases (see fig. 2). At 1% CFA and 1% chain brancher, the density was reduced to 1.0 g/cm3. With 1.5% CFA, density was 1.05 g/cm3, while 2% CFA reduced density dramatically to 0.7 g/cm3, for an overall weight reduction of 44%. With the addition of 1% Cesa-extend, the foam structure was significantly improved despite the higher loadings of Hydrocerol. Smaller and more uniform cells are evident in fig. 4. This, even though the melt flow rate remained roughly the same as in the first test.

Clearly, Cesa-extend chain brancher provides higher melt strength and allows for higher let down rates of foaming agent.

Without the use of the Cesa-extend, it would be difficult to achieve the kind of density reductions required to help make PLA a more competitive option for food packaging. www.clariant.com

bioplastics MAGAZINE [01/10] Vol. 5

23

Foam Article contributed by BioFoam

Jan Noordegraaf, Managing Director Synbra, Etten Leur, The Netherlands

EPS

Compressive strength (kPa)

40 g/l

200

30 g/l

200

Bending strength (kPa)

35 g/l

Young’s modulus (MPa)

40 g/l

300

30 g/l

300

4.0

30 g/l

C-value (-)

3.0

35 g/l

2.6

30 g/l

2.7

Thermal conductivity (MW/m·K)

35 g/l

34

30 g/l

33

Table 1 some physical ad thermal properties of BioFoam compared to EPS

‘Cradle to Cradle‘ Certified PLA Foam

S

ynbra Technology bv in Etten-Leur, The Netherlands, is the Synbra Group‘s in-house polymerisation and ‘Technology & Innovation’ R&D facility, as well as the group‘s centre of excellence for materials and product development. Synbra is a leading European producer of Expandable Polystyrene (EPS) and the first plant (5000 t/a) to use a new polymerisation technology for PLA, that was recently developed by Sulzer Chemtech and Purac Biochem, will be built by Synbra Technology in the Netherlands for the production of BioFoam®; a foamed product made from this PLA (see bM 05/2008 and 01/2009).

Processing The foam expansion process and moulding process for BioFoam is being developed at a rapid pace to facilitate approval of moulded prototypes. Parts are moulded every week for interested international customers. BioFoam processing has now left the laboratory phase and is running in series production for selected parts. The process of moulding is carefully adapted to suit expansion of the raw beads (called BioBeads) in existing EPS moulding equipment, resulting in uniform expanded beads and uniform cell structures (fig 1). A spherical and uniform series of raw beads in three classes (sized 0.6-0.7mm, 0.81.0mm and 1.0-1.4mm) can be produced to suit the specific moulding application.

With a slightly modified pre-expansion process and an industrial moulding machine existing moulds for EPS products were used to produce parts, see figures 2 and 4.

Figure 1: SEM image of an expanded E-PLA bead, with a closed cell structure and a uniform cell size.

Figure 2. Moulded parts, box and lid made in BioFoam for the logistics cool chain

Properties The physical properties of BioFoam have been determined (see table 1) and are close to those of EPS. The thermal properties are strikingly similar, which has led to an interest in refrigerated transport for medical supplies. BioFoam is resistant to liquid nitrogen LN2 and CO2 granules or dry ice, the latter is often used in the transport cool chain, see figure 2.

Of particular interest are the results for drop testing in comparison with EPS, which show that BioFoam has all the potential to become a good buffer material - a point that has not gone unnoticed by several blue chip companies, see figure 3 (a and b).

BioFoam has a better resistance to high stress deformation as can been seen from its the characteristics in comparison with EPS.

Carbon footprint Detailed information on the CO2 balance of the PLA used by Synbra will be subject of a future article. In addition, a recent study was carried

24

bioplastics MAGAZINE [01/10] Vol. 5

Foam out comparing seed trays for growing plants made from BioFoam and from cardboard as two different material solutions. It was calculated how many grams of CO2 would have been emitted to arrive at the same functional unit for BioFoam and cardboard. It was demonstrated that foams score better than the heavier part in cardboard, see figure 4. The part is a frequently used container for 15 bedding plants and weighs only 50 grams versus 200 grams in cardboard.

average drop 2-5, drop height 76 cm 80,000 70,000 60,000

G (-)

50,000 40,000 30,000

Certification

EPS 20 E-PLA 60 E-PLA 35

20,000 10,000

Being produced from the renewable resource PLA, BioFoam is an environmentally friendly alternative to the polystyrene foam products offered today. After use, the BioFoam product can be remoulded to a new product or can be completely biodegraded. Being ‘designed for the environment’ implies that there is no chemical waste, which means that the product is designed according to the so called ‘Cradle to Cradle’ principles. The Cradle to CradleSM Design was founded by William Mc Donough and Michael Braungart. The latter is also the founder of EPEA (Environmental Protection Encouragement Agency), an international scientific research and consultancy institute based in Hamburg, Germany, that improves product quality, utility and environmental performance via eco-effectiveness. Together with their USA based sister company MBDC (McDonough Braungart Design Chemistry LLC), EPEA is able to grant companies a Cradle to Cradle certificate for specific products. Synbra actively encourages its suppliers to embrace the C2C scheme.

0,000

0

5,00

10,00

15,00

20,00

25,00

30,00

Static stress (kPa)

Figure 3a. Drop testing: G-force versus static stress energy for EPS and two densities of 60 and 35 gr/l E-PLA for single drop testing.

1st drop 76 cm height 80,000 70,000 EPS 20 E-PLA 60 E-PLA 35

60,000

G (-)

50,000 40,000 30,000 20,000

Tebodin Consultants & Engineers of The Netherlands (who have a cooperation agreement with EPEA ) was asked to prepare the application package for the Cradle to Cradle certification of BioFoam.

Data was collected and compiled on material safety, water and energy utilisation, as well as information on the social responsibility of the applying company. Based on this information EPEA was able to carry out an assessment study, which has resulted in BioFoam now being officially declared a Cradle to Cradle Certified material. This is the first PLA based product in the world and the first biodegradable foam in the world with this certification. The PLA Bio-Beads made by Synbra have in the meanwhile also been certified, effectively making it the first PLA polymer to be C2C certified in the world..

10,000 0,000

0

5,00

10,00

15,00

20,00

25,00

30,00

Static stress (kPa)

Figure 3b. Drop testing: G-force versus static stress energy for EPS and two densities of 60 and 35 gr/l E-PLA for multiple drop testing

Conclusion BioFoam mouldings are based on renewable feedstock that allow a major saving in CO2 emission compared to equivalent functional units.

Clearly this explains why it is attractive to a whole range of industries.

The particle foam nature of the material allows a very wide freedom of design with the convenience hitherto only offered by EPS. www.biofoam.nl

kg CO2 emmision / part (100 year CO2 equiv) BioFoam (lactide based) Cardboard 0,04

0,06

0,08

0,10

0,12

0,14

0,16

Figure 4: Parts analysed for the comparative study and the CO2 emission originating from its production for the same functional unit.

bioplastics MAGAZINE [01/10] Vol. 5

25

Foam Article contributed by S. Zepnik, A. Kesselring, C. Michels Fraunhofer UMSICHT, Oberhausen C. Bonten FKuR Kunststoff GmbH, Willich F. van Lück Inde Plastik Betr.GmbH, Aldenhoven all Germany

F

oam sheet extrusion of thermoplastics (e.g. extruded polystyrene foam (XPS)) is a well-established foam technology. Two basic categories of blowing agents are used for foam production (table 1). The blowing agent is the primary factor controlling the foam density as well as its cellular microstructure and morphology, so determining the end-use properties of foams [1].

Physical blowing agents (PBA)

 gases (e.g. N2, CO2, C3H8 or C4H10) or low boiling pointfluids (e.g. ethanol or propanol)  separate feeding via gas injection into the polymer melt (homogenization zone)  lower foam densities and higher foam ratios with more homogeneous foam morphology than for CBA  thin-walled foam sheets, films or profiles Chemical blowing agents (CBA)

 thermally unstable chemicals (e.g. bicarbonates, azodicarbonamide, hydrazine derivatives or citric acids) which decompose or react under temperature and produce gases (e.g. N2, CO, CO2)  feeding as masterbatches together with the polymer (no critical modification of existing machinery is required in comparison to PBA)  only thick-walled products with low density reduction

Cellulose Acetate Foams A wide range of conventional polymers is available for foam extrusion processes (e.g. PE, PP, PS, PET, PVC) [1;2]. Foams based on biopolymers (starch or PLA) are the subject of recent developments and are already available on the market, especially as food trays or particle foams [3].

At present the use PLA for the production and application of foam trays for hot contents is limited due to its low heat resistance. Furthermore, the thermoforming process of PLA-based foam sheets is critical with regard to the high crystallinity and brittleness of unmodified PLA. Therefore Fraunhofer UMSICHT, FKuR GmbH and Inde Plastik GmbH, a leading manufacturer of XPS-based food trays, are developing thermoformable Cellulose Acetate foam sheets for hot food applications. Foam tests with BIOGRADE C 7500CL and different chemical blowing agents (CBAs) produced foam sheets with good thermoforming behaviour (Fig. 1).

By adding an azodicarbonamide as a CBA to the extrusion process it was possible to reduce the density of BIOGRADE C 7500CL from 1.244 to 0.454 g/cm³. The Cellulose Acetate foams exhibit a coarse morphology with non-homogeneous distribution of the cells (Fig. 2).

Furthermore, these bubbles are surrounded by compact Biograde C 7500CL as a matrix. The relatively low reduction in density and the coarse foam morphology with only a few, but large, cells is typical for foams produced with CBAs.

Table 1: Short characterization of physical and chemical blowing agents (according to [1] and [2]).

Fig. 1: Cellulose Acetate based foam sheets (right and centre) and thermoformed cup (left).

26

bioplastics MAGAZINE [01/10] Vol. 5

Foam Literature [1] D. Eaves: Handbook of Polymer Foams, Rapra Technology Ltd, 2004.

[2] S.-T. Lee: Foam Extrusion – Principles and Practice, CRC Press, 2000.

[3] http://www.ptonline.com/articles/200712cu1.html [14.01.2010].

[4] FKuR GmbH: Technical data sheet (TDS) of BIOGRADE C7500CL, http://www.fkur.com/produkte/biograder/ biograder-c-7500-cl/datenblaetter.html [14.01.2010].

[5] L. B. Bottenbruch: 3. Technische Thermoplaste: Polycarbonate, Polyacetale, Polyester, Celluloseester, in G. W. Becker, D. Braun: Kunststoff-Handbuch, Hanser Verlag, 1992.

[6] J. E. Mark: Polymer Data Handbook, Oxford University Press, 1999.

Fig. 2: Morphology of Cellulose Acetate foam [digital microscope; magnification: 25-times (left) and 50-times (right)].

In comparison to an XPS produced with PBAs, the Cellulose Acetate foams are stiff and have a high tensile modulus due to the relatively high amount of compact matrix material around the bubbles determining the mechanical properties (Fig. 3).

 crystallization behaviour of the polymer competing with the nucleation and growth of the bubbles

The rigidity in combination with high heat resistance (Vicat A of Biograde C 7500CL is 111°C [4]) and thermoformability of these Cellulose Acetate foams make them attractive for rigid foam applications (e.g. trays for hot contents).

Furthermore, the excellent injection mouldability together with the foaming performance of Biograde C 7500CL are ideal for the manufacturing of foam injection moulded compact parts with a (rigid) foam core. Recent developments

by Fraunhofer UMSICHT and Inde Plastik GmbH are focusing on Cellulose Acetate foams produced with PBAs. The aims of the investigation are foams with lower densities, homogeneous cells and finer foam morphologies like XPS foams. For fine, low-density foams produced with PBAs, the polymer properties have to fulfil specific requirements [1]:

Physical properties:

Rheological properties:

Therefore, Fraunhofer UMSICHT is studying the reactive modification (e.g. internal (chemical) plasticization) of Cellulose Acetate to achieve the long-term stable properties needed for physical foaming.

 heat distortion temperature and heat conductivity for a rapid increase in polymer viscosity to avoid foam collapse

 high gas solubility in the polymer melt but poor gas solubility in the finished foam  boiling point, molecular weight or vapour pressure of the physical blowing agent  physical polymer properties such as molecular chain structure or degree of crystallinity To achieve these required properties, Cellulose Acetate has to be modified. At present external (physical) plasticization is the most common method of Cellulose Acetate modification.

Blending is very difficult due to its Hansen solubility parameter as well as the strong hydrogen bonds (Fig. 4) influencing the miscibility of Cellulose Acetate [5].

 specific melt viscosity and melt stability for a good gas dispersion and distribution as well as stable foam morphology without collapse

www.umsicht.fraunhofer.de www.fkur.com www.indeplast.de

Thermal properties:

2500

18

2250

16

2000

14

1750

1250 1000 CH2OR H

XPS (EMPERA 350N)

Para (1.5%)

O Azo-5 (1%)

0 Para (1.5%)

0 XPS (EMPERA 350N)

250 Azo-5 (1%)

2 Azo-4 (0.7%)

500

Azo-3 (1%)

750

4

Azo-2 (1%)

6

Azo-3 (1%)

8

1500

Azo-4 (0.7%)

10

Azo-2 (1%)

12

Fig. 3: E-modulus and tensile strength of different Cellulose Acetate foams in comparison to an XPS (red).

Azo-1 (2.5%)

E-Modulus [MPa]

20

Azo-1 (2.5%)

Tensile strenght [MPa]

 wide processing window without thermal degradation to achieve a specific melt rheology

O H OR

H

H

OR

H

(R is COCH3 or H)

Fig. 4: Molecular structure of Cellulose Acetate [6].

bioplastics MAGAZINE [01/10] Vol. 5

27

Foam

K

ANEKA Corporation is a Japanese chemical company which develops, manufactures and sells various chemical products. Kaneka’s business interests are concentrated on seven fields, which are chemicals, functional plastics, foodstuffs products, life science products, electronic products, synthetic fibers and expandable plastics and products.

www.kaneka.com

In the expandable plastics and products field, Kaneka deals in particle foamed polystyrene (Kanepearl™), polyethylene (Eperan™) and polypropylene (Eperan™ PP) and extruded polystyrene foam boards (Kanelite Foam™). In the area of particle polyolefin foams products, Kaneka is one of the major suppliers worldwide with manufacturing locations in Japan, Belgium, Malaysia and China.

