bioplastics MAGAZINE 05-2010

ISSN 1862-5258

September/October

05 | 2010

Basics Bio-Polyolefins | 52 Personality

bioplastics

magazine

Vol. 5

30 Preview

Mark Verbruggen | 56

Highlights Fibers / Textiles | 12 Polyurethanes / Elastomers | 42 1 countries

... is read in 9

FKuR plastics - made by nature!® Bio-Flex® resins… taking PLA further!

Please visit us at K 2010 to see this bottle & other innovative products.

We look forward to seeing you at B66 in Hall 6

FKuR Kunststoff GmbH Siemensring 79 D - 47877 Willich Phone: +49 2154 92 51-0 Fax: +49 2154 92 51-51 sales@fkur.com

FKuR Plastics Corp.

921 W New Hope Drive | Building 605 Cedar Park, TX 78613 | USA Phone: +1 512 986 8478 Fax: +1 512 986 5346 sales.usa@fkur.com

www.fkur.com

Bottle made from Bio-Flex®

s– e u q i t s pla o i b R u FK de r u o T Le on i t a v o n l’In

Editorial

dear readers ISSN 1862-5258

As promised (or rather as expected) we have hit a new record.

This issue of bioplastics MAGAZINE is once again the biggest ever.

One reason, certainly, is the upcoming K’2010, the world‘s biggest trade fair for plastics and rubber, that takes place in Düsseldorf, Germany from 27th October to 3rd November. In a comprehensive show preview we try to give you as much information as possible on the different bioplastics-related exhibits, including a centrefold with floor plan of the exhibition. This will be complemented by our show review in the next issue. From now on, we also offer a special K’2010 service on our website www.bioplasticsmagazine.com, especially for visitors interested in bioplastics. And please be sure to visit our booth in Düsseldorf in Hall 7 (C09).

MAGAZINE

Vol. 5

30 Preview

Mark Verbruggen | 56

bioplastics

Oh! And let me remind you of one special highlight at K‘2010 for all those interested in bioplastics: On October 28th, 29th, and 30th we will be hosting ‘Bioplastics Business Breakfasts’. Find out in this issue about this unique opportunity for gathering the latest information and for networking.

05 | 2010

Personality

Another reason for this ‘bumper’ issue is the number of articles and news items related to our two focus topics, namely: ‘Polyurethanes | Elastomers’ and ‘Fibres | Textiles’, which also covers the nonwoven sector as well as filament for brushes. You can see just how wide the areas of potential application for bioplastics really are - and they are growing week by week!

In addition to our ‘basics’ article on the ‘Basics of Bio-Polyolefins’ we again have opinions, news and much more to offer. We are particularly happy to be able to present in this issue the top five companies/products that have been shortlisted from more than 20 entries for the Bioplastics Award 2010. The Bioplastics Award 2010 is presented jointly by bioplastics MAGAZINE and European Plastics News.

September/October Basics Bio-Polyolefins | 52

Highlights Fibers / Textiles | 12

Polyurethanes / Elasto mers

| 42 ... is read in 91 countries

I hope you enjoy reading bioplastics MAGAZINE.

Yours

New:

Follow us on twitter: http://twitter.com/bioplasticsmag

Be our friend on Facebook: http://www.facebook.com/pages/bioplastics-MAGAZINE/103745406344904

bioplastics MAGAZINE [05/10] Vol. 5

bioplastics MAGAZINE [05/10] Vol. 5

New:

K 2010 30 Extract from Cashew Nut Shell 21

K Show Guide 34 New Biomaterial 28

New Filaments for Brushes 13

PA11 Fibres and Polyether Block Amide Nonwovens 14

Sustainable Fabrics Can be ‘NICE’ 16 Basics of Bio-Polyolefins

Innovative Floor Covering 17

Personality

Loving Both High Fashion and Nature 16

The Zero Impact Collection 18

Fashion Helmet 19

Report New Biobased Polyurethane from Lignin and Soy Polyols 42

Unique Soft Bioplastics 44

Bio-based ‘Cold Weather’ Thermoplastic Elastomer 46

Same Performance just Greener...

50

Mark Verbruggen

Sustainability Counts Through the Life Cycle

Follow us on twitter: http://twitter.com/bioplasticsmag

Novamont (Photo by Philipp Thielen)

Editorial News Application News Suppliers Guide Event Calendar

Cover Ad

Optimized Processing of Natural Materials in Pilot Scale Shortlist

A large number of copies of this issue of bioplastics MAGAZINE is wrapped in a compostable film manufactured and sponsored by FkUR Kunststoff GmbH

12

Envelope

Silk Crepe Kimonos made with PLA Fibers

Editorial contributions are always welcome.

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

Fibers | Textiles

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

10

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.

Cover-Story

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

08

bioplastics MAGAZINE is read in 91 countries.

Event

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

Event Preview

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

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

Innovative Biodegradable and Compostable Cling Film

bioplastics magazine

Bioplastics Business Breakfast

Tölkes Druck + Medien GmbH 47807 Krefeld, Germany Total Print run: 7,000 copies

Print

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

Media Adviser

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

Head Office

Mark Speckenbach

Layout/Production

Dr. Michael Thielen Samuel Brangenberg

Publisher / Editorial

Imprint Content 3

5

22

62

64

Sep/Oct

05|2010 Materials

Bioplastics Award 2010 26

Polyurethanes | Elastomers

Basics

52

56

Opinion

58

20

Like us on Facebook: http://www.facebook.com/pages/bioplastics-MAGAZINE/103745406344904

News

New BoPLA Line Started Production

New Priorities for Bioplastics

Over a month earlier than planned, Taghleef Industries has successfully started the production of the new NATIVIA™ film from its plant in San Giorgio di Nogaro, Italy.

With effect from September 1 Prof. Christian Bonten took on responibility for the plastics technology institute (IKT) at the University of Stuttgart, Germany.

He succeeds Prof.

HansGerhard Fritz. Bonten, who was previously Director of Technology and Marketing at bioplastics compounder and supplier FKuR Kunststoff GmbH in Willich, Germany, Prof. Christian Bonten (Photo aims to put special accent on courtesy Universität Stuttgart) the areas of nano-additives and bioplastics, thus broadening and strengthening the profile of Stuttgart University in matters of modern materials. MT st

NATIVIA is based on 100% renewably sourced Ingeo™ PLA by NatureWorks®

www.ikt.uni-stuttgart.de.

NATIVIA is a biodegradable and compostable film complying with the European standard EN13432.

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

The start-up of the new line took place on August 18th, 2010 and since the following week the commercial production has commenced successfully. The first shipments of NATIVIA were be made in early of September 2010.

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

Valerio Garzitto, CEO Ti Europe explains “We are particularly proud of the work carried out by our technicians. The BoPLA line was ordered just 5 months ago, and we already obtained an enthusiastic result being able to be on the market now with a film with excellent characteristics.”

Brueckner was the main supplier of this new BoPLA line. Mr Karl Zimmermann, Brueckner Sales Director, remarked that “Brueckner had been working hard together with Taghleef technicians to obtain such a valuable and advanced results. This is the proof of the perfect teamwork of two companies whose leading philosophy is innovation combined with development.”

Within the next weeks the first productions of 25 and 30-my-thicknesses metallized NATIVIA films will take place. NATIVIA™ films are produced for multiple applications, such as fresh produce, bakery, confectionery, snacks, dairy, other perishable goods and different kind of lidding. In the non-food sector examples are labelling and stationery MT

• International Trade in Raw Materials, Machinery & Products Free of Charge • Daily News from the Industrial Sector and the Plastics Markets

C

M

• Current Market Prices for Plastics.

Y

CM

• Buyer’s Guide for Plastics & Additives, Machinery & Equipment, Subcontractors and Services.

MY

CY

CMY

K

er.com lastick www.p

• Job Market for Specialists and Executive Staff in the Plastics Industry

sional Profes Fast • • te a d Up-to-

www.ti-films.com.

bioplastics MAGAZINE [05/10] Vol. 5

News

Procter&Gamble to Use Bio-PE

Award for Biobased Polymer

Brazilian petrochemical company Braskem will supply its sugarcane ethanol-based polyethylene (PE) to multinational consumer products company Procter & Gamble‘s (P&G) cosmetics lines Pantene Pro V®, Max Factor® and Cover Girl® packaging.

Stefanie Kind, PhD student at the Institute of Biochemical Engineering of the Technische Universität Braunschweig, was awarded with the prestigious ‘Young Metabolic Engineer Award’ During the Metabolic Engineering Conference in Jeju, South Korea, an international jury selected five most excellent papers out of 200, among these the work by Stefanie Kind. In a ‘best of the best’ competition with short presentations she stood up to top-class competitors from the USA and Asia.

P&G already uses Braskem‘s oil-based PE, but negotiations on ‘green’ PE supply began when the Brazilian firm started the biopolymer project, approximately three years ago, Braskem‘s polymers business VP Rui Chammas told journalists during an event in Sao Paulo.

Braskem started producing the green resin this month at the Triunfo petrochemical hub, in Rio Grande do Sul state (see next page).

Gisele Bündchen presenting Panthene in bio-PE (Photo: Agencia Fotosite)

The first P&G product line to use the sugarcane ethanol resin is Pantene, and packaging made with the biopolymer will be available from 2011, according to P&G corporate affairs director in Brazil, Gabriela Onofre. P&G plans to expand the use of the ‘green’ PE beyond to other items, Gabriela said.

Chammas added that most of the plant‘s production has already been negotiated with approximately 20 Brazilian and foreign companies, from which 10 were not publicly disclosed. “More than two-thirds of the production will be exported,“ Chammas said.

“P&G‘s commitment to use renewable bio-derived plastic in its global beauty and grooming product packaging is an important step forward in its efforts to improve the environmental profile of its products,“ said Dr. Jason Clay, Senior Vice President of Market Transformation of World Wildlife Fund, U.S. “We applaud this announcement as part of their leadership in finding innovative solutions to the sustainability challenges facing the world today.“ “This innovation is truly consumer-driven. As we talk with women around the world, they tell us that they want to make themselves more beautiful without making their environment less beautiful,‘‘ said Gina Drosos, Group President, Global P&G Beauty. “With this new packaging innovation, women can have confidence that their favorite brands are helping to make a difference.“ “Using sugarcane-derived plastic represents another step in P&G‘s commitment to environmental sustainability and the development of sustainable innovation products,“ said Len Sauers , P&G Vice President, Global Sustainability. “P&G is making significant progress in environmental sustainability through our work with external partners. Together, we are working on creative solutions that deliver science-based sustainable innovations.“ MT Sources: Bnamericans [2010-08-13] PRNewswire via COMTEX [2010-08-12]

bioplastics MAGAZINE [05/10] Vol. 5

www.pg.com www.braskem.com.br

Stefanie Kind, graduated in biology, received the award for systems wide metabolic engineering of the soil bacterium Corynebacterium glutamicum into a tailor-made cell factory for production of diaminopentane as building block for the innovative bio-polyamide PA5.10. The ‘2010 Young Metabolic Engineer Award’ recognizes her research, supervised

by Prof. Dr. Christoph Wittmann, as groundbreaking model project towards a bio-based economy for the production of chemicals, materials and fuels.

Her work is part of a joint collaboration of the Institute of Biochemical Engineering with an industrial consortium including BASF SE, Daimler AG, Fischerwerke GmbH and Robert-Bosch GmbH. The project supported by the Federal Ministry of Education and Research within the initiative BioIndustry21. Stefanie Kind is further sponsored by the Max-Buchner Foundation of the German Society for Chemical Engineering and Biotechnology (DECHEMA). www.tu-braunschweig.de

Braskem Inaugurated Green Ethylene Plant On September 24, in the Triunfo Petrochemical Complex (Triunfo, Brazil), Braskem inaugurated, the world’s largest ethylene-from-ethanol plant, permitting the production of 200,000 tons of green polyethylene per year. As a result, the company will be providing the world with resin made from renewable sources, and taking another step towards its goal of becoming the world leader in sustainable chemistry with diversified and competitive raw material sources.