These products are applied in the production of automotive parts, containers for food, insulation materials etc.

As a novel product in Kaneka‘s range of particle foam products and based on their proprietary expansion technology, the company is introducing expanded PHBH (poly 3-hydroxybutyrate-co-3hydroxyhexanoate).

Bio-Based Biodegradable PHA Foam

PHBH is an entirely bio-based biodegradable polymer, which originates from edible plant oil (corn-, soybean- or palm oil) or non-edible plant oil. Like other biopolymers from the family of the polyhydroxyalkanoates PHBH is produced by microorganisms in the fermentation process, where it is accumulated in the microorganism’s body for nutrition. It is then collected through a cleaning and granulation process.

The main features of PHBH are its excellent biodegradability, combined with a high degree of hydrolysis and heat stability. PHBH can be biodegraded in aerobic (ISO14851), anaerobic (ISO14853, 15985) and compost (ISO14855) conditions. The hydrolysis stability of PHBH is superior to most of the biodegradable polyesters available on the market today. Regarding the heat stability, the Vicat softening point (ASTM D1525, 10N) is about 110°C. Consequently the material can withstand the heat generated by boiling water.

Kaneka‘s facility for PHBH resin production, located in Japan, is estimated to be operational in the autumn of 2010, having a capacity of 1000 t/a. Currently PHBH is mainly applied by film, sheet, bottle and injection-molding industries, to which it is supplied as granulates.

In the near future, Kaneka is planning to offer PHBH also in the form of expanded foam particles, with an expansion ratio of up to 35 times. Expanded PHBH foam particles have about the same secondary processability as their polyolefin counterparts.

Complex shapes can be easily made using steam-chest-molding techniques and can be further treated by sawing, punching and bonding. The mechanical properties and dimensional stability of molded expanded PHBH foam particles are in line with those of expanded polyolefin molded foam particles. Therefore target applications are like for polyolefin foam particles, e.g. containers for a variety of consumer goods, parts for automotive, building insulation, soundproofing and horticultural engineering.

Kaneka bio-based foam will ultimately contribute to create a society with a lower carbon footprint, as stated by a company spokesperson. MT

28

bioplastics MAGAZINE [01/10] Vol. 5

Foam

Heat-Resistant PLA Bead Foam

A

ccording to Sekisui Plastics Co., Ltd., a large expanded polystyrene (EPS) company headquartered in Osaka, Japan, the company has developed the world‘s first heat-resistant and biomass-based bead foam. This bead foam is made of polylactic acid (PLA) by Sekisui‘s unique manufacturing process which enhances the high-temperature dimensional stability of PLA bead foam and retains specific properties of PLA, such as mechanical strength, solvent resistance and weather resistance.

www.sekisuiplastics.com www.unitika.co.jp/terramac

For the bead foam Sekisui Plastics uses a heat-resistant foam grade of PLA resin developed by Unitika Ltd. Unitika developed the PLA resin for heat-resistant extruded foam and launched it on the market in January 2005. In Sekisui Plastics’ unique process, the expandable PLA beads have become possible to be more easily moulded and highly crystallised in the final foam products by keeping the crystallinity of the PLA low when expanding.

This BiocellerTM, (the Sekisui Plastics trademark for their plant-derived foamed plastic), surpasses EPS and EPP (expanded polypropylene) in dimensional stability.

The Bioceller, when expanded 6-fold, changes little in dimension at 150°C. It is excellent in terms of oil resistance, weather resistance, and mechanical properties against compression. Colouring the bead foam is easy. Volatile organic compounds are not emitted by the foam. Since the material is expandable from 6 to 25 times and has excellent mould performance it can be moulded into any shape.

This heat-resistant PLA bead foam could be used in any application where EPS or EPP is currently used. However, the main targets would be the following applications (which require more heat-resistance and environmental properties): automotive parts, toys, heat insulators etc.

Sekisui Plastics have been developing this material in their research institute. Now they have started marketing, and further technical development, of the material as a company-wide project. Several items using their PLA bead foam are almost ready for market launch. There is also a plan to build a new six hundred ton per year plant depending on the market situation. - MT

bioplastics MAGAZINE [01/10] Vol. 5

29

Foam

PLA Foam Trays Article contributed by Doug Kunnemann, NatureWorks LLC, resp. for commercial activities focused on food packaging and food service ware in the United States

T

wo organizations, Sealed Air Corporation in Duncan, South Carolina, USA, and Dyne-a-Pak in Laval, Quebec, Canada, are North American pioneers in the development of fresh food foam trays manufactured from NatureWorks Ingeo™ PLA. As a result of their efforts, brand owners and retailers have a performance alternative to polystyrene foam trays — an alternative that lowers greenhouse gas emissions and energy consumption as well as delivering the potential for food waste diversion from landfill.

Sealed Air was first to bring a solution to market in North America with Cryovac brand NatureTRAY™, an Ingeo foam meat, poultry, and fresh produce tray. NatureTRAYs are certified industrially compostable by the Biodegradable Products Institute to the ASTM 6400 standard for biodegradable plastics. (Ingeo resins also meet EN13432 composting standards.)

Retail grocery customers can select from a variety of sizes.

Sealed Air also offers a line of robust NatureTRAYs designed specifically for the needs of meat, poultry, and fresh produce processors.

In May 2008, NatureTRAY received the Institute of Packaging Professionals AmeriStar Award for excellence. One of Sealed Air’s most recent NatureTRAY customers is Prima Bella Produce, Tracy, Calif. Prima Bella utilizes the tray for its line of fresh corn on the cob (see photo).

30

www.natureworksllc.com www.sealedair.com www.dyneapak.com

bioplastics MAGAZINE [01/10] Vol. 5

Billions of polystyrene trays are produced in North America every year. Sealed Air estimates that even if a relatively small percentage — under 10% — were converted to Ingeo foam, the environmental benefits would be significant. For example, replacing 90 million polystyrene trays with Ingeo bioresin would save over 1,300,000 liters (340,000 gallons) of gasoline, and reduce greenhouse gas emissions by the equivalent of over 18,000,000 km (11,184,681 miles) driven.

“As the economy continues to rebound, an increasing number of companies will be in position to adopt these products,” said

Foam

Richard Douglas, director of sales and marketing for Sealed Air Corporation Cryovac brand rigid packaging and absorbents group. â&#x20AC;&#x153;To meet near and long term demand, we are continuing to invest in production capabilities that will manufacture NatureTRAYs with ever greater economies of scale.â&#x20AC;?

Dyne-a-Pak sells polystyrene and bioresin-based foam trays in Eastern Canada and in the Northeastern region of the United States. The companyâ&#x20AC;&#x2122;s Dyne-a-Pak Nature foam tray is made with Ingeo polylactide and has been on the market for about one year and represents a multiyear research and development effort. This product has received a QSR Magazine-FPI Foodservice award for manufacturing innovation.

â&#x20AC;&#x153;The manufacturing characteristics of Ingeo were relatively similar to polystyrene in terms of extrusion and thermoforming, which meant the bioresin would fit well with our manufacturing processes,â&#x20AC;? said Mario Grenier, Dyne-a-Pak vice president and general manager. â&#x20AC;&#x153;We also wanted a resin supplier that had the technical expertise to partner with us during the research and development stage as well as one that could assure a steady supply of resin. NatureWorks met both of these selection criteria.â&#x20AC;?

magnetic_148,5x105.ai 175.00 lpi 45.00° 15.00° 14.03.2009 75.00° 0.00° 14.03.2009 10:13:31 10:13:31 Prozess CyanProzess MagentaProzess GelbProzess Schwarz

c i t e n tics g s a a l P M for

Dyne-a-Pak sells to grocery chains, food distributors, fast food outlets, bakeries, and meat packers. The Dynea-Pak Natureâ&#x201E;˘ foam tray, which has a density around 0.056 g/cmÂł (similar to regular polystyrene trays), is offered in a range of sizes. This bioresin foam tray is certified compostable by the Biodegradable Products Institute to the ASTM 6400 standard. The tray was also successfully tested for conformance to the EN13432 compostability standard by Organic Waste Systems in Belgium.

Dyne-a-Pak reports that production of the Ingeo used in the Dyne-a-Pak Nature foam tray requires 50% less water and 49% less fossil fuel to manufacture as compared to petroleum-based polystyrene products and emits 60% less greenhouse gas than an equivalent amount of polystyrene.

Grenier said that Dyne-a-Pak originally entered the bioresin foam tray segment of the market because it wanted to offer an alternative to polystyrene â&#x20AC;&#x201D; an alternative that was sourced from renewable resources.

He anticipates that as the market matures the lower carbon footprint of the Ingeo-based foam trays will become a major selling point. The company has observed a marked rise of interest in its Dyne-a-Pak Nature foam trays during the last quarter of 2009 and attributes this fact to gradual improvements in the economy and a trend toward reducing the environmental impact of packaging products.

â&#x20AC;˘ International Trade in Raw Materials, Machinery & Products Free of Charge â&#x20AC;˘ Daily News from the Industrial Sector and the Plastics Markets

C

M

â&#x20AC;˘ Current Market Prices for Plastics.

Y

CM

â&#x20AC;˘ Buyerâ&#x20AC;&#x2122;s Guide for Plastics & Additives, Machinery & Equipment, Subcontractors and Services.

MY

CY

CMY

K

er.com lastick www.p

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

sional Profes Fast â&#x20AC;˘ â&#x20AC;˘ te a d Up-to-

bioplastics MAGAZINE [01/10] Vol. 5

31

Foam

Article contributed by William Kelly, VP Technology and Gary Larrivee, VP Technical Support Cereplast, Inc., Hawthorne, California, USA

A True Compostable Foam

C

ereplast Compostable 5001® is perfectly suited to meet the needs of all converters, manufacturers and brand owners interested in substituting Polystyrene foam with an environmentally sustainable plastic.

Cereplast Compostable 5001 is a compostable foam using Ingeo™ PLA and various biodegradable and compostable components. Currently PLA based polymers are the dominant resin in the biopolymer industry from a technology and supply standpoint.

The market for expanded polystyrene is greater than five billion dollars per year in the USA. With cities and counties banning the use of polystyrene packaging consumers are demanding alternative products. What is attractive about using a Cereplast foam polymer is that the finished products can biodegrade in 180 days or less in a commercial compost facility.

Many disposable products are made of low density polystyrene foam materials. These foam products however will not biodegrade, even when filled with starch. Degradation of the starch will not cause the polystyrene to degrade and all the ‘additive’ technology has not been scientifically proven, nor demonstrated.

Many of the applications that exist in polystyrene based foam materials are suitable for Cereplast Compostable materials such as clam shell food containers, meat trays, egg cartons, mushroom and berry boxes and a variety of packaging applications. Densities down to 0.08 g/cm3 using conventional equipment were achieved and Cereplast is continuing research to further reduce densities. These products have the same look and feel as the polystyrene foam parts that they are replacing. There is no Bisphenol A (BPA) or any other harmful compounds found in Cereplast 5001.

From a technical standpoint, it is difficult to produce from an unmodified PLA a viable foam product. In order to produce low density foam PLA based resins the polymer must be modified to increase molecular weight and elasticity. Increasing intrinsic viscosity and melt strength is also key to producing a good foam product. One method to increase melt elasticity and molecular weight is to utilize chain extenders associated to the end groups of PLA. Increases in melt elasticity and molecular weight result in producing foams with reduced cell size, increased cell density and lowered bulk foam density when compared to unmodified PLA foam. Cereplast specialty is to modify Ingeo PLA manufactured by NatureWorks.

Cereplast Compostables 5001 represents an outstanding opportunity for companies across the plastic supply chain used to foam plastic resins and are seeking to become more environmentally sustainable and reduce the industry’s reliance on oil. Cereplast Compostable 5001 is the successful result of a several years research and development project which answers the growing demand for more sustainability from the plastic industry. www.cereplast.com

32

bioplastics MAGAZINE [01/10] Vol. 5

Materials

High Heat Injection Molding PLA

O

n January 14, NatureWorks LLC introduced its second generation Ingeo™ bioresin (PLA) solution targeted primarily at injection molding of semi-durable consumer products. This new patent-pending solution is the latest in a series of breakthroughs for Ingeo™ applications, which already include high heat thermoforms, films, and gift and transactional cards.

NatureWorks’ new compounded resin technology enables the production of injection molded parts with a heat deflection temperature of up to 140°C (modified version of ASTM E2092) or 65°C (HDT B), notched Izod impact strength greater than 140 J/m, and modulus of about 3,000 MPa. “Different formulations based on this new development, with a reduced amount of impact modifier will lead to HDT B values of up to 140°C,” explained Jed Randall, Research Scientist at NatureWorks. Injection molding cycle time compares to styrenic resins, for which the new technology now offers a low-carbon, cost-competitive, performance replacement.

Designated Ingeo 3801X, the new formulation combines a high percentage polylactide base resin with a tailored additive package designed to achieve the high heat, impact, and cycle time performance requirements of semi-durable products such as cosmetics, consumer electronics, toys, office accessories, and promotional products. “The introduction of this high heat technology demonstrates that the Ingeo family is maturing significantly, steadily broadening into a host of applications where these materials are a performance substitute for non-renewably sourced plastics,” said Marc Verbruggen, president and CEO of NatureWorks. “In the six years since we entered the market with our world-scale facility, the injection molding community has shown significant interest in our first generation product. The industry has already developed a compelling array of injection molded consumer products, with items that include lipsticks and compacts, mobile phones, and auto interior parts. Today, we’re pleased to announce support for ongoing development efforts with a product that has been custom designed to address enhanced property and performance requests.”

NatureWorks is selectively opening this proprietary technology to Ingeo compounding partners, as Verbruggen explains.

“NatureWorks firmly believes that the continuing development of Ingeo solutions for durable applications is best complemented by the innovations, expertise, and capabilities that our compounding partners offer.” www.natureworksllc.com

A Novel, Lightweight, Heat-resistant PLA

A

mong the most significant challenges for the wider application of PLA is its low heat resistance: native PLA usually turns soft at around 60 ºC, which not only makes it incapable of holding heated food or a hot drink, but also causes deformation during container transport.

Enhancement of the heat resistance of PLA has been achieved already by adding fillers, or mixing with hard plastics. However these treatments often have unfavorable consequences such as an increase in density and difficulties in recycling. In the case of semi crystalline plastics adding nucleating agents is another approach, however for PLA, which crystallizes at a rather slow rate, such treatment does not bring about a significant improvement in heat resistance.

By means of novel recipes and process equipments, Supla Co. Ltd. of Taiwan have developed SUPLA™ C that has a unique crystallization behavior, which results in a high HDT at around 100ºC (HDT B 120°C/hr, 0.45 MPa). Furthermore, because not much fillers were added, the density was kept at a level almost equivalent to native PLA. This lightweight characteristic results in a higher Melt Flow Rate of 31.9 g/10min (190ºC, 2.16 kg), which makes Supla C advantageous over other types of modified PLA in injection molding. Besides, the products would be lighter, so it is energy saving during transportation of the moulded products. Supla C minimizes the difficulties in forthcoming challenges towards recycling of PLA products, because in general, recycling of composite materials is more difficult than that of pure, homogeneous materials.

PLAs with superior heat resistance have potential markets such as food wares, stationery, gifts, toys, 3C housing (3C = computer, communication and consumer electronics) etc. Supla C is suitable for all of the above applications, and is expected to exhibit particular strength in thin wall housing which is the mainstream in the design of 3C goods. supla.com@msa.hinet.net

bioplastics MAGAZINE [01/10] Vol. 5

33

Application News

Fancy Potato Poncho

http://spudcoat.co.uk

Last September, the Spanish sustainable products brand ‘EQUILICUA‘ presented an original garment made from bioplastic – 100% biodegradable and compostable (even home compostable in a backyard compost bin). It is a raincoat that comes with seeds incorporated into it that promote the disintegration of this new generation of materials made completely from bioplastic that is based on potato and corn starch (BIOTEC).

The ‘plantable‘ potato poncho is the first product from the collection that the company calls ‘Fantastic Bioplastic‘, and for which Equilicua is already developing new projects based on plastic resins made from renewable resources. The idea is to work with diverse biocompatible materials for the production of future designs, going from textiles to other types of consumer goods. The company also wants to introduce these ecomaterials to the final consumer in a creative and innovative way. The slogan of the company - “Equilicua, thought-provoking products” - nicely sums up its principal objective.

The so-called ‘Spudcoat’ was specially designed for excursions and outdoor activities (on foot or by bike). It is a large model made for people wearing backpacks. The space to insert any type of seeds is incorporated in the chest area. The graphic printing is done using biodegradable inks, free of solvents, so that the whole product can be absorbed into the natural environment if it is lost, or at the end of its life cycle (when it is recommended that the coat be buried to speed its breakdown).

For the ethical company gift sector personalized raincoats are available as an eco-alternative for public or private institutions and businesses committed to the environment and Corporate Social Responsibility.

Today, Equilicua is working on the development of new designs for distributors of the product. The potato raincoat can be purchased in Spain for example from Greenpeace and in the United Kingdom from Comp Bio Products Ltd. In China, the ecological product business Livegreen is launching the garment. Various selling points are available in European countries and the introduction to the Canadian and American markets is expected in the spring of 2010. MT

PTT Mascara Packaging At Luxepack in Monaco last fall, Oekametall fom Bamberg, Germany presented a new standard mascara packaging line. It is made with renewably-sourced material DuPont™ Biomax® PTT1100, a high-performance packaging polymer with excellent surface gloss, chemical and scratch resistance.

“By increasing the standard range with a mascara pack made of Biomax PTT1100, we are contributing to the awareness for sustainability. The resin has been the best material in terms of processability, dimensional stability and gloss for our quality standards“ says Mrs. Jasmin Hamida, Packaging Innovation Manager at Oekametall.

This new standard product provides beauty packaging with luxury aesthetics and high performance while reducing the impact of the environment of the package. Because of the natural scratch resistance and gloss of Biomax PTT1100, Oekametall does not need to apply an additional solvent-based coating to ABS and SAN. It is a great example of reducing the environmental footprint with no impact on performance and aesthetics requirement of the beauty industry.

DuPont Biomax PTT1100 (PolyTrimethylTerephthalate) is a polyester-type resin with up to 37% renewably-sourced content (bio-PDO™ based on corn or beet sugar) and a performance similar to polybutylene terephthalate (PBT) and polyethylene terephthalate (PET). It is intended for use in high-performance cosmetic packaging with a lower environmental footprint.

Its attributes include a glossy surface for attractive aesthetics, excellent resistance to common personal care and cosmetic formulations, a naturally opaque to translucent appearance, good colorability, high scratch resistance and excellent environmental stress cracking resistance. Such attributes can create the potential for additional cost-savings during production, including the elimination of additional barrier layers for protection against scratches or more chemically-aggressive cosmetic formulations. This injection-moldable resin is especially suitable for use in cosmetic packaging applications including compact cases, cream jars, thin-walled perfume caps and mascara caps as presented at Luxepack. MT www.dupont.com

34

bioplastics MAGAZINE [01/10] Vol. 5

Application News

OLYMP Tests PLA Shirt and Blouse Fabrics OLYMP Bezner GmbH & Co. KG of Bietigheim-Bissingen, Germany is permanently on the look-out for innovative production processes to manufacture their up-market business shirts. The limited possibilities open to them when using thread and cloth made from cotton required the development of new alternative raw materials.

Eberhard Bezner, Olymp‘s owner and CEO, is not just a highly experienced textile specialist, but an expert on innovative fabrics. By carefully studying the latest global developments in the manufacture of fabrics and textiles he came across the spunbond process for the production of PLA fibres. Now Olymp is testing the use of PLA as a fabric for shirts and blouses.

Alongside advantages such as good wicking, good colour performance and high tear resistance, polylactide fibres constitute a particularly resource-friendly bioplastic. “To harvest a kg of cotton up to 20,000 litres of water are required,“ explains textile expert Herbert Ostertag, who has worked closely with Olymp for several years. Lactic acid production is significantly more environmentally friendly because water consumption is minimal and in certain circumstances renewable resources from local agriculture can be used.

The test garments produced so far consist of 65 % cotton and 35 % PLA. The latter percentage could be higher and thus a shirt would be much more economical in the use of resources.

“A Chinese supplier has been researching and experimenting on our behalf for some time now, looking at the possibility of using polylactide fibres, which are already used in other types of product, in garment manufacture,“ explains Marc Fritz of OlympMarketing. “OLYMP first made some sample shirts from polylactide material for test purposes. These were thoroughly tested in our laboratory in Bietigheim-Bissingen for washing performance, ease of care, light resistance, stretch and tear resistance and their resistance to abrasion in daily wear“.

At the same time the first trials were carried out to test the performance and skin tolerance of the shirts when actually worn. Despite not yet having planned an advertising and marketing strategy the expectations are that this year the company will have 2000 shirts made to test the reaction of customers in selected department stores. MT www.olymp.com

Biodegradable And Compostable Sugar Sachet A new product has joined the range of catering solutions available in Mater-Bi® by Novamont from Italy. The biodegradable and compostable sugar sachet, born of a partnership between Novamont and Novarese Zuccheri joins the cutlery, plates and cups already available.

With their personalisable print, the new sachets use paper extrusion coated with a special grade of Mater-Bi. This groundbreaking solution has the same performance characteristics of traditional packaging but, since it is biodegradable and compostable, it can be disposed of together with organic refuse meaning it is also eco-friendly.

Laminates obtained with Mater-Bi extrusion coating ensure performance very similar to that of traditional plastics. They create a barrier against gasses and fats and have excellent thermal resistance making this type of laminate particularly suitable for food packaging. www.novamont.com

bioplastics MAGAZINE [01/10] Vol. 5

35

Application News

Roll-Bag Solution for Bio-Bags

www.roll-o-matic.com

Roll-o-Matic, Denmark, stands for solutions that are flexible, faster and easier to operate, and in addition financially attractive. One example is Roll-o-Matic‘s star-sealed T-shirt kit for Delta converting lines. This kit is a newly developed and patented solution, which allows the production of star-sealed T-shirt bags, normal T-shirt, sinus/wave top, bottom- sealed and other bags on a standard Delta T-shirt line without any additional modules.

developed a new concept: a star-sealed T-shirt bio-bag that comes together with a matching plastic waste bin.

It keeps the costs at a minimum, and compared to other set-ups the costs of the star-sealed kit is only a fraction. The stable solution with a line speed up to 160 m/min / 300 cycles / 2 lanes led to a very positive customer feedback.

Sacme, have been very content with the Roll-o-Matic starsealed kit solution, which allows flexible and stable production of star-sealed T-shirt bags. “With a flexible solution like this we are sure to give our customers an opportunity to extend their product range without having to make a heavy investment.”

And the star-sealed kit solution is environmentally and financially favourable: As the skirt on the bag is very short, the waste of material is minimized to about half of the traditional skirt length. Star-sealed bags have a strong bottom, which allows ‘downgauging‘, i.e. producing thinner but not weaker bags.

Bio-Bag Example from Italy With a slight adjustment of sealing temperature and sealing pressure, Roll-o-Matic Delta line with a star-sealed T-shirt kit is also able to run biomaterial, which makes the bag production even more environment-friendly. Italian leader in the production of Mater-Bi articles Sacme has

The concept is called Geo & Gea, the aerated system for collecting wet waste. The star-sealed T-shirt bag fits perfectly into the waste bin, and for the end user it functions as a waste bin for fruit, vegetables or other degradable products.

The new concept has been very successful, as the market for smart solutions like this is still growing.

“And in a market where demands can change quickly, we believe it is a favourable choice,“ comments Mr. Birger Sørensen, Managing Director at Roll-oMatic, Denmark.

Innovative Hospital Waste Management System Pharmafilter BV, a bioenergy technology company based in Amsterdam, The Netherlands, has selected Mirel bioplastics by Telles (Lowell, Massachussetts, USA) for a suite of disposable products for hospital use. Pharmafilter BV is currently commercializing its patented Pharmafilter system as a cleaner, more efficient way for hospitals and the healthcare industry to reduce contaminated solid waste, food, and wastewater through anaerobic digestion. Outputs are biogas for fuel or power generation, biomass for energy conversion, and clean water.

The initial range of single use products to be made from Mirel include: service ware items, bed pans and trash bags.

Use of such disposable products made from Mirel can mitigate the need for reusable items, thus reducing human contact with contaminated service ware and its related safety concerns. Mirel products will be disposed of along with the hospital and healthcare wastes, and fed to the Pharmafilter system. The initial pilot project is scheduled to begin operation in March 2010 at Delft Hospital in Amsterdam.

“We selected Mirel because it fits right into our system,” said Eduardo Van Den Berg, CEO of Pharmafilter BV. “Mirel has the performance properties for single-use plastic service

36

bioplastics MAGAZINE [01/10] Vol. 5

applications and it is biobased and biodegradable, so it is the most appropriate solution for the Pharmafilter process.”

“Mirel’s broad range of applications and biodegradation properties make it an ideal product to integrate with anaerobic digestion systems for waste disposal and bioenergy production,” said Bob Engle, General Manager, Telles. “We are excited about our role in this innovative process for the conversion of potentially harmful waste products into bioenergy. In addition to the primary use of Mirel as a biobased plastic for high performance service ware and packaging, Mirel may offer a secondary value as an energy source arising from its disposal through anaerobic digestion.”

Pharmafilter cooperates with its partners to realize its goal: a cleaner hospital and a cleaner environment. Pharmafilter utilizes water experts with skills ranging from pollution to purification and receives important and indispensable support in the Netherlands and in Europe. Partners include the Ministries of Health, Welfare and Sport; VROM; Ministry of Transport, Public Works and Water Management; Waterboard Delfland; STOWA Reinier de Graaf Groep; Municipality of Delft; European environment subsidy Life+; SenterNovem; and BTG. www.mirelplastics.com

Application News

Forest Plant Container Made in Chile

www.udt.cl

In Chile the development of biodegradable materials dates back about a decade. One of the highlights in this area is the work of the University of Concepción through the Technological Development Unit (UDT). In 2005 for example, UDT was involved in the set-up of a pilot scale production of biodegradable polymers, such as polyhydroxyalkanoates (PHAs) and polylactic acid (PLA). The raw material used for the bacterial fermentation of lactic acid was organic waste generated by the famous Chilean wine industry, where the residue of the grapes was used as an organic substrate.

High Value for Forestry Currently UDT, in conjunction with the Chilean companies Proyectos Plasticos and Forestal Minico, is developing a forestry plant container from biodegradable composite materials consisting of PLA, wood waste and various additives. This development has been motivated by an attractive market in Chile that has grown up around forest production and which uses polypropylene plastic containers in nurseries for the development and transfer of seedlings into the forest. Here the seedlings are manually removed from the container and planted in the ground, which can constitute a risk of damage to the seedlings. This in turn leads to significant losses in the forestry sector, as up to 5% of seedlings are destroyed on average. To avoid such losses a biodegradable container was delveloped that survives the nursery stage and can be planted together with the seedling in the forest.

Technological innovation and concrete results This technological innovation developed by UDT has led to a PLA-based material with up to 50% wood flour content. Compared to pure PLA, this leads to lower production costs, improved processability by injection moulding and an increased rate of biodegradation.