The project, which absorbed investments of almost R$500 million, was based on the company’s own technology.

“The completion of this project is a landmark for Braskem, the realization of a dream shared with our clients, who can now acquire an even more sustainable product,” declared the company’s CEO, Bernardo Gradin. Braskem’s ‘Green plastics’ are exceptionally eco-friendly, since the process used to produce each ton of polyethylene from the primary raw material removes 2.5 tons of carbon dioxide from the atmosphere. “Braskem’s green plastics are made from CO2 sequestered from the atmosphere through sugarcane photosynthesis. It is also the most competitive of all plastics made from renewable sources. And this has been widely acknowledged by the market, which recorded demand three times greater than the plant’s capacity,” added Gradin.

Construction of the green ethylene plant was concluded 16 months ahead of schedule, under budget and with no accidents resulting in workers having to take time off. Due to its extreme importance, Braskem challenged its team to complete the project as rapidly as possible and with the highest safety standards. More than 2,200 workers were involved in the construction, more than 700 of whom living in Triunfo and the vicinity. Of this total, 174 had completed the Programa Acreditar (Believing Program), which had provided almost 250 Triunfo residents with eight months of training in electrics, structural assembly, plumbing, carpentry and welding.

Ethylene specification took place 12 hours after the plant’s start-up, on September 3, and green polyethylene production began a week later. The polymerization process, which converts ethylene into resin, is carried out in Braskem’s existing plants in the Triunfo Complex. The final product has the same properties and characteristics as conventional polyethylene and can be processed by clients’ equipment without the need for any adjustments.

Braskem is also considering implementing a new green ethylene unit, due to market interest. “Investments in polymers have underlined Braskem’s confidence in the country’s growth and its potential for leading the development of products made from renewable sources, thanks to its competitive advantages,” Gradin concluded. www.braskem.com.br

Event

Bioplastics Business Breakfast

A

t K’2010, the world‘s biggest trade show for the plastics and rubber industries which is being held in Düsseldorf, Germany from October 27th to November 3rd, 2010, bioplastics will certainly have an important role to play.

Visitors to K’2010 can benefit from the huge number of exhibitors presenting products and services around biobased and biodegradable plastics. In addition bioplastics MAGAZINE offers a unique chance to get more first-hand information and to talk directly to the experts.

On three days during the show (Oct. 28th, Oct. 29th and Oct. 30th) bioplastics MAGAZINE will host a Bioplastics Business Breakfast. At these mini-symposia, succinct and to the point, the delegates will have the chance to listen to, and discuss, high quality presentations, and to benefit from a unique networking opportunity. Take advantage of this special opportunity, from 8 a.m. to 12 noon, to pick up detailed information before the show doors open (the trade fair opens at 10 am).

These breakfast meetings, where tea, coffee and croissants will be served, are being held at the CCD Ost, Messe Düsseldorf, Germany, right on the fairgrounds. Every delegate at the Bioplastics Business Breakfast will also receive a free ticket for admission to the K’2010 show. (The ticket also includes free public transportation – except taxis!)

Conference fees start at EUR 199.00 (for subscribers to bioplastics MAGAZINE).

supported by

28. - 30.10.2010

Bioplastics in Packaging

Messe Düsseldorf, Germany

BIOPLASTICS BUSINESS BREAKFAST

B

3

PLA, an Innovative Bioplastic Injection Moulding of Bioplastics

At the World’s biggest trade show on plastics and rubber: K’2010 in Düsseldorf bioplastics will certainly play an important role.

www.bioplastics-breakfast.com

Contact: : Dr. Michael Thielen (info@bioplastics-magazine.com)

bioplastics MAGAZINE [05/10] Vol. 5

On three days during the show from Oct 28 - 30, biopolastics MAGAZINE will host a Bioplastics Business Breakfast: From 8 am to 12 noon the delegates get the chance to listen and discuss highclass presentations and benefit from a unique networking opportunity. The trade fair opens at 10 am.

Event

Programme: 28.10.2010

Bioplastics in packaging

08:00-08:30

Basics of Bioplastics

Michael Thielen, bioplastics MAGAZINE

08:30-08:50

Bioplastics ‘Packaging and Legislation’

European Bioplastics, Jöran Reske

08:50-09:10

Sustainable Packaging

Nextek, Edward Kosior

09:10-09:20

Q&A

09:20-09:40

PLA Based Packaging Solutions

Huhtamaki, Kurt Stark

09:40-10:00

Starch based Packaging

Novamont, Stefano Facco

10:00-10:20

Polyester (PBAT) Packaging

BASF, Jens Hamprecht

10:20-10:30

Q&A

10:30-10:50

Coffee & Networking

10:50-11:10

Bo-PLA

Taghleef, Frank Ernst

11:10-11:30

Green PE and its application in the packaging sector

Braskem, speaker t.b.c.

11:30-11:50

End of Life

Panel discussion

11:50-12:00

Q&A

29.10.2010

PLA, an innovative bioplastic

08:00-08:30

Basics of Bioplastics

Michael Thielen, bioplastics MAGAZINE

08:30-08:50

Basics of PLA

Uhde Inventa-Fischer, Andreas Grundmann

08:50-09:10

The Latest in Ingeo Performance Developments

NatureWorks, Mark Vergauwen

09:10-09:20

Q&A

09:20-09:40

Processing PLA

NaKu, Johann Zimmermann

09:40-10:00

Enabling performance in the PLA industry

Purac, Ruud Reichert

10:00-10:20

Barrier Coating of PLA

Institut für Kunststoffverarbeitung (IKV) Aachen, Karim Bahroun

10:20-10:30

Q&A

10:30-10:50

Coffee & Networking

10:50-11:10

Bi-oriented PLA

Taghleef, Frank Ernst

11:10-11:30

Blown PLA Film - Challenges & Opportunities

Huhtamaki, Ingrid Sebald

11:30-11:50

PLA Particle Foam

Synbra, Jan Noordegraaf, Peter Matthijsen

11:50-12:00

Q&A

30.10.2010

Injection moulding of bioplastics for durable applications

08:00-08:30

Basics of Bioplastics

Michael Thielen, bioplastics MAGAZINE

08:30-08:50

Inj. Moulding Compounds

FKuR, Christoph Lohr

08:50-09:10

Machinery

Coperion, Uta Kuehnen

09:10-09:20

Q&A

09:20-09:40

Injection Moulding of PLA

A.S.T., Bruno Camerlengo

09:40-10:00

Injection Moulding of PHA

Telles, Debra Darby

10:00-10:20

Injection Moulding of PBS / bio-EP

Mitsubishi Chemical, Dietrich Albrecht

10:20-10:30

Q&A

10:30-10:50

Coffee & Networking

10:50-11:10

Bio-Polyamide for Injection Moulding

Evonik, Frank Lorenz

11:10-11:30

Bio-Polyethylene for Injection Moulding

Braskem, t.b.c.

11:30-11:50

Hot-runners for use with Bioplastics

t.b.c.

11:50-12:00

Q&A

This programme is preliminary.

All topics and speakers are subject to changes

bioplastics MAGAZINE [05/10] Vol. 5

Cover-Story

Innovative Biodegradable and Compostable Cling Film Article contributed by Stefano Facco New Business Development Director Novamont, Novara, Italy

N

ovamont continues its development with the Second Generation Mater-BiŽ products: at K’2010 (the international trade fair for plastics and rubber), taking place in Dßsseldorf, Germany from October 27th to November 3rd, Novamont will be unveiling the first industrial cling film that is biodegradable and compostable and is made using renewable resources.

Plastic food packaging film, known as cling film or cling wrap, has in the past literally revolutionised the food industry. It has become a major contributor to food safety, both protecting and preserving it. At the same time it is now regarded as an essential and cost-effective tool for food presentation.

These films do contribute to food safety, they protect food from micro-organism and fast deterioration due to uncontrolled water and oxygen exchange. It also seals in odours to prevent them from spreading to other foods stored nearby.

Since plastic wrap is difficult to recycle and is rarely reused, it often contributes to unsorted household waste. New options, such as possible compostability, do offer new recycling possibilities by using already well established waste streams, such as the one for kitchen waste.

10

bioplastics MAGAZINE [05/10] Vol. 5

Cover-Story

The demand for this specific application was already raised some 10 years ago, when first brand owners, retailers and catering companies started to search for a product which had similar mechanical properties to PVC, a more favourable environmental profile like polyolefines, and a further end of life option, in this case composting, which would allow these products, generally highly contaminated with foodstuff, to be recycled aerobically or anaerobically.

The development took quite a long time, as the technical profile of such a product is complex, taking into consideration various benchmarks which had to be met. First of all, of course, the optical appearance and transparency, which has to be similar to that offered by the conventionally used materials. Another important aspect is the balanced mechanical properties at very low gauge, as such films are mainly used in the gauge of 10 to 12 µm, with extremely high puncture resistance and excellent elongation values. Another major target which had to be achieved was the cling property of the film, on itself as well as on glass or ceramic. But one of the most exciting and outstanding properties achieved was a perfectly tuned water vapour transmission rate (WVTR) which allows many products to be kept fresh for longer in the fridge.

The stretchy cling film can be used for any kind of foodstuffs, even food that has a high fat content (oils, sauces, butter, etc.) or that is acidic. This property is not always given for standard materials, depending on the raw materials and its additives.

The product was developed by Novamont together with its partners and has outstanding technical characteristics of strength and stretch similar or better than traditional products developed for domestic use without using any plasticisers or additives that could transfer into food.

After use it can be disposed of as organic waste as it has been certified as compostable in accordance with standard EN13432 and is compatible with various kinds of composting plant technology.

Besides the very peculiar and newly developed extrusion conditions, it is specially formulated to be easy to tear off without needing a serrated cutting edge, making it safer and more convenient.

As previously described, an intrinsic characteristic of the material is its high permeability to water vapour, helping to evaporate the condensation that forms particularly with warm food or in the fridge. This makes it ideal for preserving and protecting foodstuffs.

Mater-Bi is the main product developed by Novamont. While providing the same strength and performance as traditional plastics, it is made of renewable resources of agricultural origin.

It reduces greenhouse gas emissions and the consumption of energy and non-renewable resources, thus completing a virtuous circle: the raw materials of agricultural origin return to the earth through processes of biodegradation and composting, without releasing pollutants.

Photo: Philipp Thielen

www.novamont.com

Our covergirl Anna thinks: “This is great: biobased and biodegradable packaging, and now this new compostable cling film – that is what we have really been waiting for.”

bioplastics MAGAZINE [05/10] Vol. 5

11

Fibers | Textiles

T

he Teijin Group based in Tokyo and Osaka, Japan, announced earlier this year that its BIOFRONT heat-resistant PLA based bioplastic will be used in silk crepe kimonos worn by staff at Murasaki, a Japanese restaurant operated

by Kikkoman Corporation in the Japan Industry Pavilion of the 2010 World Expo in Shanghai, China.

The kimono (着物) is a Japanese traditional garment (for 着= ‘pull on’ and 物 = ’thing’) worn by women, men and children ‘in the old days’. Today a kimono it is worn on special occasions.

The material for the kimonos worn by the staff at the Shanghai Expo Murasaki restaurant was produced in collaboration with the city of Kyotango, home of traditional Tango silk crepe, or chirimen, which is known for its unique water ripple-like texture.