The technology involves the production of biodegradable composite material pellets in a co-rotating twin screw extruder, which produces a compound of the components including additives to achieve a good compatibility between PLA and wood, and to improve its mechanical properties and processability. The pellets are then injection moulded by Proyectos Plasticos into forest containers.

In a second stage of this innovation nutrients are incorporated in the formulation of the material, to be released in a controlled manner during the biodegradation process in the soil, thereby improving plant growth.

The results of the biodegradation in line with ASTM 5338D have been established in terms of weight loss and release of CO2 as a product of microbial activity in about 120 days. MT

Bags for Electronic Road Toll Tags

www.inapol.cl www.costaneranorte.cl

Inapol Ltda, Chile is a bag manufacturer who has already developed some products from bioplastics, for example Mater-Bi from Novamont. Now they announced to be the first producer in Chile to launch a bag made 100% from bioplastic raw material for a big client. “We have already made 150,000 bags of a Mater-Bi material that will be used by Costanera Norte to wrap ‘electronic tags’ for toll roads instead of using polypropylene,” says Sebastián Aguilar, Gerente Comercial of Inapol.

Due to heavy traffic and many congestions in Santiago, Chile had introduced a toll system for the use of interurban highways.

Toll roads are fully automated using electronic toll collection technology. This entails drivers fixing an electronic tag in their vehicle which communicates with roadside equipment. These tags are distributed free of charge by the private operators of the toll roads as part of their concession contract.

“This is the first initiative of a big company in our country in order to make concrete actions to promote renewable and biodegradable materials, “ says Sebastián Aguilar. “Costanera Norte started a campaign to reduce CO2 emissions, and they thought that this bag could be a contribution for that purpose. We made that bag, and here in Chile is the first initiative to promote this kind of materials.” MT

bioplastics MAGAZINE [01/10] Vol. 5

37

Materials

Misleading Claims and Misuse

Proliferate in the Nascent Article contributed by Ramani Narayan University Distinguished Professor Michigan State University Department of Chemical Engineering & Materials Science Chairman of ASTM Committee D20.96 on Environmentally Degradable Plastics & Biobased Products Chairman of ISO/TC 61(Plastics) SC1 (Terminology) and US expert to TC 61/SC5/WG22 on biodegradable plastics

B

iodegradation takes place when microorganisms utilize carbon substrates to extract chemical energy that drives their life processes. The carbon substrates become ‘food’ which microorganisms use to sustain themselves. For this to occur, the carbon substrate needs to be transported inside the cell.

Molecular weight is an important but not only criterion for transport across cell membrane. Factors like hydrophobic-hydrophilic balance, molecular and structural features also govern transport across the cell membrane. Under aerobic conditions, the carbon is biologically oxidized to CO2 inside the cell releasing energy that is harnessed by the microorganisms for its life processes. Under anaerobic conditions, CO2+CH4 are produced. Thus, a measure of the rate and amount of CO2 or CO2+CH4 evolved as a function of total carbon input to the process is a direct measure of the amount of carbon substrate being utilized by the microorganism (percent biodegradation). This is fundamental, basic biology and biochemistry taught in freshman classes and can be found in any biochemistry textbook. This forms the basis for various National (ASTM, EN, OECD) and international (ISO) standards for measuring biodegradability or microbial utilization of chemicals, and biodegradable plastics [1,2].

It would seem obvious and logical from the above basic biology lesson that to make a claim of biodegradability, all that one needs to do is the following: Expose the test plastic substrate as the sole carbon source to microorganisms present in the target disposal environment (like composting, or soil or anaerobic digestion or marine), and measure the CO2 (aerobic) or CO2+CH4 (anaerobic) evolved. A measure of the evolved gas provides a direct measure of the plastics substrate carbon being utilized by the microorganisms present in the target disposal environment (% biodegradation).

ASTM and ISO test methods teach how to measure the percent biodegradability in different disposal environments based, again, on the fundamental biochemistry described above.

It has been claimed by a few companies for quite some time that the addition of a low percent (about 1-5%) of proprietary additives in the form of a masterbatch to polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), and other carbon chain polymers renders the carbon chain polymer completely (the claim has been 100%) biodegradable in both aerobic (composting, soil) and anaerobic (landfills) environments – that would mean that 100% of the polymeric carbon is completely utilized by microorganisms as measured by the evolved CO2 (aerobic) or CO2+CH4 (anaerobic) – if this is true, then such data should be provided to substantiate the claim.

There are two classes of additives being marketed – ‘oxo’ and ‘organic’ which are sold as masterbatch concentrates. The ‘oxo’

38

bioplastics MAGAZINE [01/10] Vol. 5

Materials

of Standards Continues to BioPlastics Industry Space additive is supposed to promote chain scission, thereby making the polymer small enough to be utilized by the microorganisms present in the disposal environment. The ‘organic’ additive initiates or promotes microbial attack, and that in some way triggers the microorganism to begin breaking down the carbon-carbon backbone chain polymer.

Unfortunately, the scientific data and the literature do not support the actual claims being made in the market place. Many reports in the peer-reviewed literature include ‘biodegradation’ in the title; however, the meaning and context of the term is very broadly and loosely applied. Let’s look at several examples: Evidence of microbial growth on the surface of the polymer is reported as ‘biodegradable’ This is then extrapolated by manufacturers to claim that their product is 100% biodegradable, and some go onto claim that this can occur anywhere from 9 months to 5 years.

Some studies use the ‘biodegradable’ term to indicate that the PE samples were subjected to a biotic environment (soil, compost) as part of their experimental procedure. They go on to measure weight loss, molecular weight reductions, carbonyl index, mechanical property loss (films becoming brittle). Additive manufacturers reference these studies and extrapolate to stating that their product is ‘completely (100%)

biodegradable’ in the environment based on weight loss and physical, chemical, or mechanical property loss. However the fundamental biology/biochemistry data showing carbon utilization by the microorganisms as measured by the evolved CO2 (aerobic) or CO2+CH4 (anaerobic) is missing.

A peer reviewed Chem Communication journal (an established, well respected journal) paper [3] reported increasing the rates of biodegradation of polyolefins, by anchoring minute quantities of glucose, sucrose or lactose, onto functionalized polystyrene. A mere 2-12% weight loss and formation of carbonyl groups was evidence for biodegradation.

In another peer reviewed scientific journal paper, polyethylene and polypropylene were put in a composting environment after solvent extraction to remove the antioxidants present, and it was reported that PP lost 60% mass over six months, whereas low density polyethylene lost only 10%. It is well known that unstabilized PP will degrade in the environment. Professor Scott summarizes this in his book chapter as follows: PP biodegrades much more rapidly than LDPE by mass loss in compost, and ethylene-propylene copolymers biodegrade at rates intermediate between polypropylene and ethylene. This implies that 60% of the PP carbon has been utilized by microorganisms present in compost

What does Biodegradable Mean?

Can the microorganisms in the target disposal system (composting, soil, anaerobic digestor) assimilate/utilize the carbon substrate as food source completely and in a short defined time period?

Environment - soil, compost, waste water plant, marine Hydrolytic Oxidative Enzymatic Polymer chains with susceptible linkages

Biodegradation (Step 2): Only if all fragmented residues consumed by microorganisms as a food & energy source as measured by evolved CO2 in defined time and disposal environment

STEP 1 Oligomers & polymer fragments Complete microbial assimilation

defined time frame, no residues STEP 2

CO2 + H2O + Cell biomass

bioplastics MAGAZINE [01/10] Vol. 5

39

Materials as measured by evolved CO2. However, no such data was available in the referenced text [4,5].

There are many more examples where physical, chemical, and mechanical property losses are used to claim ‘biodegradability’. In some papers microbial colonization or biofilm formation is used to make claims of biodegradability. Weight loss, molecular weight reductions, carbonyl index, mechanical property loss, biofilm formation, microbial colonization do not confirm the microbial utilization of the polymeric carbon substrate, nor does it provide the amount of carbon utilized or the time to complete microbial utilization.

Misuse of Standards There have been a number of standards developed by Standards writing organizations like ASTM, EN, and ISO [6]. They are summarized below: Biodegradability under composting conditions  Specification Standards ASTM D6400, D6868, D7021  Specification Standards EN 13432 (European Norm)  Specification Standards ISO 17088 (International Standard) Biodegradability under marine conditions  Specification Standard D 7021 Biodegradability Test Methods – ASTM Standards  Compost D5338  Soil D5988  Anaerobic digestors D5511, ISO15985 (Biogas energy)  Accelerated landfill D5526  Guide to testing plastics that degrade in the environment by a combination of oxidation and biodegradation ASTM D6954 As discussed in the beginning all Standards for measuring biodegradability are based on fundamental biochemistry principles outlined earlier of carbon utilization by microorganisms as measured by the evolved CO2 (aerobic) and CO2+CH4 (anaerobic).

A specification standard provides the specifications for pass/fail and provides the basis for making claims for example claims of compostability (biodegradability under composting conditions) has to meet the ASTM, EN, or ISO specification standards.

There are also test methods to measure biodegradability under disposal conditions as shown above. Test methods teach how to measure biodegradability under the specific disposal environment. The results of such a test could be 0% or 100% biodegradability or somewhere in between. There are additive based products that claim to be in compliance with or pass ASTM D5526 or 5511. However, this meaningless unless one provides the results obtained from the test – then one can say that using ASTM D5511, I obtained xx% biodegradability.

ASTM D6954 is referenced in a number of oxo-degradable plastic claims. In an article published in this magazine’s last issue, ASTM D6954 was identified as an acknowledged and respected Standard Guide for performing laboratory tests on oxo-biodegradable plastic. It is a generally accepted principle that Standards should be followed in its entirety, not modified to suit one’s convenience or expediency or only certain parts of the standard followed and applied. It is a three tiered testing procedure - loss in properties and molecular weight by thermal and photooxidation processes and other abiotic processes (Tier 1), measuring biodegradation (Tier 2), and assessing ecological impact of the products from these processes (Tier 3). Key points of this Standard are:

40

bioplastics MAGAZINE [01/10] Vol. 5

Materials  accelerated oxidation data must be obtained at temperatures and humidity ranges typical in that chosen application and disposal environment, for example, in soil (20 to 30°C)  Tier 1 accelerated oxidation tests are not indicators of biodegradability and should not be used for the purpose of meeting the specifications as described in ASTM D 6400 and claiming compostability or biodegradation during composting  For determining biodegradation rates under composting conditions, Specification D 6400 is to be used, including test methods and conditions as specified  Complete mass balances are to be reported in Tier 1  Tier 2 report must state the following: Extent of biodegradation (carbon dioxide evolution profile to plateau as per standards) and expressed as a percentage of total theoretical carbon balance  Percentage of gel or other nondegradable fractions.

Basically, this means that pre-treatment of samples at 6070°C in a dry oven is not acceptable. It also means that Tier 1 cannot be performed alone, but both Tier 2 and 3 must be completed. As indicated earlier, there are several references to meeting D6954 however no data is provided, except maybe Tier 1 data. However, claims of total biodegradability are being made. This is misleading and false.

The recent 2009 paper by Odeja et al. titled ‘Abiotic and Biotic degradation of oxo-biodegradable polyethylenes’ [7] is closest to the D6954 procedures. The oxo-biodegradable PE samples that were abiotically degraded in natural and saturated humidity for one year were biodegraded in a mixture of soil:compost:perlite (1:1:2) at 58°C for three months. The percent biodegradability as measured by evolved CO2 was 3.61% (abiotic natural humidity) and 5.70% (abiotic saturated humidity). The percent biodegradability for samples weathered for one year in PP envelopes in compost at 58°C was 12.4%, and at 25°C was 5.4% after three months.

Given this kind of almost negligible biodegradability data after one year weathering and subsequent exposure to an aggressive, biologically active compost environment for 3 months, it is surprising to note Professor Scott’s claim that oxo products will totally biodegrade in the environment. The above study shows that a significantly large amount of the degraded plastics some of which could be microscopic would be released into the environment.

Environmental & Health Consequences Making hydrophobic polyolefin plastics like PE unstable and degradable, and releasing them into the environment without ensuring that the degraded fragments are completely assimilated by the microbial populations in a short time period, has the potential to harm the environment and create human health risks. The fragments, some of which could be microscopic can transport through the ecosystem and potentially have serious environmental and health consequences. In fact, stringent ‘REACH laws’ governing the release of almost all chemicals (small molecules) are

becoming the norm in Europe and other countries including Canada, require the chemical to be completely assimilated by microorganisms in the ecosystem if it is to be released into the environment.

In a recent Science article, Thompson et al. [8] reported that plastic debris around the globe can erode (degrade) away and end up as microscopic granular- or fibre-like fragments, and that these fragments have been steadily accumulating in the oceans. Their experiments show that marine animals consume microscopic bits of plastic, as seen in the digestive tract of an amphipod.

The Algalita Marine Research Foundation [9] reports that degraded plastic residues can attract and hold hydrophobic elements like polychlorinated biphenyls (PCB) and dichlorodiphenyltrichloroethane (DDT) up to 1 million times background levels. The PCBs and DDTs are at background levels in soil, and diluted out, so as to not pose significant risk.

However, degradable plastic residues with these high surface areas concentrate these chemicals, resulting in a toxic legacy in a form that may pose risks in the environment.

Japanese researchers [10] have similarly reported that PCBs, DDE and nonylphenols (NP) can be detected in high concentrations in degraded PP resin pellets collected from four Japanese coasts. This work indicates that plastic residues may act as a transport medium for toxic chemicals in the marine environment More recently the issues surrounding microscopic plastics release into the environment and causing environmental and human health problems was the subject of recent issue of the Philosophical Transactions (of the Royal Society) B titled “Plastics, the Environment, and Human Health” [11].

Conclusions 1. Incorporating biodegradability into plastics in concert with targeted disposal system like composting or anaerobic digestion offers an environmentally responsible end-oflife value proposition.

2. Weight loss and other physical, chemical and mechanical property reductions do not constitute a measure of the percent biodegradation, although they may help in the process.

3. Microbial assimilation/utilization of the substrate carbon as measured by the evolved CO2 (aerobic) and CO2 + CH4 (anaerobic) is a measure of biodegradability.

4. Degradation or partial biodegradation is not an option as it may have potential environmental and human health consequences.

5. Complete biodegradation (microbial assimilation) of the plastic substrate in the targeted disposal environment (like composting) in a short defined time period is a necessary requirement.

Note: A complete list of references can be downloaded from www.bioplasticsmagazine.de/201001

bioplastics MAGAZINE [01/10] Vol. 5

41

From Science & Research

Disposal of Bio-Polymers via Energy Recovery

T

o achieve a maximum degree of sustainability for biopolymers, even in the method of their disposal, there is increasing discussion on the subject of cascade benefits and CO2 reduction costs in connection with so-called ‘end of life options’ by adopting appropriate disposal options. The advantages of the ‘incineration’ option as a method of disposal, as opposed to simple waste disposal, is that additional energy recovery benefits are achieved which in view of the overwhelming bio-based component of bio-polymers represents a largely CO2 neutral method of energy production. Alongside this contribution to climate protection the incineration of bio-polymer waste also contributes to resource conservation in that petrochemical based sources of energy (e.g. heating oil and gasoline) can be substituted [1].

Article contributed by Christian Laußmann, Umweltreferendar Land Nordrhein-Westfalen Bezirksregierung Münster, Germany Hans-Josef Endres FH Hannover, Germany Ulrich Giese, Dt. Inst. f. Kautschuktechn. e. V. Hannover, Germany Ann-Sophie Kitzler Achilles Papierveredelung, Celle, Germany Calorific values of bio-polymers [MJ/kg]

0

5

10

15

20

25 30 35

40

45

Polyethylene (PE) Polypropylene (PP) Polystyrene (PS) Polyamide (PA) Polycarbonate (PA) Polyethyleneterephthalate (PET) Polyvinylchloride (PVC) Polytetrafluoroethylene (PTFE) Bio-polyethylene Polycaprolactone (PCL) blend Bio-polyester Polyvinylalcohol (PVAL) Polyhydroxyalkanoate Polyester-PLA blend Starch blend Polylactide (PLA) Cellulose derivative / blend PP + 30% by wt. of wood flour Fuel oil Coal Wood Paper

Fig 1. Measured calorific values of bio-polymers compared with those of conventional plastics and petrochemical fuels [5]

References [1] General literature on the calorific value of gasoline and fuel oil [2] Troitzsch, J.: The combustion behaviour of plastics: basis, legislation, test procedures; Carl Hanser Verlag, Munich, Vienna 1982.

[3] Kaminsky, W.; Rössler, H.; Sinn, H.: in KGK – Kautschuk Gummi Kunststoffe magazine 44 (1991), pp. 846 [4] Endres, H.-J.; Hausmann, K.; Helmke, P.: Research into the influence of various adhesion agents and their content on PP/Wood compounds in: KGK – Kautschuk Gummi Kunststoffe magazine 7/8 (2006), pp. 399-404.

[5] Endres, H.-J.; Siebert-Raths, A.: Technische Biopolymere, Carl Hanser Verlag, Munich 2009

42

bioplastics MAGAZINE [01/10] Vol. 5

50

From the point of view of environmental protection one also needs to consider the question of the composition of the combustion gases emitted by bio-polymers when considering their incineration and energy potential.

Incineration of polymers In general, incineration (or burning) refers to the reaction of a substance in the presence of oxygen that is submitted to increasing temperature. It is a catalytic, exothermic reaction whose progress is maintained by the free radicals and heat radiation that it emits [2]. Pyrolysis, on the other hand, is an irreversible chemical breakdown resulting from increased temperature without the presence of oxygen and with no oxidation process [2, 3].

The significant factors that affect the composition of the incineration gases are (i) the way in which energy is produced, (ii) the amount of oxygen available (ventilation) and (iii) the physical properties or chemical composition of the incinerated materials.

Experiments To carry out comparative experiments, in addition to various bio-polymers, two conventional thermoplastics, polypropylene (PP) and a natural fibre reinforced polymer (WPC - wood plastic composite) with a high PP content (70%) and the coupling agent maleic acid anhydride, were selected [4]. The conventional polymers served as a reference against which one could evaluate the performance of the bio-polymers. For the experiments biopolymers from the following groups were selected:    

Various bio-polyesters Polyvinyl alcohol Polycaprolactone Polylactide

   

Starch polymers Cellulose polymers Bio-polyethylene Various polymer blends

From Science & Research Results a) Calorific values In figure 1 the calorific values of the substances tested are presented and compared with some conventional plastics, a wood-filled plastic and various fuels.

The comparison of the calorific values shows that the biopolymers tested are without exception suitable for thermal recovery because their calorific values are at least as high as that of wood and comparable to conventional polymers.

Furthermore, the calorific values of a certain few biopolymers can compete with the values obtained from coal or fuel oil. The values of the various bio-polymers are almost always the same as the conventional plastics, i.e. they are a factor of the fundamental composition of the polymer, with the presence of oxidisable components (in the case of the materials tested these were carbon and hydrogen) in relation to the non-oxidisable components (in the case of the materials tested these were water, and in particular oxygen or nitrogen) being of major significance. Even the conventional plastics polyamides and PET, have lower calorific values than polypropylene and polyethylene, because of the heteroatoms nitrogen and oxygen.

Amongst the combustion gases from almost all of the polymers tested certain substances classified as (eco)toxologically critical were found, with the aromatics benzene, toluene and naphthaline being the most common.

The formation of these substances is observed principally at the 800°C combustion temperature, but also, to a reduced extent, at 400°C. In this connection it is important to note that the formation of these critical substances is not limited to the purely hydrocarbon based plastics such as PP, but that the substances were detected in the combustion gases of almost all of the tested polymers, i.e. also in those containing oxygen.

At the higher combustion temperatures it can be seen that the dependency of composition of a polymer‘s combustion gases of the elementary structure of the polymer is reduced, and that the origin of the raw materials is of no significance.

Furthermore, the fact that a renewable source for the raw materials is of no significance in determining the nature of the combustion gas, is seen in the example of bio-PE where the same products were identified in the combustion gas as those seen in the combustion gas of conventional PE. The composition of the combustion gases is therefore not determined by the raw material basis but above all by the elementary composition of the polymer.

b) Emissions

Summary

When investigating the combustion emissions it was seen that these were mainly influenced by the chemical composition of the bio-polymers and the combustion temperature.

The evaluation of the test results showed that the biopolymer materials tested for their calorific value are without exception suitable for thermal energy recovery. As with other materials and fuels, the calorific value and the composition of the combustion gas of a bio-polymer is in principal determined only by the elementary composition of the material and any additives. With regard to the composition of the combustion gas, even with bio-polymers a few (eco)toxicologically critical substances were identified. The fact that a substance is biodegradable does not necessarily mean that when such a substance is burned there will be no emission of (eco)toxicologically critical substances. But in this context it should should however be pointed out that these types of decomposition products also occur during thermal energy recovery of conventional plastics and even natural materials such as wood.

At the lower combustion temperature (400°C) the gases in many cases exhibit, as expected, structural compositions similar to those from the incinerated polymers. The composition of the combustion gas hence consists, in a large part, of the relevant monomers, oligomers and chain breaks which are partially oxidised to form aldehydes and ketones.

And so the bio-polymers emit the corresponding carbonic acid esters, caprolactone in the case of polycaprolactone and dilactide and lactide oligomers in the case of polylactides.

With increasing temperature of combustion the increased atomization of the fuel fragments the structural relationship between polymers and the associated combustion product is reduced.

A general view of the influence exerted by the combustion temperature on the bio-polymer tested, and on PP as a classic petrochemical olefin, is given in table 1.

Combustion gas

Combustion temperature 400°C

Combustion temperature 800°C

Structural relationship to the original polymer

Often present

Hardly ever present

Key factor in the type of combustion emission

Fundamental elements and polymer structure

Almost exclusively fundamental elements

Product spectrum

Diversified  several substance groups

Very little diversification  aromatic compounds dominant

Completeness of combustion

Lower

Higher  more CO2, CO and H2O than the break-up product

(Eco)toxological hazard of the substances

Less frequent incidence More significant incidence

Table 1: Comparative impact of temperature on the character of the combustion gases

In addition the general recognition that the higher combustion temperature of 800°C is not favourable from an ecotoxicological point of view in terms of the combustion gases produced, has been confirmed. When burning biopolymers there is no higher potential for the emission of hazardous substances than when burning conventional domestic and trade waste.

Biobased polymers do however have an additional decisive advantage: burning bio-polymers is a largely CO2 neutral source of energy creation thanks to their basis of overwhelmingly renewable raw materials, and hence the burning of bio-polymers represents a logical and sustainable waste disposal system with an additional energy cascade benefit.

bioplastics MAGAZINE [01/10] Vol. 5

43

Basics

C

Basics of Cellulosics

ellulose, as a major component of plants, is the most abundant raw material and therefore one of the oldest and most widely used chemical in the world. Cellulose (Fig. 1) is a polysaccharide consisting of anhydroglucose units (D-glucose units) linked together by ß-(14) glycosidic bonds to form linear chain structures [1]. The degree of crystallinity and the crystal structure depends on the origin and pretreatment of the cellulose. In general the polymer is not processable as a thermoplastic, it is very stiff and is insoluble in water and most common organic solvents as a result of the very strong hydrogen bond network formed by the hydroxyl groups and the ring and bridge oxygen atoms [1]. The cohesion between the chains is favoured by the high spatial regularity of the hydrogen-bond forming parts [2].

Article contributed by S. Zepnik, A. Kesselring, R. Kopitzky, C. Michels, all Fraunhofer UMSICHT, Oberhausen, Germany

Cellulose is derived either from wood pulp or cotton linters by delignification in a multi-step process and because of its unprocessable behaviour the raw cellulose is modified. The modification of cellulose is often combined with depolymerisation by oxidation, acid or alkaline reactions and laundering [3].

CH2OH O

H

O

H OH

H

H

OH

H

OH

OH

H

Viscose solutions, cellulose esters and ethers are the major groups of chemically modified cellulose derivatives. They have been used in a wide range of applications such as fibres, films or plastics.

Viscose Solutions

H H

O

H

O

CH2OH

n

Fig. 1: Molecular structure of cellulose [3].

S OH

OH O

O

OR

HO

OH

NaOH + CS2

O HO

C S-Na+

O O

O

OH

n

O O

O O

O RO

OR

RO

S R=

C S-Na+

Fig. 2: Treatment of cellulose with alkali and carbon disulfide [5].

44

bioplastics MAGAZINE [01/10] Vol. 5

OR

Pure cellulose is treated with a strong base e.g. sodium hydroxide (‘alkalization’) and then mixed together with carbon disulfide to obtain cellulose xanthate (Fig. 2) [4]. This viscose is extruded into an acid solution either through a slit die to produce cellophane or through a spinneret to receive rayon fibres.

Rayon was the first man-made manufactured fibre based on renewable raw cellulose. Today there are two basic processes to produce rayon – the viscose method and the cupramonium method (cuprammonium silk).

Other methods such as the nitrocellulose process are negligible due to their inefficiency. Different types of rayon – regular rayon, high wet modulus rayon, high tenacity rayon, crupamonium rayon – can be produced.

The properties of rayon fibres are more similar to those of other natural fibres such as cotton rather than those of thermoplastic fibres such as nylon. Rayon exhibits a silk-like appearance coupled with a good maintenance of its brilliant colours [6]. As a natural fibre, rayon is a highly moisture absorbent and breathable material which is easy to dye. The fibre shows antistatic behaviour and does not pill during fabrication [6]. In general, rayon as a cellulose-based fibre shows high flammability but the use of a flame retardant can

Basics

improve the flame protection. A major advantage is its ability and versatility to blend with other fibres. Rayon is used in a wide range of applications, e.g. yarns, textiles or reinforcements (Fig. 3).

Cellophane Cellophane is a cellulose-based thin and highly transparent film made from viscose solutions under special process condition to obtain a nonbrittle plasticized film. Finally the film is dried and rolled up through heated mills. In the 90â&#x20AC;&#x2122;s the Fraunhofer Institute IAP developed a new process based on an amine oxide method to produce blown films from cellophane [7]. Thanks to its biodegradability and low permeability to air, oils, greases, and bacteria but with a coincidental high permeability to water vapour, cellophane is widely used for food packaging. The films are printable and weldable. Further applications of cellophane are self-adhesive tapes, semipermeable membranes or even displays. Cellophane is a brand of Innovia Films Ltd (Cumbria, UK) [8].

Fig. 3: Example of Rayon yarn (photo: Wikipedia)

Cellulose Esters (organic and inorganic) Due to its structure with three reactive OH-groups on each anhydroglucose units, cellulose can be transformed into various numbers of organic and inorganic acid esters [9]. However industrial esterification is limited to derivatives with reproducible properties. Therefore esterified organic esters are obtained only from a small range of saturated aliphatic organic acids with up to four carbon atoms [9]. The most important organic cellulose esters which are in large-scale production are cellulose (di)acetate (CA), cellulose (tri)acetate (CTA), cellulose acetate butyrate (CAB) and cellulose acetate propionate (CAP). CA, CAB and CAP are white amorphous materials whereas CTA is semi-crystalline. They are commercially available as powders or flakes [9]. Major suppliers of the raw esters are Acetati Spa, Celanese, Daicel, Eastman or Rhodia.