Using special techniques developed by Kyotango artisans, Teijin‘s advanced eco-friendly Biofront fibers were interwoven with silk fibers to produce a new material that retains the beautiful texture and sheen of Tango silk crepe.

Kimono silk crepe fabric using Biofront PLA (photo: Teijin)

Silk Crepe Kimonos made with PLA Fibers Teijin‘s Eco-friendly BIOFRONT bioplastic worn by Japanese restaurant staff at Japan Industry Pavilion, Shanghai EXPO

Kimonos worn at the Shanghai Expo Murasaki Restaurant (photo: Kikkoman) 12

bioplastics MAGAZINE [05/10] Vol. 5

Under the ‘Tango Biofabrics’ project launched last year, Teijin has been working with the city of Kyotango to develop new, ecofriendly applications for Biofront, by combining its advanced PLA fibers with Kyotango‘s traditional silk craftsmanship.

Biofront, an environmentally friendly bioplastic (PLA) produced from plant-based feedstock, is superior to conventional bioplastics in terms of both heat resistance and durability. Its melting point of 210°C is significantly higher than the 170°C melting point of conventional PLA, which allows Biofront to withstand ironing. Other Biofront products can endure hightemperature processing, such as fabric dyeing and plastic molding.

The Teijin Group also organized its own exhibit in the Japan Industrial Pavilion of the 2010 World Expo, aiming to further promote brand awareness in China, where Teijin has been operating since 1970s, as well as worldwide. MT www.teijin.co.jp/english

Photos: Philipp Thielen

Fibers | Textiles Proganic filaments

New Filaments for Brushes

T

he bio-plastic PROGANIC®, award winner of the first prize for Innovation for Bio based Material and application of the Year by the nova institute, has now reached full market maturity and can definitely replace nearly all conventional plastic products. The new material is now making great headway with diversification into filaments and fibers.

Furthermore, the fact that Proganic is now temperature stable to 90°C (HDT/B) without any unnatural additives makes the spectrum of possible applications nearly infinite. As countless are the tests that are currently ongoing with a number of global brands as well as one of the worlds leading food packaging suppliers. “It is our aim to diversify the compound Proganic and make it suitable for as many practical applications as possible. Since we have perfected form stability and the process for injection moulding we are well equipped to conquer most of the plastic dominated markets,” states CEO Oliver Schmid.

Article contributed by Daniel Ridge Proganic GmbH Rain am Lech, Germany www.proganic.de

The compound has been successfully extruded into filaments of 42 µm for use in lavatory brushes, 35 µm for dishwashing brushes and 20 µm for brooms and dustpan brushes. The rigidity of the filament makes them exceptionally durable and effective in all brush applications. The 20 µm filaments have treated by a sort of spiralling in order to increase their volume.

This allows for better dust pick up and a fuller looking brush.

The process of extrusion was undertaken by Hahl Gmbh, a division of Lenzing Plastics, extruders of synthetic filaments for the brush and technical textile industries. Hahl initially extruded filaments of 40, 80 and 120 µm. The rigidity and the strength show that the filaments are ideal for brushes where these characteristics are of importance.

A leading brush manufacturer in Europe has now successfully inserted the 40 micron filaments into a series of newly designed brushes where all of the plastic elements have been replaced with Proganic. The new series of brushes will be launched in September/October 2010.

Toothbrush prototype

The plan to launch the first Proganic toothbrush is also under way; however the rigidity of the filaments in this case is proving to be a drawback. The conventional plastic filaments in toothbrushes have a higher elasticity and this must replicated with the natural compound so that the brush filaments return to a vertical position. Toothbrushes are required to undergo the same rigorous testing as any food safe product so it maybe sometime in development before they are launched.

bioplastics MAGAZINE [05/10] Vol. 5

13

Fibers | Textiles

PA11 Fibres and Polyether Block Amide Nonwovens Bag made from Rilsan PA11 fibres

A

special grade of Rilsan® Arkema’s 100% bio-sourced technical polymer PA11 can be applied to spin high performance fibres. These technical fibres combine a unique set of characteristics: light weight, soft touch, bacteriostatic properties, and wear resistance.

With its long-standing experience over more than 60 years, Arkema today is the world leader in castor oil chemistry, which produces Rilsan PA11, the first high performance polyamide entirely derived from a 100% renewable and ecological raw material.

In addition to its renewable source, Rilsan PA11 production is characterized by 15% (average) lower fossil energy requirements than for petroleum-based nylon polyamides1.

The CO2 missions related to the production of Rilsan PA11 are on average 75% lower1 On the strength of its expertise, Arkema continues its development work on its bio-sourced polyamide in order to target new markets in which ecological challenges and a quest for technical performance have become a genuine concern as well as a differentiating factor.

Mindful of these expectations, Arkema has developed a specific PA11 grade that can be extruded into fibres. The most advanced textile applications using these fibres may currently be found in the footwear, clothing and luggage markets.

Arkema plans to extend the development to other textile applications requiring both optimum technical performance and a vegetable origin.

Rilsan PA11 fibres feature key characteristics such as pleasant touch, dimensional stability, bacteriostatic activity without the need for a specific treatment, and outstanding resistance to wear and abrasion.

14

bioplastics MAGAZINE [05/10] Vol. 5

The French company SOFILA and the Japanese company UNITIKA FIBRES offer innovative textile products based on Rilsan PA11, combining both the environmental and the technical benefits, for the footwear, clothing and luggage markets.

Another innovation from Arkema promises to open up revolutionary opportunities for the design of durable elastomer nonwovens for superior performance, lighter weight, and ease of assembly.

Arkema’s high elongation and high energy recovery polyether block amide Pebax® nonwoven material is produced with the meltblown process. As a meltblown web, Pebax and Pebax Rnew (with its 20 to 90% renewable carbon content) can be used to make roll goods with a large width which are then cut into narrow widths. These nonwovens are suitable replacements for many narrow elastic and spandexcontaining woven or knit textiles. As potential waistband for example, 200 g/m² Pebax webs afford total recovery when stretched 100% repeatedly, and elongation at break of up of 600%. They also have excellent hot-wash and dryclean resistance.

Melt spinning of nonwovens is a rapidly growing process, and is a simple and inexpensive approach to convert polymer directly into roll goods.

Both Rilsan PA11 textiles as well as Pebax Rnew will be shown at K’2010 (see separate article). MT www.arkema.com 1: Source of data for the petroleum-based nylon polyamides: Plastics Europe

Fibers | Textiles

Sustainable Fabrics Can be ‘NICE’

C

.L.A.S.S. ( C re a t i v i t y Lifestyle And Sustainable Synergy) demonstrated that eco-friendly fabrics are innovative, sustainable, and fashionable at the NICE (Nordic Initiative Clean and Ethical) Fashion Summit, which took place last December in Copenhagen in conjunction with the United Nations Conference on Climate Change.

Article: Velo Composition: 100% Ingeo PLA Mill: BOSELLI E. & C. SPA David Andersen

The event was a pioneering initiative spearheaded by the Nordic Fashion Association (NFA) to help raise awareness about sustainability within the fashion industry. C.L.A.S.S was appointed the official supplier of all the eco-responsible textiles at the event.

In a bid to show key fashion industry decision makers that textiles can be both aesthetically appealing and sustainably produced, C.L.A.S.S. provided more than 20 leading Nordic designers from Denmark, Finland, Sweden, Iceland, and Norway with a range of fabrics that were incorporated into 40 garments. The selection of fabrics included a range of innovative renewable fabrics, recycled and repurposed textiles, and organic and natural fabrics.

Article: Ecomais Composition: 100% Ingeo PLA Mill: FRIZZA SPA Aan Hernández

The winner of the design competition was Saara Lepokorpi from Finland. The winning two-piece outfit featured a 100 percent Ingeo™ fiber by Fama Jersey Spa, as well as new milk/wool/viscose and viscose/silk blends by Olimpias (Piobesi). Ingeo, a biopolymer manufactured by NatureWorks, is made from renewable plant material, not oil.

“The fashion industry must be commended on its willingness to push the boundaries of design by incorporating fabrics that not only provide comfort and performance, but also offer options for lowering the carbon footprint of textiles and fibers,” said Eamonn Tighe, NatureWorks business development manager, Europe.

“Importantly, the fashion industry’s work is spurring designers in many different fields to adopt synthetics made from renewable resources.”

Article: Maspun 1007030 RPLA Composition: 100% Ingeo PLA Mill: FA-MA JERSEY SPA Maxjenny

Other notable dresses at the fashion summit that used Ingeo textile included those shown in the pictures. www.c-l-a-s-s.org

16

bioplastics MAGAZINE [05/10] Vol. 5

All photos courtesy of Danish Fashion Institute.

Fibers | Textiles

Innovative Floor Covering

P

ietra, from Tandus (Dalton, Georgia, USA), is the first commercial modular carpet made with Ingeo™ biopolymer in an innovative core and sheath fiber system. Utilizing the first 100% recycled content backing, Pietra contains 4559% recycled content and 10% post consumer content by total product weight. Pietra is 100% closed loop recyclable and warranted for 15 years in a commercial application.

Pietra was chosen as the first Tandus style utilizing Ingeo fibers because of Ingeo’s performance, carbon footprint, and design versatility. Travertine, one of the most frequently used stone floorings in modern architecture, influenced Pietra’s color and texture. Pietra embodies travertine’s characteristic, naturally occurring cavities and ‘troughs’, which express qualities of warmth and craftsmanship.

Packed with grays, earth neutrals, saturated blues, greens, corals, and rusts, Pietra complements any space and helps to reduce the carbon footprint of the organization purchasing it. Ingeo biopolymer is manufactured by NatureWorks. www.tandus.com

‘Obama’ dress by Gattinoni

Black dress made from Ingeo PLA fibers

Loving Both High Fashion and Nature

G

uillermo Mariotto, the artistic director of noted Italian fashion house Maison Gattinoni, has a passion for finding the balance between humans and nature. Mariotto said, “I chose the environment and nature over a fashion that is increasingly aware of business and not particularly oriented towards the future.” Mariotto has been exploring the potential of Ingeo™ PLA fiber for high fashion. Ingeo manufactured by NatureWorks, is a polymer made from renewable plant material, not oil.

A stunning dress made from 100% Ingeo fabric highlighted the Maison Gattinoni’s January 2010 fashion show. A manufacturing process that includes calendaring is responsible for the bright finish and silky soft texture of the dress. Creativity Lifestyle And Sustainable Synergy (C.L.A.S.S), Lei-Tsu, and Boselli E. and C. Spa collaborated on the development of the fabric.

Another product created by Mariotto is a caftan out of Ingeo fiber.

The dress is the designer’s tribute to U.S. President Barak Obama.

The president’s face is hand painted on the material. www.gattinoni.net

bioplastics MAGAZINE [05/10] Vol. 5

17

Fibers | Textiles

www.fashionhelmet.eu

The Zero Impact Collection

T

he excellence of Italian craftsmanship and design is recognized across the world.

Italian designer Riccardo Rizieri Broglia took on a very personal project. Broglia wanted to create a line of shoes that embodied all of the qualities of handmade goods with an exceptionally low carbon footprint. Calling his new line ‘Zero Imact’, the designer utilized calendered Ingeo™ fiber. Ingeo was chosen because it combines all of the delicacy of silk to the touch, is versatile, performs well, and is made with renewable plant material. Broglia believes this collection reveals a balance between glamour and innovative materials that is as rare in today’s fashion industry. Ingeo biopolymer is manufactured by NatureWorks. www.rizieri.net

18

bioplastics MAGAZINE [05/10] Vol. 5

Fashion Helmet

T

ake a product that has traditionally been sold as a safety necessity and then build a successful business by transforming that product into a fashion statement. The products in question are motorcycle, motor scooter, ski, and bicycle helmets. The company seizing an opportunity is Italy’s Fashion Helmet.