Property

CA

CAB

CAP

Density [g/cmÂł]

1,23 - 1,32

1,16 - 1,21

1,19 - 1,21

Flexural Modulus [MPa]

758 - 4210

827 - 1790

1160 - 1860

Tensile Strength [MPa]

39,5 - 125

15,9 - 51,5

22,1 - 41,5

Tensile Elongation [%]

2,2 - 70

30 - 51

3 - 45

Rockwell Hardness

38 - 112

40 - 83

55 - 96

Notched Izod Impact [J/m]

51 - 195

80 - 534

80,6 - 533

Table 1: Some properties of CA, CAB and CAP [according to 10]. Fluctuation range is due to plastizer and additive content

They are non-toxic, odorless and less flammable than nitrocellulose.

Furthermore these esters show good resistance to weak acids, mineral and fatty oils as well as petroleum [9]. Typical properties of CA, CAB and CAP are compared in table 1. Because of the narrow window between the melting and decomposition temperature as well as the strong interactions between the non-esterified OH-groups these cellulose esters must be additivated to produce thermoplastic materials. The easiest way is plasticization, whereas blending is another possibility [11], but due to high hydrogen Hansen solubility parameters blending is limited. On the other hand the incorporation of a second substituent into CA (e.g. CAB) weakens the strong hydrogen network and enhances the miscibility with plasticizers or polymers. Therefore the mouldability and modification of CAB and CAP is generally better than for CA.

bioplastics MAGAZINE [01/10] Vol. 5

45

Basics Virgin CA has a high glass transition with a degree of polymerization (DP) around 300, a high transparency, stiffness and chemical resistance. These properties are favourable for solvent-resistant and grease-resistant coatings (paper products, wires or fabrics), fibres, lacquers (electrical insulation or capacitors) or filter tows [12;13]. In 2002, the total consumption of CA flakes in the United States, Western Europe, Japan, and China was 655,000 tonnes [13]. Raw CAB is used as binders in protective and decorative coatings for instance for. textiles, paper, plastics or metals because of its excellent colour, toughness, flexibility, flow control and weather resistance [12]. Pure CAP exhibits properties between CA and CAB that make it useful for inks, varnishes or coatings [12]. Furthermore CAP is highly effective to disperse pigments since it is stable to UV-light and does not react with metallic pigments or fluorescent substances.

Plastics made of CA, CAB or CAP can be used for different processing technologies including injection moulding or extrusion, to manufacture a wide range of products such as cosmetic or personal care containers, tool or toothbrush handles, displays, optical safety frames and profiles (Fig. 4).

The most important producers of cellulose ester compounds are Albis Plastic GmbH (Cellidor CP, Cellidor CB), Eastman (Tenite Acetate, Tenite Butyrate, Tenite Propionate), FKuR GmbH (BIOGRADE), Mazzucchelli (Sethilithe, Plastiloid, Bioceta) and Rotuba (Auracell, Naturacell).

Further applications of cellulose esters are liquid crystalline solutions [11].

CTA dissolved in a mixture of trifluoroacetic acid and dichloroacetic acid or trifluoroacetic acid and dichloromethane exhibits brilliant iridescence, high optical rotation and viscosity-temperature profiles characteristic of a typical anisotropic phase containing liquid crystalline solutions [13]. Wet spinning of these solutions results in fibres with significantly higher strength than conventional cellulose ester based fibres.

Nitrocellulose

Fig. 4: Example products made of BIOGRADE (FKuR GmbH)

Nitrocellulose (NC) is the most important inorganic cellulose ester. It has been produced for more than 150 years by nitrating cellulose through exposure to nitric acid or other nitrating agent (often a mixture of nitric and sulphuric acid). The density of NC increases with the DS (DS is between 1.8 and 2.8) and ranges from 1.5 to 1.7 g/cmÂł [14]. In general, cellulose nitrates are white, transparent and non-toxic but show high flammability or even deflagration due to friction or shock. Because of its flammability this inorganic cellulose ester is used in military explosives [14]. With a dielectric constant of about 7 and a specific resistance of 1011 to 1012 â&#x201E;Ś/cm, industrial NC is considered to be a good insulator. The mixture with camphor as plasticizer was the first thermoplastic compound to produce flexible films for X-ray or photo applications (Eastman Kodak). They show excellent filmforming properties with an elongation at break from 3 to 70% and a tensile strength from 50 to 100 N/mm² [14]. Today cellulose nitrate is often used in lacquer, coating or printing ink applications because of its good adhesive and mechanical properties. NC is compatible with many other raw materials including plasticizers (e.g. phthalates), polymers (e.g. polyesters), pigments or additives. The total annual production of NC amounts to approximately 150.000 tonnes [14]. DOW Chemical (DOW Wolff), Hagedorn NC and Nobel Nitrocellulose are major suppliers of NC.

Cellulose Ethers Cellulose ethers are derived from alkylation of pure cellulose by the reaction with alkylating reagents usually in presence of a base (generally sodium hydroxide) and an inert diluent (Fig. 5). The base, in combination with water, activates the cellulose matrix by destroying hydrogen-bonded

46

bioplastics MAGAZINE [01/10] Vol. 5

Basics Cellulose Sodium hydroxide Water Organic diluent Alkylating reagent(s) Aqueous diluents or water

Reaction

Purification

Drying

By-products, organic diluent, water

Organic diluent, water

Grinding

Packout

Fig. 5: General operation scheme for the production of cellulose ethers [15].

crystalline domains and increasing accessibility to the alkylating reagent. The activated matrix is often defined as alkali cellulose. [15].

The most important cellulose ethers are watersoluble and therefore a key additive in many water-based formulations to control the rheology (e.g. thickening or flow behaviour). Water-binding (absorbency, retention), colloid and suspension stabilization, film formation, lubrication and gelation are further valuable properties. Therefore cellulose ethers still have a broad range of applications including coatings, cosmetics, pharmaceuticals, adhesives, printings, ceramics, textiles or papers [15]. In 2000 the total worldwide consumption of cellulose ethers was around 371,000 tonnes.

Methyl, ethyl and benzyl cellulose have been available since the mid-1930s and are soluble in organic solvents.

Water-soluble cellulose ethers like sodium carboxymethyl cellulose or hydroxyethyl cellulose have grown rapidly in the past decades since their investigation. In addition to dry powders, cellulose ethers are also supplied in liquid forms such as fluidized suspensions or water solutions.

Most types of ethers contain mixed substituents (e.g. hydroxylethyl cellulose) to enhance or adjust the properties of monosubstituted derivatives. In general, cellulose ethers are non-toxic and no adverse environmental factors are reported.

Ethyl cellulose (EC) is a nonionic, water-insoluble but organo-soluble polymer with a specific gravity of 1.12 to

1.15 g/cm³ [15]. Furthermore it is colourless, odorless and tasteless with a melting point around 160°C. Typical tensile strength lies between 46 and 72 MPa, whereas the elongation at break ranges from 7 to 30 % [15]. It is manufactured by the reaction of alkali cellulose with a large amount of ethylene chloride and sodium hydroxide. EC has a wide range of applications from food through pharmaceutical to personal care including water barriers, rheology modifiers, binders, flexible film formers, masking or time-release agents. Moreover EC provides excellent thermoplasticity and modification behaviour by using plasticizers, waxes or other polymers. Therefore, the polymer is available for conventional thermoplastic processing technologies such as extrusion, laminating or moulding. The major producers of EC are DOW Chemical (DOW Wolff) and Hercules.

Methyl cellulose (MC) is a nonionic, surface-active and water-soluble polymer with a high melting point around 290°C [15]. The tensile strength runs from 58 to 79 MPa and the elongation at break ranges from 10 to 15 % [15]. MC is produced through reaction of alkali cellulose with methylene chloride. Major suppliers of MC as well as mixed methyl cellulose ethers (e.g. hydroxylpropyl methyl cellulose) are Clariant, Cognis, DOW Chemical (DOW Wolff), Hercules, or Shin-Etsu Chemical. MC and its derivatives are used as thickeners, binder, adhesive, coatings or stabilizer [15].

Sodium carboxylmethyl cellulose (CMC), also known as cellulose gum, is an anionic mixed cellulose ether with a wide range of substitution. CMC is soluble in hot and cold water whereas it is not soluble in organic solvents. Solutions of CMC tend to be pseudoplastic or thixotropic depending on the molecular weight [16]. It is produced by reaction of sodium chloroacetate with alkali cellulose. The molecular weight of CMC ranges from 9 x 104 to 7 x 105 and has a high water binding capacity. In general, CMC is an extremely versatile polymer for food applications, as adhesives, in pharmaceuticals, cosmetics, ceramics or paper products [15]. CMC is produced by a large number of suppliers worldwide, e.g. Daicel, DOW Chemical (DOW Wolff), Hercules, Lamberti, Penn Carbose. www.umsicht.fraunhofer.de

References [1] T. Heinze, et al.: Esterification of Polysaccharides, Springer, 2006.

[2] D. Klemm, et al.: Comprehensive Cellulose Chemistry – Volume 1: Fundamentals and Analytical Methods, WILEYVCH, 1998.

[3] E. Ott, et al.: Cellulose and Cellulose Derivatives, 2nd Edition, Interscience Publishers, 1954.

[4] H. Krässig, et al.: Cellulose, in: Ullmann‘s Encyclopedia of Industrial Chemistry, WILEY Interscience, 2004.

[5] http://en.wikipedia.org/wiki/Rayon [04.12.2009].

[6] http://www.swicofil.com/viscose.html [30.11.2009].

[7] http://idw-online.de/de/news2591 [04.12.2009].

[8] http://www.innoviafilms.com/ [04.12.2009].

[9] K. Balser, et al.: Cellulose esters, in: Ullmann‘s Encyclopedia of Industrial Chemistry, WILEY Interscience, 2004.

[10] http://www.ides.com/generics/CA/CA_typical_properties.htm [06.12.2009].

[11] L. B. Bottenbruch: 3. Technische Thermoplaste: Polycarbonate, Polyacetale, Polyester, Celluloseester, in G. W. Becker, D. Braun: Kunststoff-Handbuch, Hanser Verlag, 1992.

[12] Eastman cellulose-based speciality polymers, Eastman Chemical Company, www.eastman.com [06.12.2009].

[13] K. J. Edgar: Cellulose esters, organic, Vol. 9, in H. F. Mark: Encyclopedia of Polymer Science and Technology, Part III, Vol. 9-12, 3rd edition, WILEY Interscience, 2004, pp 129-158.

[14] D. Klemm et al.: Comprehensive Cellulose Chemistry – Volume 2: Functionalization of Cellulose, WILEY-VCH, 1998.

[15] T. G. Majewicz, et al.: Cellulose ethers, Vol. 5, in H. F. Mark: Encyclopedia of Polymer Science and Technology, Part II, Vol. 5-8, 3rd edition, WILEY Interscience, 2004, pp 507-532.

[16] Ethocel – Ethylcellulose Polymers: Technical Handbook, DOW Cellulosics, 2005, www.dow.com [11.12.2009].

bioplastics MAGAZINE [01/10] Vol. 5

47

Politics

Bioplastics Situation in Brazil Article contributed by: João Carlos de Godoy Moreira CEO, Biomater Eco-Materiais São Carlos, SP, Brazil Décio Escobar de Oliveira Ladislau Economist Master in Environmental Science author of the Blog Bioplastic News

T

he Brazilian bioplastics industry demonstrates its potential: new production facilities are ready to go, new applications are in the final stage of development and the market is gaining the attention of the government. But there is still a lack of specific legislation, and a lack of consumer and media understanding.

This article tries to summarise the background to the technical and market developments which have made biobased and biodegradable plastics a reality today. Biobased and biodegradable plastics caught the attention of the mainstream media when several municipalities, in very different Brazilian states, started to promote municipal and state legislation banning ‘normal‘ plastic bags, or to grant benefits for biodegradable and compostable products or for those with a potential carbon footprint advantage.

Last year there were 44 initiatives, at all levels of government, with regard to legislation in favour of biodegradable plastics. Apparently independent from each other, these initiatives were the start of a movement in favour of, and a general discussion on, biodegradable plastics in the media and in government. While some legislative projects promoted ‘oxo-degradable‘ plastics, showing a lack of information of the legislators, other federal Environment Ministry representatives are quite well informed and have made clear statements on this subject. Two representatives from the petrochemicals and plastics industry, Plastivida and National Plastic Institute (INP), have also made clear their derogatory view of ‘oxodegradable’ plastic and support the general negative consensus on these materials. A Solid Wastes National Policy project is currently at the stage of final debate in the National Congress and a consensus about the right initiatives is near.

Recently, some companies directly involved in the compostable bioplastics business (BASF, Corn Products, Innovia, Biomater EcoMateriais, Rodenburg Biopolymers, Natur-Tec and CBPack) got together and formed ABICOM - the Brazilian Association of Compostable Plastics.

The main aims of this new association are education, and promotion

48

bioplastics MAGAZINE [01/10] Vol. 5

Bioplastics@ interpack 2011 Düsseldorf, 12-18 May 2011 Your Way to interpack: www.interpack.com of biopolymers and compostable plastics in general.

Legislative initiatives will be supported and a ‘compostable logo‘, based on a third party certification program, is to be established. This is to be backed by the Brazilian standard ABNT NBR 15448, which corresponds to ASTM D6400 and EN13432 standards.

Following the examples from ABA (the Australasian Bioplastics Association) and TBIA (the Thailand Bioplastics Industry Association), ABICOM will endeavour to work in close cooperation with the successful and well structured European Bioplastics Association. Headed

by Veruska Regolin (Innovia Films), ABICOM is about to start inviting others players (converters, end users, consumers, bioplastics and raw material producers, NGO’s), from all sectors involved in the development of this supply chain, to join forces. The goals are to pursue the dialogue with the government, support the education process and install a certification system with an official ‘compostable and biobased logo‘ for correct identication and traceability of certified products.

Book noW! ate: D ng i s 10 o 0 cl 2 b. e F 28

Meanwhile, a number of compostable bioplastics start-up companies in Brazil are preparing themselves for the business ahead. Joint ventures are being formed and all the major players are now scaling up pilot plants or launching their new bioplastic businesses on an industrial scale. The first items produced from bioplastics materials were introduced to the market about 4 or 5 years ago, mostly in the form of packaging and shopping bags. Many of them were, and still are, produced in pilot plants or using imported raw materials. Recently several new and different bioplastic products have been launched onto market. The market is moving quickly and the strongest point is that Brazil has an abundance of clean energy and a huge capacity to produce renewable agricultural resources on a very competitive basis.

Examples are starches, sugar cane, tobacco, vegetable oils, or cellulose for PLA, TPS, PHA and other biopolymer product families.

Also the technologies related to ethanol and vegetable oil conversion have become commercially available. The

bioplastics MAGAZINE [01/10] Vol. 5

49

Politics ethanol produced in Brazil today (about 23 billion litres per year) uses only 1.5% of the arable land. Brazil is working to double productivity in the same area by investing in technological improvements, without using genetically modified sugar cane. This means that the use of cane sugar is not impacting the balance of food production. The crops to produce biofuels are harvested far away from the rainforests and conservation areas, occupying about 10 million hectares of a total of 1.6 billion hectares of arable land.

Worldwide production of bioplastics on a commercial level has raised concerns about possible competition for natural resources and land. Brazil is trying to convince the global community that it is indeed possible to produce food, beverages, biomaterials, natural fibres, fuel and electricity in some cases from agricultural products, in a competitive and sustainable way. Thus there is no place for the last remnants of neo-Malthusians who want to bury advances being made in agricultural technology.

Issues such as these promise to generate less controversy on such a scale at the start the production of bioplastics from non-food biomass, such as bagasse from cane sugar or agricultural waste or tobacco. Another strong point in Brazil‘s favour is that biofuel production could also provide a platform for the socalled second generation of bioplastics, which can also use the lignin, cellulose (biomass), glycerine and other by-products of biodiesel and others.

The petrochemical company Braskem is a pioneer in the large-scale production of a sustainable plastic resin made from ethanol, well known in Brazil as ‘Green Plastic‘. However, there are more investment projects by petrochemical companies in biobased polymers, the most significant in the short-term being:  Braskem: 200,000 tonnes per annum of HDPE made from ethanol. Investments of US$ 150 millions. Start-up in 2010.  Dow Chemical and Cristalsev: 350,000 tonnes per annum of LLDPE made from ethanol. Investment of US$ 1 billion. Start-up in 2011.  Solvay: 60,000 tonnes per annum of PVC in 2011 based on ethanol.  Quattor: 100,000 tonnes per annum in 2012 of propylene based on glycerine for PP production.  Oxiteno: Production of ethylene glycol and propylene glycol from the hydrogenolysis of sugar cane. ‘Biorefinery concept’ using 50,000 hectares, enough to produce 4 million tonnes of cane per year. Estimated investment of US$ 300 million.

Apparently the development of technology in many fields of biopolymers is not a problem for Brazil. There has been a lot of investment and work carried out for a long period of time in universities, research centres and private companies.

In addition there is a great effort by the government in funding research for industry and academia.

Especially in this kind of industry the use of renewable resources will be based on the sustainability triangle (economic, social and environmental). This opens the market for further agricultural activities providing more than food and animal feed, thus helping to balance the complicated competitiveness of this sector which is subject to the weather and its consequences in harvest productivity and final prices. And better than that, this will create thousands of new ‘green jobs‘ in these agro-idustries. Brazil is very committed to being a society living with low-carbon emissions in the near future. And of course this new industry, in conjunction with sustainable management of agriculture, has much to contribute to this scenario. www.biomater.com.br

50

bioplastics MAGAZINE [01/10] Vol. 5

Basics

Glossary In bioplastics MAGAZINE again and again the same expressions appear that some of our readers might (not yet) be familiar with. This glossary shall help with these terms and shall help avoid repeated explanations such as ‘PLA (Polylactide)‘ in various articles.

Bioplastics (as defined by European Bioplastics e.V.) is a term used to define two different kinds of plastics:

Blend | Mixture of plastics, polymer alloy of at least two microscopically dispersed and molecularly distributed base polymers.

a. Plastics based on renewable resources (the focus is the origin of the raw material used)

Carbon neutral | Carbon neutral describes a process that has a negligible impact on total atmospheric CO2 levels. For example, carbon neutrality means that any CO2 released when a plant decomposes or is burnt is offset by an equal amount of CO2 absorbed by the plant through photosynthesis when it is growing.

b. à Biodegradable and compostable plastics according to EN13432 or similar standards (the focus is the compostability of the final product; biodegradable and compostable plastics can be based on renewable (biobased) and/or non-renewable (fossil) resources).

Bioplastics may be - based on renewable resources and biodegradable; - based on renewable resources but not be biodegradable; and - based on fossil resources and biodegradable.

Amylopectin | Polymeric branched starch molecule with very high molecular weight (biopolymer, monomer is à Glucose) [bM 05/2009].

Amyloseacetat | Linear polymeric glucosechains are called à amylose. If this compound is treated with ethan acid one product is amylacetat. The hydroxyl group is connected with the organic acid fragment.

Amylose | Polymeric non-branched starch molecule with high molecular weight (biopolymer, monomer is à Glucose) [bM 05/2009].

Biodegradable Plastics | Biodegradable Plastics are plastics that are completely assimilated by the à microorganisms present a defined environment as food for their energy.

The carbon of the plastic must completely be converted into CO2 during the microbial process. For an official definition, please refer to the standards e.g. ISO or in Europe: EN 14995 Plastics- Evaluation of compostability - Test scheme and specifications. [bM 02/2006, bM 01/2007].

50

bioplastics MAGAZINE [10/01] Vol. 5

Cellophane | Clear film on the basis of à cellulose.

Cellulose | Polymeric molecule with very high molecular weight (biopolymer, monomer is à Glucose), industrial production from wood or cotton, to manufacture paper, plastics and fibres.

Cradle-to-Cradle | (sometimes abbreviated as C2C): Is an expression which communicates the concept of a closed-cycle economy, in which waste is used as raw material (‘waste equals food’). Cradle-to-Cradle is not a term that is typically used in àLCA studies.

Cradle-to-Grave | Describes the system boundaries of a full àLife Cycle Assessment from manufacture (‘cradle’) to use phase and disposal phase (‘grave’).

Fermentation | Biochemical reactions controlled by à microorganisms or enyzmes (e.g. the transformation of sugar into lactic acid).

Gelatine | Translucent brittle solid substance, colorless or slightly yellow, nearly tasteless and odorless, extracted from the collagen inside animals‘ connective tissue.

Compost | A soil conditioning material of decomposing organic matter which provides nutrients and enhances soil structure. (bM 06/2008, 02/2009)

Glucose | Monosaccharide (or simple sugar).

G. is the most important carbohydrate (sugar) in biology. G. is formed by photosynthesis or hydrolyse of many carbohydrates e. g. starch.

Compostable Plastics | Plastics that are biodegradable under ‘composting’ conditions: specified humidity, temperature, à microorganisms and timefame. Several national and international standards exist for clearer definitions, for example EN 14995 Plastics - Evaluation of compostability - Test scheme and specifications [bM 02/2006, bM 01/2007].

Humus | In agriculture, ‘humus’ is often used simply to mean mature à compost, or natural compost extracted from a forest or other spontaneous source for use to amend soil.

Composting | A solid waste management technique that uses natural process to convert organic materials to CO2, water and humus through the action of à microorganisms [bM 03/2007].

Copolymer | Plastic composed of different monomers.

Cradle-to-Gate | Describes the system boundaries of an environmental àLife Cycle Assessment (LCA) which covers all activities from the ‘cradle’ (i.e., the extraction of raw materials, agricultural activities and forestry) up to the factory gate

Hydrophilic | Property: ‘water-friendly’, soluble in water or other polar solvents (e.g. used in conjunction with a plastic which is not waterresistant and weatherproof or that absorbs water such as Polyamide (PA).

Hydrophobic | Property: ‘water-resistant’, not soluble in water (e.g. a plastic which is waterresistant and weatherproof, or that does not absorb any water such as Polethylene (PE) or Polypropylene (PP).

LCA | Life Cycle Assessment (sometimes also referred to as life cycle analysis, ecobalance, and àcradle-to-grave analysis) is the investigation and valuation of the environmental impacts of a given product or service caused (bM 01/2009).

Basics

Readers who would like to suggest better or other explanations to be added to the list, please contact the editor. [*: bM ... refers to more comprehensive article previously published in bioplastics MAGAZINE)

Microorganism | Living organisms of microscopic size, such as bacteria, funghi or yeast.

PCL | Polycaprolactone, a synthetic (fossil based), biodegradable bioplastic, e.g. used as a blend component.

PHA | Polyhydroxyalkanoates are linear polyesters produced in nature by bacterial fermentation of sugar or lipids. The most common type of PHA is à PHB. PHB | Polyhydroxyl buteric acid (better poly3-hydroxybutyrate), is a polyhydroxyalkanoate (PHA), a polymer belonging to the polyesters class. PHB is produced by micro-organisms apparently in response to conditions of physiological stress. The polymer is primarily a product of carbon assimilation (from glucose or starch) and is employed by micro-organisms as a form of energy storage molecule to be metabolized when other common energy sources are not available. PHB has properties similar to those of PP, however it is stiffer and more brittle.

PLA | Polylactide or Polylactic Acid (PLA) is a biodegradable, thermoplastic, aliphatic polyester from lactic acid. Lactic acid is made from dextrose by fermentation. Bacterial fermentation is used to produce lactic acid from corn starch, cane sugar or other sources.

However, lactic acid cannot be directly polymerized to a useful product, because each polymerization reaction generates one molecule of water, the presence of which degrades the forming polymer chain to the point that only very low molecular weights are observed.

Instead, lactic acid is oligomerized and then catalytically dimerized to make the cyclic lactide monomer. Although dimerization also generates water, it can be separated prior to polymerization. PLA of high molecular weight is produced from the lactide monomer by ring-opening polymerization using a catalyst.

This mechanism does not generate additional water, and hence, a wide range of molecular weights are accessible (bM 01/2009).

Saccharins or carbohydrates | Saccharins or carbohydrates are name for the sugar-family.

Saccharins are monomer or polymer sugar units. For example, there are known mono-, di- and polysaccharose. à glucose is a monosaccarin. They are important for the diet and produced biology in plants.

Sorbitol | Sugar alcohol, obtained by reduction of glucose changing the aldehyde group to an additional hydroxyl group. S. is used as a plasticiser for bioplastics based on starch.

Starch | Natural polymer (carbohydrate) consisting of à amylose and à amylopectin, gained from maize, potatoes, wheat, tapioca etc. When glucose is connected to polymerchains in definite way the result (product) is called starch. Each molecule is based on 300 -12000-glucose units. Depending on the connection, there are two types à amylose and à amylopectin known [bM 05/2009].

Starch (-derivate) | Starch (-derivates) are based on the chemical structure of à starch.

The chemical structure can be changed by introducing new functional groups without changing the à starch polymer. The product has different chemical qualities. Mostly the hydrophilic character is not the same.

Starch-ester | One characteristic of every starch-chain is a free hydroxyl group. When every hydroxyl group is connect with ethan acid one product is starch-ester with different chemical properties.

Starch propionate and starch butyrate | Starch propionate and starch butyrate can be synthesised by treating the à starch with propane or butanic acid. The product structure is still based on à starch. Every based à glucose fragment is connected with a propionate or butyrate ester group. The product is more hydrophobic than à starch.

Sustainable | An attempt to provide the best outcomes for the human and natural environments both now and into the indefinite future.

One of the most often cited definitions of sustainability is the one created by the Brundtland Commission, led by the former Norwegian Prime Minister Gro Harlem Brundtland. The Brundtland Commission defined sustainable development as development that ‘meets the needs of the present without compromising the ability of future generations to meet their own needs.’ Sustainability relates to the continuity of economic, social, institutional and environmental aspects of human society, as well as the non-human environment).

Sustainability | (as defined by European Bioplastics e.V.) has three dimensions: economic, social and environmental. This has been known as “the triple bottom line of sustainability”. This means that sustainable development involves the simultaneous pursuit of economic prosperity, environmental protection and social equity. In other words, businesses have to expand their responsibility to include these environmental and social dimensions. Sustainability is about making products useful to markets and, at the same time, having societal benefits and lower environmental impact than the alternatives currently available. It also implies a commitment to continuous improvement that should result in a further reduction of the environmental footprint of today’s products, processes and raw materials used.

Thermoplastics | Plastics which soften or melt when heated and solidify when cooled (solid at room temperature).

Yard Waste | Grass clippings, leaves, trimmings, garden residue.

bioplastics MAGAZINE [10/01] Vol. 5

51

Subscribe now and get a gift* + the next six issues for € 149,–** please fill in the form and fax to +49-2161-631045 or subscribe online at www.bioplasticsmagazine.com Mrs.

Mr.

Name:

First Name:

Title:

Function:

Company: Department:

R&D

Marketing / PR

Project Dept.

Purchasing

Sales

other:

Address Street/No.: Town:

ZIP (Postal Code):

Country:

State:

Phone:

Fax:

Email:

http://www.

Kind of business or interest in the field „bioplastics“ University / Research / Science

Trade (Brand owner, Wholesale, Retail)

Institution / Association

Enduser

Raw material supplier

Politics / Administration

PR / Marketing / Advertising agent

Machine- / Equipment supplier

Converter (please specify, e.g. film blowing, injection molding, blow molding) Other (please specify) No. of Employees Creditcard information

Amex

Visa

Mastercard

I prefer to pay by money transfer I will pay by PayPal to mt@bioplasticsmagazine.de

Name on card:

6-20 21-100 101-500 500-1000

Card number: Expiry date:

0-5

more than 1000 Verification code:

Amount approved: EUR 149.00 Signature:

VAT-number (EU only, except Germany): An invoice will be mailed to you soon.