Fashion Helmet was formed in 2004 by people with more than 20 years of related experience in fashion research and design. The company’s helmets are hand-crafted and fully compliant with the highest European safety standards. But it’s what’s on the outside that captures attention, not only from wearers but from passers by.

The traditional hard outer shell comes in a host of vibrant colors and designs — some classical, others stunningly modern, all eye catching.

Recently the company offered a new ‘capsule’ collection of helmet covers. The collection features Ingeo™ calendered cloth fashion covers, as well as covers made with vegetable dyed and tanned leather. Both fabric and leather covers are made by Conceria Tre Effe in Italy. Ingeo cloth is a manufactured fiber from NatureWorks and is made from renewable plant material, not oil.

The company features Ingeo fabric covers because Ingeo matches the company’s vision to have customers “wear something truly out of the ordinary.”

Report Photovoltaic Panel

www.polymer-pilotplants.com www.iwmh.fraunhofer.de

Optimized Processing of Natural Materials in Pilot Scale

T

he Fraunhofer Pilot Plant Centre for Polymer Synthesis and Processing (PAZ) in Schkopau, Germany, is a joint initiative of the Fraunhofer Institutes for Applied Polymer Research (IAP) and Mechanics of Materials (IWM) in Halle. Working together with companies from all over the world tailor-made complete solutions in pilot scale are developed from monomers by way of synthesis and polymers are used to produce finished and tested components.

In the processing area the development of materials and processes such as compounding and extrusion using, for example, natural fibres such as wood, flax, sisal or hemp for filling and reinforcement functions are carried out on different industrial scale twin screw extruders. Custom-designed, highly filled, natural fibre compounds and components produced from them can be made - for example to increase material strength, stiffness and impact strength. Samples of such compounds in pellet form can be produced for test purposes in quantities up to a tonne or more.

Optimising of the mechanical properties of wood/plastic composites (WPC) for injection moulding is a core competence of the Pilot Plant Centre. Typically WPC materials have a high strength and stiffness but they are also very brittle in regard to impact stress. For instance it has been possible, by the addition of further innovative fibres in small amounts, to increase the impact strength of materials with a wood fraction of 40% by more than 130%, compared to a ‘standard WPC’ at room temperature. At a temperature of -25°C the improvement was even more than 160%.

Model system of a polymer based photovoltaic module For injection moulding processes an injection moulding machine is available with a clamping force of 200 tonnes, or alternatively two innovative injection moulding compounders (compounding and injection moulding in one process step) with clamping forces of 1300 and 3200 tonnes. Components with shot weights of 50 up to 9000 grams can be produced. In addition, to optimise the processing conditions and mechanical properties of natural fibre composites, a further field of research covers biopolymers such as PLA. A focus on polyurethane processing (clear coat moulding technology and the manufacture of highly transparent, thin surfaces) is new at the Pilot Plant Centre. The aliphatic materials being investigated offer a wide spectrum of adjustable mechanical properties and represent a special field in the processing of polyurethanes. Particularly in regard to photovoltaic applications the use of bio-based polyurethane is also being investigated. These materials, consisting of a polyol derived from renewable vegetable oils, can help to reduce the amount of fossil fuel based polyurethane products and improve the environmental profile of these materials over the whole life cycle. The current investigations address the processing parameters as well as the resulting properties, e.g. the heat and weather stability.

The Fraunhofer Pilot Plant Centre is available to support the industry, e.g. by producing sample lots and pre-series in pilot scale up to the point of introduction onto the market, as well as for mould and material testing, for example complex testing of material and component properties.

20

bioplastics MAGAZINE [05/10] Vol. 5

Materials

Extract from Cashew Nut Shell for Electronic Equipment

T

he Japanese NEC corporation, with more than 100 years expertise in technological innovation, is newly emphasizing its responsibility and position as a leader in the integration of IT and network technologies that benefit businesses and people all over the world.

During the 2013 fiscal year NEC is aiming to realize mass production of a completely new and significantly different bioplastic, suitable for a wide range of electronic equipment.

The new component is primarily based on cellulose to be combined with cardanol - and both of the feedstocks are derived from agricultural scrap. Thus NEC will proudly and effectively side-step the discussion regarding whether to use plant material as animal feed, human foodstuffs or fuel, by using plant stems and cashew nut shells as basic resources whilst avoiding CNSL (cashew nut shell liquid) which is otherwise a dangerous pollutant.

The new composite will have a plant composition ratio of more than 70% as well as outstanding physical properties such as durability in strength and malleability twice that of conventional PLA and comparable to CA. The heat resistance is more than twice as high as PLA (1.3 times higher than CA) and water resistance is absolutely on a par with PLA and 3 times more than CA. The moulding time of this revolutionary new and noncrystalline bioplastic can be compared to conventional cellulose or petroleum-based plastics and is less than 50% of PLA. CJ www.nec.com

Anzeige_105x148_BIB:2011-hoch

21.07.2010

12:41 Uhr

Seite 1

www.bio-based.de

iBIB2011

International Business Directory for Innovative Bio-based Plastics and Composites

In spring 2011, iBIB2011, the first ever international directory of major suppliers of bio-based plastics and composites, will be published as a means of opening up a range of new customers to companies in the bio-materials sector.

The aim of iBIB2011 is to put industrial suppliers and customers in contact with each other. Two major characteristics of new markets such as bio-based plastics and composites are ‘insider knowledge’ and a lack of transparency, which prevent the sector from developing as quickly as it might. The iBIB2011 will help firms to find the best biobased solutions available worldwide. iBIB2011: 250 pages • 100 companies, associations, R&D • 20 countries Book your page(s) now at: www.bio-based.de

Contact: Dominik Vogt, Phone: +49 (0)2233 4814 – 49 dominik.vogt@nova-institut.de

Publisher

21 MAGAZINE Vol. Huerth 5 nova-Institut GmbH | Chemiepark Knapsack bioplastics | Industriestrasse 300 [05/10] | D-50354

Application News

Eco-Packaging for Salads Quality and environmental sustainability: these are the key elements of the non-GMO biodegradable and compostable Mater-Bi® packaging for salads, the result of the collaboration between the Italian companies Novamont and Ecor. The experimental project is an absolute first in Italy and the first in Europe to be used for ready-to-serve salad produce of the IV range with Demeter certification, attesting to its biodynamic farming origins.

The idea behind the experimental project was to find packaging for the IV range of products (fruit and vegetables ready for consumption) which, besides being suitable to preserve fresh produce and give it a longer shelf-life, is also sustainable, i.e. it limits the environmental impact of the materials used. Added value which becomes a matter of consistency in the case of biological and biodynamic products, which are products obtained by farming that respects the natural rhythms, increases the humus in the soil and gives man a product with high organoleptic and nutritional properties.

Thus the convergence between Ecor, Novamont and biodynamic agricultural company Filogea means that a market sector in constant growth such as that of pre-washed packaged salads can now offer consumers a 100% compostable pack, the nonGMO components of which (coated cardboard and film) are fully compostable. Consumers who choose the biodynamic ready-to-serve salads produced by Filogea in stores specialising in biological products do not need to be concerned about how to dispose of the pack. Besides using renewable resources and ensuring the optimal conservation of the product, the innovative packaging consisting of cartonboard ‘spread’ with Mater-Bi and packaged with MaterBi film can be thrown away along with the kitchen waste.

www.novamont.com www.ecor.it

Luxury Perfume Packaging What do Britney Spears and Clarifoil have in common? The answer is quite simple: they both know that beautiful packaging is vitally important. Clarifoil is delighted that its’ cellulose film has been selected for Britney Spears recently re-packaged perfume Curious.

Marion Bauer, Marketing Manager, Clarifoil: “The luxury market of perfume has high expectations from its packaging and consistently Clarifoil is able to deliver with materials that are more environmentally friendly, yet give that exceptional finish.”

Clarifoil is the world’s leading producer of innovative cellulose acetate films used for labels, carton windows and print lamination. www.clarifoil.com

New Bio-Based Twist Film for Europe (BUSINESS WIRE) Breakthrough Technology Offers Twist Films Made from 100% Biodegradable/Compostable Material Cereplast, Inc. El Segundo, California, USA, recently announced that it has partnered with Sezersan Ambalaj (Sezersan), a subsidiary of Aşcı Group in Turkey, to produce bio twist films made from Cereplast Compostables® resins. The first-of-itskind, patented product will serve as wrap packaging for a variety of food products distributed throughout Europe.

The Sezersan bio twist film will be manufactured using Cereplast Compostables 7003 bio resin, designed to provide high strength, toughness and process ability for products. Under the terms of the multi-million dollar agreement, Cereplast will begin monthly shipments of 100 to 150 tonnes of bio resin in December 2010.

The new bio twist film has substantial form memory capability (dead-fold behavior) and is heat sealable. The film is also thinner than other twistable product and may be made into opaque or s e m i - t r a n s p a re n t , film-like material.

The bio twist film will be used as packaging for a variety of brands in the food industry in Europe. www.cereplast.com www.sezersan.com.tr

22

bioplastics MAGAZINE [05/10] Vol. 5

Applications

PLA cups for AVIANCA airline

P

hoenix Packaging Group (PPG) is one of the most important packaging manufacturing conglomerates in Latin America with sales in more than 30 countries in the Americas. And as a leader in innovation the Phoenix Packaging Group is very proud to have presented the world‘s first Ingeo™ PLA cup for an airline.

The Colombian airline Avianca for their part is a company very active with regard to environmental awareness, so it was only a question of time before these two came together to their mutual benefit - but more about this later.

Biowaste mixed with ground cup flakes

“Avianca is closing the life cycle - a matter they are very concerned about - by using thermoplastic PLA cups with an eye on LCIA“, Giovanna Cruz Nieto, Business Project Leader of Phoenix Packaging Group said to bioplastics MAGAZINE. The airline uses the thermoformed PLA cups during national and international flights, to treat the environment with maximum respect. After use the cups are collected for composting at a composting facility that belongs to the Colombian Environmental Control Center (Control Ambiental de Colombia). This company also composts materials such as market and flower waste and industrial ‘bio‘-residues as well as food waste.

So, during/after a flight, when any waste is collected, the PLA cups are separated. Due to legislation, for international flights leaving Bogotá the complete waste is incinerated at the respective destination. But for all domestic flights and for those arriving in Bogotá, all PLA cups are composted, which takes between 6 and 12 weeks. Actually, the cups are ground into small flakes and mixed with other compostable bio-waste. But even complete cups can be composted very well and actually test runs are being perfumed at the moment to verify this.

Left: before drinking - right: after collecting

Always busy and ‘go-ahead’, PPG was approached by NatureWorks in 2005 and did not hesitate to start trials with Ingeo immediately. Finally, in 2009, Phoenix Packaging offered their developments to Avianca, duly aware of their environmental consciousness and already being their supplier for other packages at that time.

Avianca presented this fascinating opportunity to their president in February 2009. “And so, hand in hand with Avianca and in close cooperation with the Environmental Control Center we came to the point that we have reached today” Giovanna Cruz Nieto admitted, not only proud of this business in general, but primarily of the great environmental impact. This PPG initiative is really different, because this is the first closed life cycle with post consumer residues.

Ground cup flakes are mixed with biowaste

www.grupophoenix.com www.avianca.com

Avianca thus can be named as the first and pioneer enterprise in introducing and permanently using PLA cups, along with KLM who started to use PLA coated paper cups in June 2009 - mainly for hot beverages - and ANA in Japan, who carried out a project with PLA cups within the framework of their ‘e-flight‘ campaign in 2009.

Encouraged by the success enjoted by Avianca‘s PLA cup, Phoenix Packaging Group looked into other Ingeo products and thus launched the “We serve the planet” GeoPack® line earlier this year. With factories in Colombia, Venezuela and Mexico they will open another new plant in Virginia (USA) this coming September. - CJ/MT

bioplastics MAGAZINE [05/10] Vol. 5

23

Applications

High Performance Composite Panels from Renewable, Bio-based Polymers Article contributed by Tomasz Czarnecki Technical Marketing Manager François de Bie Head of Sales and Marketing EconCore NV, Leuven, Belgium

E

conCore is proud to present the first 100% bio-based composite panel. Recently EconCore has optimized the patented ThermHex production technology to produce honeycomb cores and sandwich panels made from biobased plastics.

“Today, the exploitation of the economical advantages of weight reduction has become essential for many industries”, says François de Bie, EconCore head of sales and marketing.

“Bio-based polymer materials are still relatively expensive compared to for example polypropylene (PP) alternatives what has limited the use of these materials in structural applications. Bio-based sandwich panels can be used in for example re-usable packaging, furniture, automotive interiors, separation walls or agricultural applications.”

EconCore provides cutting edge production technology that enables its customers to produce cores and sandwich panels at optimal performance and lowest cost.

www.econcore.com

Figure 1: honey comb cores and panels made from renewable resources

EconCore’s patented ThermHex technology allows for costefficient production of hexagonal honeycomb cores from a range of thermoplastic polymers like for example PP, PE, PET, PVC, ABS, PC, PPS, PEI, PLA and many others.

Thermoplastic skins of the above mentioned thermoplastic polymers can be added in a second step in the production line to form mono-material sandwich panels, but also glass or carbon fiber composite, CPL, non-woven, aluminum or steel skins are possible. Another example includes polypropylene honeycomb faced by wood-flour / polypropylene composite.

This sandwich panel concept, where high modulus but lightweight and inexpensive skins are laminated on the honeycomb, exhibits outstanding mechanical performance level while the solution is fully recyclable and eco-friendly. To show the benefit, such 20 mm sandwich panel whereby the skins are only 1 mm thick has bending stiffness equivalent to that of solid polypropylene at more than 14 mm thickness or to almost 3 mm thick steel sheet and this at total weight of less than 4 kg per square meter…

By combining its innovative production technology with renewable materials, EconCore is able to present a sandwich panel that has excellent mechanical properties, while still being cost competitive to traditional sheet materials.

24

bioplastics MAGAZINE [05/10] Vol. 5

Figure 2: Hexagonal Honeycomb core.

The last six months EconCore has optimized its technology for continuous production to produce PLA (Poly-Lactic Acid) based hexagonal honeycomb cores. Only moments after the core is produced skin layers are added in a second step of the continuous production process. These skins can be made of unfilled PLA material to make a mono material panel or, in case a higher performance is required, they can be replaced with a composite version of e.g. natural fiber reinforced PLA. The ‘optical’ advantage of the 100% PLA honeycomb sandwich panel over the composite one will be its level of transparency and light transmission, surely attracting the designer’s eye!

To give an example of efficiency of sandwich panels, a 100% based PLA ThermHex panel at a thickness of 20 mm has equivalent bending stiffness to that of 12 mm thick solid PLA sheet or chipboard, as shown in table 1. Same rigidity is offered by a 10 mm thick plywood panel, known very well for its outstanding mechanical performance, but unfortunately also for its relatively high cost. Looking at weight of the PLA ThermHex, it is 4 times less compared to its monolithic sister.

The solid wood-based products, used in large volumes in the furniture and construction market segments, appear to be ‘solid’ also in regard to their weight as they are up to factor of 2 – 3 heavier than the honeycomb board.

The EconCore technologies for automated continuous production of honeycombs are protected by granted patents.

The company has sold a number of licenses to well established partners who have successfully introduced panels using the EconCore patents. The application list started with reusable packaging but started to grow fast after the first licensee was installed with its first ThermHex line. Players in the market

Total panel thickness (mm)

segments of automotive, B&C or furniture appeared to be very attracted by the idea of cost and weight savings.

In general EconCore supports licensees in their application development and integration of EconCore technologies into existing production lines. The company offers engineering services to select and optimize core-skin material combinations providing maximal mechanical performance at an optimal compromise between material cost, production cost and weight saving. “This know-how, combined with the cutting edge ThermHex technology, allows to maximize cost saving potential of our customers” says Tomasz Czarnecki, Technical Marketing Manager at EconCore.

Besides for more traditional polymers EconCore has recently received a lot of interest from companies that would like to use bio-based skin materials like natural fiber filled PP or PLA and natural fiber based non wovens. These skin materials in combination with renewable core materials would fit in a range of market segments like automotive, building & construction, furniture, sign & display and packaging market segments.

“We are currently looking for partners that would be interested in bringing these PLA panels to the market”, says François. “The other possibility would be where EconCore takes ownership of producing the panels and selling these to a distributor company that has access to the different markets where these panels could be used.”

At K’2010 EconCore is present at the booth of ThermHex Waben GmbH (Hall 08b Stand D79)

100% PLA ThermHex sandwich panel (0.8 mm skins / 90kg/m³ core)

Solid PLA panel

Chipboard

Plywood

20

12.1

12.4

9.8

Relative bending stiffness

1

1

1

1

Total panel weight (kg/m²)

3.7

15.1

9.9

5.9

Table 1: Weight saving potential of PLA ThermHex sandwich panel, compared to solid PLA panel and traditional wood-based materials

bioplastics MAGAZINE [05/10] Vol. 5

25

Bioplastics Award

Shortlist bioplastics MAGAZINE and European Plastics News have decided to team up and jointly present the 5th Bioplastics Award.

After having received in excess of 20 submissions for the Bioplastics Award 2010 the judging panel have reviewed them all and now publishes details of the five most promising proposals.

The 5th Bioplastics Awards recognises innovation, success and achievement by manufacturers, processors and users of bioplastic materials. There are no separate categories as previously. To be eligible for consideration in the awards the proposed company, product, or service must have been developed or been on the market during 2009 or 2010.

The following companies/products are shortlisted (without any ranking) and from these the winner will be announced during the 5th European Bioplastics Conference on December 1st, 2010 in Düsseldorf Germany:

EconCore – PLA Honeycomb Sandwich Structure Over the last 6 months EconCore has optimized the production technology to produce PLA based hexagonal honeycomb cores using a continuous production process. Only moments after the core is produced skin layers are added in a second step of the continuous production process. These skins could be made from unfilled PLA material to make a mono material panel or, in case a higher performance is required, could be replaced with consolidated flax in a PLA matrix.

Key advantages:  Made from renewable, biobased polymers  Increased performance at reduced weight  Reduced production cost versus traditional panels and materials  Excellent strength and stiffness  Good impact resistance The PLA honeycomb sandwich structure is 100% renewable, minimizes the use of PLA and is hence also price competitive with (much heavier) products made from traditional plastics.

Toyota - The Application of Bioplastics for the New Luxury Hybrid Car ‘SAI‘ The Toyota Passenger Vehicle Development Center 2 of Toyota Motors Corporation has been very active in the area of bioplastics development since 2003, thus being one of the world‘s pioneers. The success of the bioplastics applications in the new luxury Hybrid Car, the ‘SAI‘, is an outstanding example not only for the wide variety of the material utilization but also the wide range of the application area.

Parts of Biomassbased plastics Scuff Plate, Cowl Sidetrim, Finish Plate Tool Box Ceiling, Front Pillar, Center Pillar Roofside trim, Sunvisor Baggage Trim, baggage Sidetrim baggage Doortrim, baggage Floormat

26

bioplastics MAGAZINE [05/10] Vol. 5

Materials Biomass-based Petroleumbased

Technology

PolyLactide (PLA)

Polypropylene (PP)

Compatibilized Compound

Biomass-based Polyester

Polyethylene Terephthalate

Conjugated Fiber

PolyLactide (PLA)

Polyethylene Terephthalate

Composit Fiber

Door Trim

PolyLactide (PLA) /Kenaf

Seat Cushon

Caster Oil based Polyol

Composit Product Polyol / Isocyanate

Polyurethane

Bioplastics Award

Proganic: A New Material for Injection Moulding of High Quality Products Proganic is a bio-polymer based on PHA (Polyhydroxyalkanoates), as well as a combination of renewable vegetable oils, waxes and natural minerals which provide sealing and water resistance. It can be used as a replacement for a variety of thermoplastics including PP and ABS. Technically it is most comparable to ABS plastic.

Proganic is tested for the ‘ultimate aerobic biodegradability of plastic materials in an aqueous medium‘ according to ISO 14851 (by measuring the oxygen demand) and ISO 14852 (by analysis of evolved carbon dioxide). It is home compostable in both open and closed composters at 20°C. It conforms to the European Norm EN 71, Articles 3 and 9 (toys) and it also conforms to the requirements of the American Food and Drug Administration (FDA) for use in the food and beverage industry. Proganic products currently available directly from Propper include watering cans, flower pots, self adhesive hooks, egg cups and spoons, strainers.

ICO: ‘Green Planet’ Environmentally Friendly Writing Instruments and Office Supplies A variety of products are made from the biodegradable material PLA, derived from corn starch, such as bio-degradable pens, paperclip holder, letter opener, stapler, perforator and pen stands.

These products decompose in environments with a high humidity (50-70%), high temperature (60-80°C), microorganisms and oxygen.

Furthermore, there are also recycled paper products in this range, such as the paper pen and various folders for filing, best illustrated in the attachment.

ICO Stationery Manufacturing JSC has developed a unique product range among the green product manufacturers. Not only does ICO make ballpoint pens from bio-material – of which there is already a great variety on the market - but they offer a full range including desk accessories such as pen stands, staplers, perforators and folders. Catalogues and leaflets are issued on a regular basis to promote these environmentally friendly products.

FKuR / Fujitsu: Eco Keyboard Fujitsu KBPC PX ECO Fujitsu Technology Solutions is the leading IT infrastructure provider in Europe. In order to provide respective consumer electronics solutions to the ecologically-aware consumer, the Eco keyboard KBPC PX ECO was developed using the materials from FKuR Kunststoff GmbH. 45% of the plastics components used in this keyboard were replaced by materials made from renewable resources. For the keyboard base Biograde® C 7500 CL was chosen. Parts made from Biograde meet the special requirements for keyboards and in some cases even exceed the properties of oil-based plastics.

This new Eco-Keyboard underlines Fujitsu’s Green IT commitment to saving CO2 emissions, and represents a further innovation for Green IT.

bioplastics MAGAZINE [05/10] Vol. 5

27

Materials

New Biomaterial

B

IOTEC Biologische Naturverpackungen GmbH & Co. KG located in Emmerich, Germany, have added a new material with the brand name BIOPLAST 200 to their product portfolio of biological natural packaging.

This is a completely new thermoplastic material which is 100% biodegradable and does not contain any plasticizer. This new starch-based plastic material is particularly suitable for blown film, sheet film and profile extrusion, thus also for injection moulding. Unlike thermoplastic starch (TPS), no plasticizers are added to the potato starch which is used in its original native condition. This and the consistent abdication of raw materials stemming from genetically modified organisms (GMO) result in a material with features fully in line with the increasing expectations of consumers and end users. Bioplast 200 is registered as a biodegradable material with Vinçotte (No. O 10-406-A) acc. to EN 13432.