**offer valid until March 31, 2010

*If you return this fax-form and subscribe before March 31, 2010, you‘ll get a nice bioplastics MAGAZINE daypack-rucksack. Every 10th new suscriber will get a watch.

Subscription

bioplastics MAGAZINE [01/10] Vol. 5

51

Event Calender Feb. 17 , 2010 CO2-Emissionshandel nach 2012 die Konsequenzen des Klimagipfels von Kopenhagen Westhafen Tower (Beiten Burkhardt), Frankfurt/M., Germany www.agrion.org

Feb. 24 , 2010 Algenbiomasse - Eine ökologische und ökonomische Perspektive für Hessen Darmstadt, EUMETSAT Zentrale, Darmstadt, Germany www.cib-frankfurt.de

March 3-4, 2010 25. Internationales Kunststofftechnisches Kolloquium Eurogress, Aachen, Germany www.ikv-kolloquium.de March 8-10, 2010 GPEC 2010 - Global Plastics Environmental Conference The Florida Hotel & Conference Center Orlando, Florida, USA www.4spe.org

March 14-16, 2010 3rd Workshop ,,Fats and Oils as Renewable Feedstock for the Chemical Industry“ Emden / Germany www.abiosus.org

March 15-17, 2010 Worldbiofuels Markets Amsterdam / Netherlands www.worldbiofuelsmarkets.com

March 15-17, 2010 4th annual Sustainability in Packaging Conference & Exhibition Rosen Plaza Hotel, Orlando, Florida, USA www.sustainability-in-packaging.com

March 16-17, 2010 EnviroPlas 2010 Brussels, Belgium www.ismithers.net

March 31 - April 01, 2010 Bioplastics and Green Composites 2010 Workshop Delta Hotel, Guelph, Ontario, Canada www.bioplastics2010.com

April 13-15, 2010 Innovation Takes Root 2010 The Four Seasions - Dallas, Texas, USA www.InnovationTakesRoot.com

52

bioplastics MAGAZINE [01/10] Vol. 5

Events April 16-18, 2010 CannaTrade - International Hemp Fair Basel / Schweiz

May 02-04, 2010 11th International Conference on Biocomposites Toronto / Canada

June 07-09, 2010 6th International Conference on Renewable Resources & Biorefineries Düsseldorf / Germany

www.biocomposites-toronto.com

www.rrbconference.com

May 03-07, 2010 18th European Biomass Conference and Exhibition Frankreich / Lyon

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

www.conference-biomass.com

www.wpc-nfk.de

April 20-22, 2010 7th Wood-Plastic Composites 2010 Vienna / Austria

May 06, 2010 Nachwachsende Rohstoffe und pflanzliche Chemie Frankfurt/Main, Germany

Sept. 09-10, 2010 8th International Symposium „Raw Materials from Renewable Resources“ Erfurt, Germany

www.amiplastics.com

www.agrion.org

www.narotech.de

April 20-21, 2010 3. Biowerkstoffkongress Hannover-Messe 2010, Germany

May 17-19, 2010 3rd International Conference on Engineering for Waste and Biomass Valorisation Beijing / China

Sept. 10-12, 2010 naro.tech 2010 Erfurt, Germany

www.wasteeng10.org

Oct. 27 - Nov. 03, 2010 K‘ 2010 - International trade Fair No.1 for Plastics & Rubber Worldwide Düsseldorf, Germany

www.cannatrade.com

April 19-21, 2010 CHINAPLAS 2010 - Green Plastics .

Our Goal . Our Future Industrial Forum Shanghai New International Expo Center, Pudong, Shanghia, China www.chinaplasonline.com

www.biowerkstoff-kongress.de

April 22-23, 2010 7th European Thermoforming onference Hilton Hotel, Antwerpen, Belgium www.e-t-d.org Werbeanzeige:210x148,5

26.01.2010

May 26-27, 2010 Envase Sostenible (i.e. Sustainable Packaging) Sheraton Hotel, Bogotá, Colombia

www.narotech.de

www.k-online.de/

www.plastico.com 13:59 Uhr Seite 1

www.biowerkstoff-kongress.de

Bilder: nova-Institut

Dritter Biowerkstoff-Kongress 2010

International Congress on Bio-based Plastics and Composites 20. – 21. April 2010, HANNOVER MESSE, Convention Center, Raum 2 Partner

Bio-based products are based completely or in relevant quantities on agrarian commodities or wood.

Typically bio-based products are made of Wood Plastic Composites (WPC), Naturalfibre Reinforced Plastics and Bio-based Plastics. Besides, the congress has the following main topics: ■ Industries and applications ■ Marktsituaton and trends ■ Processing procedures and material qualities ■ Research and development

Media Partner

Practically oriented for developers, producers, trades and users.

Further information regarding the innovation award on bio-based products 2010, programme and re gistration at: www.biowerkstoff-kongress.de

Organiser

Contact: Dominik Vogt, Tel.: +49 (0) 2233 4814 – 49, dominik.vogt@nova-institut.de You can meet us!

Please contact us in advance by e-mail.

bioplastics MAGAZINE [01/10] Vol. 5 nova-Institut GmbH | Chemiepark Knapsack | Industriestrasse | 50354 Huerth | Germany | contact@nova-institut.de | www.nova-institut.de/nr

53

Suppliers Guide 1. Raw Materials 10

20

30

40

50

60

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

70

80

90

100

110

120

130

140

150

180

190

Transmare Compounding B.V. Ringweg 7, 6045 JL Roermond, The Netherlands Tel. +31 475 345 900 Fax +31 475 345 910 info@transmare.nl www.compounding.nl

Du Pont de Nemours International S.A. 1.3 PLA 2, Chemin du Pavillon, PO Box 50 CH 1218 Le Grand Saconnex, Geneva, Switzerland Tel. + 41 22 717 5428 Fax + 41 22 717 5500 Division of A&O FilmPAC Ltd jonathan.v.cohen@che.dupont.com 7 Osier Way, Warrington Road www.packaging.dupont.com GB-Olney/Bucks.

MK46 5FP Tel.: +44 844 335 0886 Fax: +44 1234 713 221 sales@aandofilmpac.com www.bioresins.eu PURAC division 1.4 starch-based bioplastics 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 1.2 compounds

160

170

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

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

200

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

Grace Biotech Corporation Tel: +886-3-598-6496 No. 91, Guangfu N. Rd., Hsinchu Industrial Park,Hukou Township, Hsinchu County 30351, Taiwan sales@grace-bio.com.tw www.grace-bio.com.tw

210

PSM Bioplastic NA Chicago, USA www.psmna.com +1-630-393-0012 1.5 PHA

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

Telles, Metabolix – ADM joint venture 650 Suffolk Street, Suite 100 Lowell, MA 01854 USA INNOVIA FILMS LTD Tel. +1-97 85 13 18 00 Wigton Fax +1-97 85 13 18 86 Cumbria CA7 9BG www.mirelplastics.com England Contact: Andy Sweetman Tel. +44 16973 41549 Fax +44 16973 41452 andy.sweetman@innoviafilms.com www.innoviafilms.com Tianan Biologic 4. Bioplastics products 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

Sukano Products Ltd. Chaltenbodenstrasse 23 CH-8834 Schindellegi Tel. +41 44 787 57 77 Fax +41 44 787 57 78 www.sukano.com 2. Additives / Secondary raw materials

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

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

3. Semi finished products 3.1 films

EcoWorks

®

220

230

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

240

250

260

270

56

bioplastics MAGAZINE [01/10] Vol. 5

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

Huhtamaki Forchheim Herr Manfred Huberth Zweibrückenstraße 15-25 91301 Forchheim Tel. +49-9191 81305 Fax +49-9191 81244 Mobil +49-171 2439574

Cortec® Corporation 4119 White Bear Parkway St. Paul, MN 55110 Tel: +1 800.426.7832 Fax: 651-429-1122 info@cortecvci.com www.cortecvci.com Eco Cortec® 31 300 Beli Manastir Bele Bartoka 29 Croatia, MB: 1891782 Tel: +011 385 31 705 011 Fax: +011 385 31 705 012 info@ecocortec.hr www.ecocortec.hr

Suppliers Guide 6.1 Machinery & Molds

9. Services

Simply contact:

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

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

President Packaging Ind., Corp.

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

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

Roll-o-Matic A/S Petersmindevej 23 5000 Odense C, Denmark Tel. + 45 66 11 16 18 Fax + 45 66 14 32 78 rom@roll-o-matic.com www.roll-o-matic.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 Wiedmer AG - PLASTIC SOLUTIONS www.saidagroup.jp 8752 Näfels - Am Linthli 2 SWITZERLAND 7. Plant engineering Tel. +41 55 618 44 99 Fax +41 55 618 44 98 www.wiedmer-plastic.com 4.1 trays 5. Traders 5.1 wholesale 6. Equipment

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

Tel.: +49 02351 67100-0 suppguide@bioplasticsmagazine.com Stay permanently listed in the Suppliers Guide with your company logo and contact information.

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

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

For Example:

Wirkstoffgruppe Imageproduktion Tel. +49 2351 67100-0 luedenscheid@wirkstoffgruppe.de www.wirkstoffgruppe.de

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

10. Institutions

Sample Charge:

10.1 Associations

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

10 35 mm

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

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

20

30 35

Sample Charge for one year: 6 issues x 210,00 EUR = 1,260.00 € BPI - The Biodegradable Products Institute 331 West 57th Street, Suite 415 New York, NY 10019, USA Tel. +1-888-274-5646 info@bpiworld.org

The entry in our Suppliers Guide is bookable for one year (6 issues) and extends automatically if it’s not canceled three month before expiry.

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

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

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

bioplastics MAGAZINE [01/10] Vol. 5

57

Companies in this issue Company A&O Filmpac A. Schulman ABICOM Acetati Achilles Papierveredelung Adsale alesco Albis Plastics Arkhe Will BASF BIO4PACK Biomater bioplastics24 BioPro BMBF Bosch BPI Braskem CBPack Celanese Cereplast Clariant Corn Products Cortec Costanera Norte Daicel Daimler DLR Dow Dr. Boy DSM Dt. Inst. F. Kautsch. Tech.

DuPont Dyne-a-Pak Eastman Equilicua European Bioplastics FAS Converting Machinery FH Hannover Fischerwerke FKuR FNR Ford Forestal Minico Four Motors Fraunhofer UMSICHT Futerro Galactic Genencor Goodyear Grace Biotech Hagedorn Hallink Hercules Hiendl Hyundai Inapol Huhtamaki Inde Plastik Innovia Films Kaneka Lamberti Land NRW

Next Issue

58

Editorial

Advert 56

13 49 45 42 52 56 46 6, 10, 48

56 56 56

48 31 10 10 10 57 7, 50 48 45 32 22 48

56

8, 56 37 45 10 15 46, 50 6 5 42 34 30 45 34 3, 7 6, 42 10 6, 26, 46 15 12 37 14 6, 26, 46 6 5 20 20

56

48, 57 57 57 2, 56

57

56 46, 50 57 47 8 16 37 56 26 45, 48 28 47 42

56

Company Limagrain Mann + Hummel Mazzuchelli Michigan State University Minima Technology National Plastics Institut (Brazil) NatureWorks Natur-Tec Nobel nova Intstitut Novamont Novarese Zuccheri Novozymes Oekametall Olymp Omodo Ontario BioAuto Council Ontario BioCar Initiative Oregon State Univ.

Oxiteno Penn Carbose Plantic Plastic Suppliers Plasticker Plastividia President Packaging Proyectos Plasticos PSA Peugeot Citroën PSM Purac Qingdao HuaSheng Quattor Reifenhäuser Rhodia Rodenburg Roll-o-Matic Rotuba Sacme Saida Sealed Air Sekisui Sidaplax Solvay Sommer Needlepunch Staedtler Sukano Sulzer Chemtech Supla Symphony Environmental Synbra Telles Tianan Total Petrochemical Transmare Uhde Inventa-Fischer Unitika Univ. Braunschweig Univ. Concepción Tech. Dev. Wei Mon Werzalit Wiedmer

10 46

Publ.-Date

Editorial Focus (1)

Editorial Focus (2)

Basics

March / April

April 06, 2010

Rigid Packaging

Material Combinations

Certification

May /Jun

June 07, 2010

Injection Moulding

Natural Fibre Composites

Polyamides

Jul / Aug

Aug. 02, 2010

Additives / Masterbatch / Adh.

Bottles / Labels / Caps

Compounding

Sep / Oct

Oct. 04, 2010

Fibre Applications

Polyurethanes / Elastomers

Polyolefins

56 57

Advert

57 57 48 5, 30, 32, 33 48 46, 50 8 20, 35 35 7 34 35 5 18 12 17 50 47

56 53 57, 60

56 56 31 48 57 37 19 24 8 50 8 45 48 36 46 36

56 56

57

57 30 29 56 50 5 8 6 24 33 7 24 36

56

56, 59 56

6 56 57 29 10 37 21, 57 8 57

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

Month

bioplastics MAGAZINE [01/10] Vol. 5

Editorial

Fair Specials

K‘2010 Preview

A real sign of sustainable development.

There is such a thing as genuinely sustainable development.

Since 1989, Novamont researchers have been working on an ambitious project that combines the chemical industry, agriculture and the environment: "Living Chemistry for Quality of Life". Its objective has been to create products with a low environmental impact. The result of Novamont's innovative research is the new bioplastic Mater-Bi 速.

Mater-Bi 速 is a family of materials, completely biodegradable and compostable which contain renewable raw materials such as starch and vegetable oil derivates. Mater-Bi 速 performs like traditional plastics but it saves energy, contributes to reducing the greenhouse effect and at the end of its life cycle, it closes the loop by changing into fertile humus. Everyone's dream has become a reality.

Mater-Bi速: certified biodegradable and compostable.

Living Chemistry for Quality of Life. www.novamont.com

Inventor of the year 2007