Depending on their thickness, products made from Bioplast 200 are therefore also compostable. Of course Bioplast 200 can also be disposed of in a conventional way, e. g. in waste incineration plants. Due to the high share of applied renewable, bio-based raw materials of more than 40% the incineration of Bioplast 200 generates by far less CO2 than that of conventional, completely petroleum-based products. Compared with polyethylene (PE), more than 50% of climate relevant CO2 emissions are saved during the incineration of the material. The product can be used without any pre-treatment for flexographic and offset-printing. Its resistance to oils, greases and water offers a large variety of applications.

Depending on the duration and the kind of application, Bioplast 200 can also be used in contact with food. All raw materials used are listed in the European Directive 2002/72/EC. Its lack of odour is a result of the use of potato starch instead of corn starch.

Since 1992, BIOTEC Biologische Natur-verpackungen has been developing thermoplastic materials under the brand name Bioplast which are based on natural raw materials. Initially designed as a development unit, the company is one of the world’s leading manufacturers of bio-compounds and blends. BIOTEC belongs to the SPhere Group (France) and to BIOME Technologies plc (UK), two of the most important companies that manufacture, develop and distribute innovative Biomaterials.

28

bioplastics MAGAZINE [05/10] Vol. 5

www.biotec.de

5

th

Make it green !

SaVe tHe Date !

1/2 December, 2010 Hilton D端sseldorf

www.conference.european-bioplastics.org

Conference contact: conference@european-bioplastics.org Phone: +49 30 28 48 23 50

K‘2010 Preview

Show Preview K’2010 - Oct. 27 - Nov. 03, 2010

A

t K‘2010, the world’s biggest trade fair for plastics and rubber, opening its doors from 27 October to 03 November in Düsseldorf, Germany, about 3,100 companies will showcase their latest developments for all industry segments. Among them more than 60 companies that present their products and services in the field of bioplastics. In this K-show preview bioplastics MAGAZINE gives an overview of what visitors can expect in terms of bioplastics. For better orientation see floor plan on pages 34-35.

Biosourced Plastics in the Limelight Arkema: Biosourced plastics (as per Arkema’s definition plastics with over 20% of non-fossil carbon) already account for 30% of Arkema’s technical polymer business and call upon around two thirds of their R&D capability. These polymers offer the same properties as their oil-sourced counterparts, and even outperforming them. By exhibiting finished components and prototypes made from these materials, Arkema will showcase their biosourced polymers, and in particular: Rilsan® 11 (polyamide processed entirely from castor oil), Pebax® Rnew (up to 90% biosourced elastomer), Rilsan Clear Rnew (transparent polyamide made from 54% renewable raw materials). Rilsan HT (high temperature polymer derived from castor oil for engine-compartment automotive applications). The first office chairs designed by Japan’s n°2 furniture maker will be unveiled for preview - their main components and textiles are made from Rilsan PA11 and Pebax Rnew - as will objects made of Rilsan and Pebax Rnew developed with the Japanese company Sanko Lite, specialised in the use of Urushi natural lacquer.

SCARPA Ski boots FLASH PRO in PEBAX® Rnew

www.arkema.com 06C57

Sustainable Compounding of Biodegradable Materials Coperion/Cabopol: The first compounding plant for biodegradable plastics in Portugal underlines the expertise of the German Coperion GmbH in biodegradable material processing systems. The extrusion line went into trial operation in January 2010 with the Portuguese compounding company Cabopol, S. A. Cabopol is now the first manufacturer of biodegradable polymers on the Iberian Peninsula. Both companies are exhibitors at K’2010.

Biodegradable compounds based on compostable polyesters, with and without starch, are being manufactured.The processing system includes materials handling for all raw materials – i.e. storage, conveying, weighing and dosing – as well as compounding with downstream pelletizing and drying. The processing extruder, a ZSK MEGAcompounder PLUS, has a ZS-B twin screw side feeder and a venting unit. The die discharges into a water bath for strand cooling followed by suction drying of the strand surface prior to strand pelletizing.

Cabopol procured a ZSK 26 MEGAcompounder laboratory extruder especially for this project and during the optimization of the screw geometry and process technology was able to make use of know-how from Coperion. It is the formulations that include starch which represent a particular challenge: The melt zone in the compounding extruder has to not only melt the polymer, but also plastify the non-melting starch by adding liquid. www.coperion.com www.cabopol.com Coperion 14B33/ Cabopol 8bG45

30

bioplastics MAGAZINE [05/10] Vol. 5

K‘2010 Preview

A New Leader in Biopolymers Production

NATIVIA the first melt (Courtesy Taghleef Industries)

BOPLA Film Production Brückner Maschinenbau from Siegsdorf, Germany offers concepts for new lines or the modification of existing lines, such as:  Special raw material handling systems for the hygroscopic material PLA  A specially adapted extruder screw design for PLA ensuring gentle plastification  Special adaptation of all melt leading components ensuring gentle handling of the acidic PLA  A temperature control system specially adapted and aligned for PLA for machine and transverse stretching of the material given the fact that PLA must be stretched with considerably lower temperatures than other polymers

Braskem: Having presented its landmark project of building the first plant to produce green ethylene from sugar cane ethanol at the 2007 K’show, the Brazilian petrochemical company Braskem will have had its plant running for exactly three years when the K’2010 takes place in Düsseldorf, Germany. Built in record time, Braskem’s plant started production of ‘Green Polyethylene’ from sugar cane based ethanol as of the end of September. Its nominal production capacity is 200,000 tonnes/year, which will equal to the same amount of green polyethylene.

Ethylene is the raw material for polyethylene - the most commonly-used plastic in the world. The green polyethylene has the same properties and provides the same performance as traditional resin, but with the huge advantage of being made from a renewable resource (see p. 52). The final product, as with polymers made from naphtha or natural gas, can be used by a wide variety of industries, ranging from the automobile industry, through the cosmetics, tools, domestic utensils, and food packaging industries, to the toy manufacturing business. www.braskem.com 06D27 / 06.1W01

 Units for film surface treatment adapted to the material Taghleef Industries and Brückner recently created a concept to modify one of Taghleef’s existing BOPP lines in Italy in order to produce BOPLA - based on Taghleef’s own researches and the long track record of Brückner’s tests on its laboratory line in its German headquarters. The startup of this modified line will be in the 4th quarter of 2010 (see p. 6). www.brueckner.com 03C73

The World’s Most Advanced and Versatile Bio Resin The bioresins.eu division of A&O FilmPAC is using the K’show as the opportunity to launch and present the ECOMANN range of biodegradable/compostable PHA resins. Ecomann PHA is said to be currently the world’s most advanced and versatile bio resin. A number of different well proven resin grades exist for film and sheet, rigid and flexible injection mouldings, rigid and flexible foam and bio elastomers. Ecomann resin products have obtained all of the certifications relevant to the bio resins industry. Numerous new applications arise all the time in this very dynamic industry with a high growth rate. A&O FilmPAC’s team of multi-lingual application experts will show product samples and discuss customer projects at the K show.

A&O FilmPAC, based in the UK, represents Ecomann in the EU, Turkey, the Middle East and some East African countries. www.bioresins.eu 07.1A48

bioplastics MAGAZINE [05/10] Vol. 5

31

K‘2010 Preview

New High Performance Thermoplastic Copolyester

Consumer Awareness Boosts Demand for Bio-polyamides

DSM: Following the successful introduction of EcoPaXX™, a bio-based Polyamide 4.10, DSM Engineering Plastics will be launching Arnitel® Eco at K 2010. Arnitel Eco is a high performance thermoplastic copolyester (TPC) with a 20%50% content derived from renewable resources, depending on the hardness of the grade. The new material is specifically suited for applications in Consumer Electronics, Sports & Leisure and Automotive Interiors.

EMS GRIVORY: The interest in bio-based products from EMS-GRIVORY has been growing steadily. Specifiers in various industries chose GreenLine polymers for new applications in response to increasing environmental awareness by consumers.

According to DSM there is a clear customer need for biobased engineering plastics which combine performance with a reduced carbon footprint. LCA calculations based on Arnitel Eco show a reduction in greenhouse gas emissions, cradle to gate, of up to 50% versus oil based thermoplastic copolyesters. Arnitel Eco is a first generation product, which is currently not yet suitable for high temperatures. However, additional generations of the product are envisaged for the future.

GreenLine products show performance levels directly comparable to, or higher than, those of long established polymers. New Grilamid 1S and 2S formulations have successfully conquered applications in consumer products from hand-held electronics to sports goods, Grilamid BTR allows the production of high quality optics and Grivory HT3 helps improve connecting devices in the E&E sector.

www.dsmep.com 06B11

The Broadest Portfolio of Renewably-sourced Materials DuPont: The strategy of DuPont Performance Polymers is to offer polymers that are at least 20% renewably sourced and have equal or better performance than the entirely petrochemical-based materials that they replace. DuPont has the industry’s broadest range of highperformance, renewably-sourced polymers, including DuPont™ Sorona® EP thermoplastic polymers, which exhibit moulding characteristics similar to high-performance PBT (polybutylene terephthalate), DuPont™ Hytrel® RS thermoplastic elastomers, which contain 35% to 65% of renewably sourced material and provide the same established performance characteristics as the original Hytrel® and, thirdly, the family of DuPont™ Zytel® RS long chain nylons – initially consisting of Zytel RS polyamide 1010, which is 98% renewably sourced, and Zytel RS polyamide 610, which is more than 58% by weight renewably sourced.

Renewably sourced materials from DuPont can help reduce dependence on petroleum and reduce the net production of greenhouse gases. www.dupont.com 06D33

32

bioplastics MAGAZINE [05/10] Vol. 5

In 2009 EMS-GRIVORY introduced various series of biopolyamides - Grilamid 1S PA1010, 2S PA610, Grilamid BTR (amorphous, transparent) and Grivory HT3 PPA.

GreenLine products are made completely or partially from derivatives of castor oil. Thus GreenLine products allow users of engineering plastics to significantly reduce the CO2 and GWP footprint of their products.

GreenLine products are not at all biodegradable but fully recyclable, carrying the potential for further footprint reduction thanks to material recycling alongside the lifetime of the application. www.emsgrivory.com 06E61

New ‘Wave of TPU Specialties’ Merquinsa, the TPU Specialty Company, will be exhibiting for the first time in Hall 6, one of the main fair halls.

Under the motto ‘Everything You Can Imagine’, in line with its thermoplastic polyurethanes (TPU) specialties and sustainability focus, Merquinsa on this occasion will unveil a New ‘Wave of TPU Specialties’. Among other Pearlthane® products visitors will find Pearlthane ECO, renewable-sourced Bio TPUs (see also p. 50). Recognized global brands now make ‘Green Shoes’, ‘Green Cars‘ and ‘Green Electronics’ from Merquinsa´s Bio TPU polyester and polyether-based product ranges. Several new commercial Renewable-sourced Bio TPU applications will be exhibited at K2010. www.merquinsa.com 06A31

K‘2010 Preview

Innovations in Bioplastics Allow for New Applications FKuR: The results of the combined research activities of FKuR Kunststoff GmbH and Fraunhofer UMSICHT, Oberhausen in Germany are principally new special grades which are based on PLA or cellulose. Besides the already well-established applications in the agricultural and hygiene sectors, it is now possible to produce films for deep freeze and various multilayer applications made from Bio-Flex®.

Also at K’2010, innovations in the area of injection mouldable cellulose acetate compounds will be presented. With the Biograde® product line, FKuR sets new standards within the bioplastics range. Thanks to an excellent heat resistance (with values up to 115 °C) it is now possible to realise applications in consumer electronics and household appliances made from bioplastics.

Mouse made from Biograde® C 9550 (Source: FKuR)

www.fkur.com 06B66

FKuR Kunststoff GmbH produces and markets special customized biopolymers under the brand names Bio-Flex (polylactic acid/copolyester compounds), Biograde (cellulose ester compounds) and Fibrolon® (natural fibre reinforced polymers). The close cooperation of the company with the Fraunhofer Institute UMSICHT ensures outstanding know-how and quality standards.

Make It Possible PolyOne will feature reSound™ biopolymer compounds, which incorporate up to 50% bio-derived content by weight and offer increased sustainability without sacrificing performance.

PolyOne’s exclusive reSound biopolymer compounds combine engineering thermoplastic resins with bio-derived polymers such as PLA, PHB, PHBV and biopolyesters. reSound compounds have a unique balance of temperature, impact and cost performance that enables manufacturers to reduce the environmental impact of their products while delivering exceptional performance equal to or better than conventional engineering

resins. Potential applications and market opportunities that can benefit from the performance properties of reSound compounds, while improving the carbon footprint, include: • Consumer durable goods • Electronics equipment • Medical devices and equipment • Interior automotive components ‘Make It Possible’, PolyOne’s theme, showcases the customer-focused approach to developing innovative and responsible solutions that help its customers differentiate their products, win new business, reduce operating costs and meet sustainability goals.

www.polyone.com 08G46

Masterbatches Based on Biodegradable Carrier Polymers Lifocolor present their BIO masterbatches based on biodegradable carrier polymers using environmentally friendly colouring systems. The products, from the German company based in Lichtenfels, are suitable for colouring cellulose, polylactic acid (PLA), polymer starch, polyhydroxybutyrate (PHB) and further renewable raw materials. Lifocolor BIO colorants will allow end products to be specified as biodegradable according to the internationally accepted standard EN 13432 for the compostability of packaging materials.

www.lifocolor.de 7.1C30

bioplastics MAGAZINE [05/10] Vol. 5

33

Visit PolyOne at Hall 08b / G46

Special concepts for BOPLA film production

ask about our new durable biopolymers

Hall 3 Booth C73

Hall 7

B13

CRODA

Hall 7a

C05

D32

Marubeni Europe Nippon Gohsei Europe Kuraray Europe Mitsui Chemicals Europe Kaneka Corporation Mitsui & Co. Deutschland

Hall 7.1

C22 D06

Uhde Inventa-Fischer GmbH Holzhauser Strasse 157–159 13509 Berlin Germany info@uhde-inventa-fischer.com www.uhde-inventa-fischer.com

D18 D32

Hall 8a

B49

Fachagentur Nachwachsende Rohstoffe e.V. (FNR) A. Schulmann Snetor Gehr Kunststoffwerk Uhde Inventa-Fischer Sukano Rhodia Polyamide Clariant International The Dow Chemical Company

D12 D40 F21 G32 H28 H39 J11 K48

bioresins.eu B05 Synbra Technology C12 Ravago C20 CONSTAB (Kafrit) C30 Lifocolor Farben C48 Fukan E01-2 Zhejiang Hangzhou Xinfu Pharmaceutical A48

Hall 6

Merquinsa A42 API A75-1 Bayer MaterialScience B11 DSM Engineering Plastics B28 Evonik Industries B42 AKRO-PLASTIC B66 FKuR Kunststoff B66 Fraunhofer UMSICHT B68 GRAFE Advanced Polymers C43 Total Petrochemicals Research Feluy C57 Arkema D27 Braskem W01 Braskem D33 DuPont de Nemours Intl.

E09 Novamont E61 EMS - Chemie E80 Clickplastics A31

EMS-GRIVORY has widened its range of bio-polyamides in the GreenLine Series.

NGR Jpg K_9,5x4,95mm_#7771BB.fh 17.09.2010 15:13 Uhr Seite 1

Visit us at K 2010 Hall 6 Both E61C orM www.emsgrivory.com Y CM MY CY CMY K

Hall 5

Biesterfeld Plastic C18-1 Addiplast C18-8 Biosphere C21 BASF D10-6B Telles D10-6B Metabolix E04 M-Base engineering and Software B18

Probedruck

Hall 03

C54

Roll-o-Matic Brückner Maschinenbau Fraunhofer Insitut für Grenzflächen und Bioverfahrenstechnik Fraunhofer Institut für chemische Technologie

C73 E91

E91

Hall 01

C25

D-M-E Europe

Producer and supplier of granules: 1) Natural fiber (NF) reinforced plastics such PE, PP

e-mail: martin.snijder@greengran.com address: GreenGran BV, Galvanistraat 1, 6716 AE Ede, Netherlands

2) Bio-based compounds of a mix of NF with PLA,PHA, Ecoflex 3) Flame retardant , non halogen, as to V0 1,5 mm standards 4) Powder and granules PHA/PHB for films, foams, hot melts

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

bioplastics MAGAZINE, Polymedia Publisher GmbH Hall 07, C09

1

organized by

Show Guide

Hall 8b

A30

Natureplast Albis Plastic EconCore (at ThermHex Waben) Teknor Apex Technamation Technical Europe Cabopol PolyOne Roquette Frères Toray industries

A48

A61 D79 E83 F81 G45 G46 H63 H67

28. - 30.10.2010

Messe Düsseldorf, Germany

Hall 9

BKG Bruckmann & Kreyenborg Granuliertechnik D05 NGR - Next Generation

Recyclingmaschinen D60 Mann+Hummel ProTec GmbH (SOMOS)

Hall 11

C54

VTT Technical Research Centre of Finland

Hall 12

A51-59 SUPLA (at Intype Enterprise)

Hall 14

B33

Coperion

Hall 15

B27

KraussMaffei Berstorff

Hall 16

A55 F22

FAS Converting Machinery IFA Tulln (bei Battenfeld) Leistritz Extrusionstechnik

Hall 17

D22

A21/C22 Reifenhäuser

Bioplastics Business Breakfast

B

3

www.bioplastics-breakfast.com Contact: Dr. Michael Thielen (info@bioplasticsmagazine.com)

Bioplastics in Packaging PLA, an Innovative Bioplastic Bioplastics Business Breakfast

B

3

28. - 30.10.2010

Y IVE AGENC THE CREAT S TIC

AS FOR BIOPL STOFFGRUPPE.DE WWW.WIRK

Injection Moulding of Bioplastics At the World’s biggest trade show on plastics and rubber: K’2010 in Düsseldorf bioplastics will certainly play an important role.

On three days during the show from Oct 28 - 30, biopolastics MAGAZINE will host a Bioplastics Business Breakfast: From 8 am to 12 noon the delegates get the chance to listen and discuss highclass presentations and benefit from a unique networking opportunity. The trade fair opens at 10 am.

Like Mission: Sustainable. Naturally. Organic.

K‘2010 Preview

Roll-Bag Solution for Bio-Bags

Next Generation Recycling Machines NGR: An effective new technology for recycling bioplastics has been successfully developed by NGR (Next Generation Recyclingmaschinen) with its headquarters in Feldkirchen/ Donau, Austria. The specialists have long believed that plastics made from biomaterials cannot be recycled; NGR shows otherwise at K’2010.

Roll-o-Matic, Denmark, has developed a new Delta converting line, the DELTAmax, which has longer sealing sections than the conventional Delta. In this way it is possible to reach the optimum combination of long sealing time and high sealing pressure at zero-tension, as required for high capacity, top quality converting of the medium/large size star sealed bio-bags.

The DELTAmax can in this way reduce production cost and provide producers of bio-bags with new business opportunities.

Valuable raw material... NGR has set its sights from the outset on ‘one-step technology’, in which plastics going through the recycling process are not subjected to high temperatures. And it is above all for the recycling of valuable bioplastics that this factor is now of enormous significance.

This is because so-called natural plastics made from renewable growing resources are three to four times as expensive to produce as those based on petroleum. Moreover the typical NGR ‘one-step technology’ also offers high energy efficiency that is seen in operation via low electricity costs. ...feeding back into the production cycle. NGR regranulating technology for biological plastics is now to be demonstrated to a specialist public… www.ngr.at 9D05

“With the right converting equipment, we expect that the market for medium and large size star-sealed bio-bags will expand rapidly, and we are pleased to offer our customers the possibility to open up new business opportunities,” comments Mr. Birger Sørensen, Managing Director at Rollo-Matic, Denmark.

The DELTAmax with the star sealed T-shirt capabilities can be seen in operation at Roll-o-Matic’s stand. www.roll-o-matic.com 03C54 GRAN recycling unit from NGR.

www.ngr.at 9D05

Biodegradable Polyester Resin Zhejiang Hangzhou Xinfu Pharmaceutical Co., Ltd: BiocosafeTM is the trade name of a biodegradable polyster resin manufactured by Zhejiang Hangzhou Xinfu Pharmaceutical Co., Ltd (in short XINFU). Besides being a global leading manufacturer of Vitamin B5 XINFU specialises in the fields of biochemicals, fine chemicals and Eco-materials.

Biocosafe™ is a kind of biodegradable macromolecular polymer synthesised from diacid and diols through a direct process of condensation polymerization catalyzed with a highly effective non-toxic catalyzer that has been developed by XINFU. Biocosafe has already obtained EN13432 and ASTM D6400 certification.

Three different grades are available for various applications： Biocosafe 2003 is a high shear strength and impact grade, suitable for film and bag applications. The 1803 grade offers HDT above 60°C and an elongation at break of over 600%. Suitable for tube, and straw applications. And finally Biocosafe 1903 with an HDT above 85°C and high impact strength. This grade is suitable for injection and extrusion www.xinfupharm.com 07.1E01-2

36

bioplastics MAGAZINE [05/10] Vol. 5

K‘2010 Preview

A New Commercial Bioplastic Material with Broad Performance Capabilities Telles: Mirel™ bioplastics have made major strides forward this year. The Clinton, Iowa, USA production facility is now in operation. Mirel is available in a series of resin grades, including injection molding, thermoforming, film (cast and blown), and sheet extrusion. Mirel is ideal for a wide variety of applications, including single-use disposables; food service and packaging; compost, yard waste, and retail bags; agriculture mulch films; horticulture and marine products; and many consumer items. It is durable in use, shelfstable, heat-resistant up to 120°C, moisture-resistant, tough, and tearresistant. Mirel enables alternative waste management options including anaerobic digestion, home composting, industrial composting, soil and marine environments. Mirel offers biobased and biodegradable solutions that can help to reduce the amount of waste sent to landfills. www.mirelplastics.com 05D10-6A

Bioplastics Services Natureplast specializes in supporting plastics converters or outsourcers who want to develop and integrate products or packaging in bioplastic.

Their expertise is based on three complementary and inseparable activities to develop a successful product :  Natureplast has privileged access to all raw materials and additive bioplastics all over the world. They are even able to recommend specifications on the material best suited to the customer’s needs.  If none of the biopolymers on the market today correspond to the client’s expectations, Natureplast’s structure and network can set customized grades of material in order to meet product and process constraints.  Natureplast has also developed audit services, consulting and training to accompany you on your whole project.

www.natureplast.eu 08bA30

Beginning in 2011, Natureplast is proud to announce the opening of a laboratory completely dedicated to bioplastic research and development (compounding, injection moulding and characterisation). New grades of bioplastic will be developed to respond to industrial needs.

New BioFoam Pallet Besides their standard EPS and EPP materials Synbra will be showcasing several items produced with their newly developed BioFoam® material. This material is an expanded PLA, 100% biobased and biodegradable, and is C2C certified. BioFoam has comparable properties with EPS and within certain limits all EPS parts could also be made with this new material. Processing is done on traditional EPS equipment, however as a blowing agent CO2 is used, which makes the processing a carbon neutral operation. At its end-of-life BioFoam can be disposed of in all the traditional ways, but PLA has some additional disposal options, namely industrial composting, anaerobic digestion and feedstock recycling.

Wood/Biopolymer compound injection moulding demonstration

www.biofoam.nl 07.1B05

bioplastics MAGAZINE [05/10] Vol. 5

37

K‘2010 Preview

Innovative Biodegradable and Compostable Cling Film Novamont continue their development with the Second Generation Mater-Bi® products: at K’2010 they will be unveiling the first industrial cling film that is biodegradable and compostable and is made using renewable resources.

The stretchy cling film can be used for any kind of foodstuffs, even food that has a high fat content (oils, sauces, butter, etc.) or that is acidic. After use it can be disposed of as organic waste as it has been certified as compostable in accordance with standard EN13432 and is compatible with various kinds of composting plant technology (for more details see separate article on page 10).

www.novamont.com 06E09

Mater-Bi is the main product developed by Novamont. While providing the same strength and performance as traditional plastics, it is made from renewable resources of agricultural origin. It reduces greenhouse gas emissions and the consumption of energy and non-renewable resources, thus completing a virtuous circle: the raw materials of agricultural origin return to the earth through processes of biodegradation and composting, without releasing pollutants.

Bio Goes Functional Sukano: In order to establish long-term success, bioplastics need to provide the same processing and application performance as oil-based plastics. For such a demanding task Sukano offers highly attractive solutions with its innovative bioconcentrates for film extrusion and biobased polymer alloys for injection moulding By using SUKANO® Bioconcentrates visual and functional properties can be ideally adapted to meet the requirements of various cut film and thermoformable film applications.

Bioconcentrates contain a high amount of additives well dispersed in a biopolymer carrier and are dosed in small amounts during the film extrusion process.

For use in injection moulding applications, such as housings, biopolymers require a good balance of processability and impact properties. Focused on the needs of manufacturers and end users, these bio-based polymer alloys are compounded with the aim of achieving the desired optical or functional properties. A major emphasis was placed on good processing properties. SUKANO® BIOLOY’s are supplied pre-dried in aluminium-coated bags. www.sukano.com 8AH28

Biobased Polymer Alloys are ideally suited as alternatives to PS or ABS in housing applications

38

bioplastics MAGAZINE [05/10] Vol. 5

Resins For Paper Coating and Shrink Film BASF will be showing two new applications based on their innovative Ecovio FS: firstly there are paper cups treated with Ecovio FS Paper, the new Ecovio grade specially developed for coating paper, and then there is the new shrink film material, Ecovio FS Shrink Film.

The new Ecovio FS plastic material biodegrades even more rapidly than its predecessor and contains a higher proportion of material from renewable resources. This brings Ecovio FS Shrink Film‘s renewable content to 63% and that of Ecovio FS Paper to as much as 75 %. Ecovio FS Paper exhibits excellent adhesion to paper - even where thin coatings are used. Ecovio FS Shrink Film on the other hand allows a targeted balance between shrink performance and cohesion so that the mechanical loading of a film only 25 µm thick is greater than that of a 50 µm thick PE film.

In addition to the above the company will be showing other applications of Ecovio and Ecoflex in the packaging and agricultural industries. www.basf.com 05C21/D21

K‘2010 Preview

WPC Fully Biodegradable and Biobased Fasal Wood KG, Vienna, Austria, and the Institute for Natural Materials Technology (IFA-Tulln, Austria) will present their new development, Fasal BIO 322, at the Wittmann Battenfeld booth in Hall 16.

At the energy-efficient BIOCELL small containers will be produced as give-aways for interested visitors. Thanks to its servo hydraulic drive, up to 40% of energy can be saved.

The material Fasal BIO 322 is fully biodegradable and based on renewables: the wood particles come from PEFC certified producers.

In a joint research project this novel compound was developed on an injection moulding machine provided by Wittmann Battenfeld. The Institute for Natural Materials Technology is specialised in compounding, injection moulding, profile extrusion and testing of biomaterials and industrial by-products in combination with (bio)plastics. Fasal‘s general manager, Ing. Kresimir Hagljan, works closely with his customers right from the preparation of product drawings through tool making to manufacture of finished parts.

www.ifa-tulln.ac.at www.wittmann-group.com 16D22

Material Data Center The Internet information portal Material Data Center will be presented at the exhibition in the latest version. It includes a comprehensive biopolymer database which originates from a research project between M-Base (Aachen, Germany) and the University of Applied Science Hannover, Germany, supported by the German Agency for Renewable Resources (FNR).

A Flame Retardant PLA Blend Based on the development of a heat resistant PLA blend with 99 wt% content of PLA (see bM 01/2010) SUPLA Co Ltd from Tainan Shien, Taiwan, has developed a flame retardant PLA blend (SUPLA C1003) which meets the V0 standards of UL-94 Vertical Burning Test in 1/8”, 1/16” and even 1/32”, while its PLA content is kept as high as 90 wt% and its heat resistance (HDT) is kept to over 100 degrees C. The additive in SUPLA C1003 is halogen free. Therefore, this is the greenest flame retardant PLA blend available.

The system offers the complete set of CAMPUS® data and material data from other sources, which covers the complete international market. Additionally an application database, a trade name directory and a growing selection of searchable literature sources are offered. Comprehensive and easy to use navigation tools are available.

Material Data Center offers designers specific functionality, such as suitable programs for the determination of material parameters for different models (e.g.viscosity), a toolbox for calculating cooling times, flow length and design elements (snap fits) and CAE interfaces. www.materialdatacenter.com 5E04

SUPLA Co Ltd, whose name has just been changed to SUPLA Material Technology Inc., focuses on developing high biomass content PLA blends, answering various demands of bioplastics. SUPLA will be present at K’2010 at the booth of Intype Enterprise Co. www.supla-bioplastics.com 12A51-59

bioplastics MAGAZINE [05/10] Vol. 5

39

K‘2010 Preview

Soft Biodegradable Bioplastic Api: The APINAT family of soft biodegradable thermoplastic compounds from Api Spa, Italy, has been available since June 2008. These products are recyclable and biodegradable under aerobic conditions in accordance with EN 13432, EN 14995 and ASTM D6400 standards.

With the aim offering a wider range of bioplastic materials that can help the reduction of CO2 emissions, API has recently created a new formula based on renewable raw materials.

The content of these renewable resources can vary between 15 - 40% of the total components.

More Colorful Bioplastics Thanks to New Masterbatches

The product range includes:  APINAT DP1888 series: a petroleum-based biodegradable bioplastic.

New masterbatches made at a Clariant facility in Spain have been certified ‘OK compost’ by AIB Vinçotte. They have been formulated for biopolymer applications requiring compliance with standards governing compostability and ecotoxicity, including the harmonized EN 13432:2000 standard. Incorporating conventional additives and pigments, the new RENOL®-compostable color masterbatches and CESA®-compostable additive masterbatches bring a broader choice of colors and additive functionality to bioplastic products and packaging.

The masterbatches for compostable polymers are the result of a development program that began 15 years ago with the introduction of masterbatches for Mater-Bi™ and PLA. In 2007, Clariant introduced RENOL-natur and CESAnatur masterbatches, which use only natural, renewable colors and additives. This third option combines the color and functionality of conventional ingredients and the compostability of biopolymers.

 APINAT DP2125 series: a new product made from vegetable oils (nonfood sources).

These products are biodegradable and have a renewable content in the range between 15 - 40% depending on the hardness of the material. (for more details see article on page 44. www.apipllstic.com 6A42

www.clariant.com 08a J11

Semi-finished Bioplastics Products

www.gehr.de 8a-F21

40

bioplastics MAGAZINE [05/10] Vol. 5

GEHR Kunststoffwerk: ECOGEHR® - Bio-based plastics, unifies today nine different materials with a content of renewable resources of 45-100%.

The medium-sized company Gehr Kunststoffwerk from Mannheim, Germany has more than 75 years of experience in the processing of plastics. With Ecogehr the company has already shown highlights with semi-finished thermoplastic products based on renewable raw materials at the K’2007 exhibition. Gehr is now further developing this product line and offers their customers a product portfolio of sheets, rods, tubes and profiles. This year highlights are calendered sheets which will be mainly used in the areas of thermoforming and deep-drawing/vacuum-forming.

As an innovative company Gehr focuses on sustainability. Their efforts in environmental management were confirmed with the ISO 14001 certificate in September 2010.

bioplastics MAGAZINE Polymedia Publisher: Of course will bioplastics MAGAZINE be one of the exhibitors at K’2010. Come and meet the staff and discuss potential editorial contributions or the different marketing opportunities, such as advertizing, bannerplacement and more. Or just have a coffee and chat with us. www.bioplasticsmagazine.com 07C09

Cooperation Forum Other companies exhibiting at K’2010, that are involved in bioplastics but who were unfortunately unable to provide us with detailed information in time for this issue are:

Biopolymers Perspectives – Technologies – Markets

A. Schulmann 08aD12 Akro-Plastic 06B42 Bayer MaterialScience 06A75-1 Biesterfeld Plastic 05B18 Biosphere 05C18-8 BKG Bruckmann & Kreyenborg Granuliertechnik 09A48 Carolex 08aF26 CONSTAB Polyolefin Additives 07.1C20 CRODA 07B13 D-M-E Europe 01C25 Evonik Industries 06B28 FAS Converting Machinery 16A55 Fraunhofer Insitut für Grenzflächen und Bioverfahrenstechnik 03E91 Fraunhofer Institut für chemische Technologie 03E91 Fukan 07.1C48 Kaneka Corporation 07aD32 KraussMaffei Berstorff 15B27 Kuraray Europe 07aD06 07aD06 Leistritz Extrusionstechnik 16F22 Marubeni Europe Plc., Chemical Group 07aC05 Mitsui Chemicals Europe 07aD18 Mitsui & Co. Deutschland 07aD32 Nippon Gohsei Europe 07aC22 Ravago Distribution Center 07.1C12

Photos: TFZ/Sporrer, Fraunhofer IAP/Armin Okulla, Henkel AG

GRAFE Advanced Polymers 06B68

Herzogschloss Straubing, Bavaria/Germany 11 November 2010 Visit of Companies and Institutes 10 November 2010

Reifenhäuser 17A21/C22 Rhodia Polyamide 08aH39 Roquette Frères 08bH63 Snetor 08aD40

Information and Registration: www.bayern-innovativ.de/biopolymere2010

Technamation Technical Europe 08bF81 Teknor Apex 08bE83 The Dow Chemical Company 08aK48 Toray industries 08bH67 Total Petrochemicals Research Feluy 06C43 Uhde Inventa-Fischer 08aG32 VTT Technical Research Centre of Finland 11C54

bioplastics MAGAZINE [05/10] Vol. 5

41

Polyurethanes | Elastomers

New Biobased Polyurethane from Lignin and Soy Polyols M. Özgür Seydibeyoğlu Manjusri Misra Amar Mohanty Bioproducts Discovery & Development Centre Department of Plant Agriculture, University of Guelph, Guelph, Ontario, Canada

Figure 1: Lignin Particles (Electron Microscopy Images)

L

ignin being the second most abundant polymer in the world is undervalued which is a by-product in the pulppaper and lignocellulosic industries [1]. Lignin with high e-modulus value (5-6.7 GPa) offers many new materials as a polymer and as a reinforcing phase. Lignin particles are shown in Figure 1 (Electron microscopy Hitachi S-570 at 10 kV).

On the other side, biobased polyurethane materials take a lot of attention to replace petroleum based polyurethanes (Figure 2 showing lignin incorporated polyurethane structure) [4].

Polyurethane has two important components, the isocyanate and the polyol. These two reactants have many different forms creating a wealth of different of products and applications.

Recent research is focused on replacing petroleum based polyol with plant based polyols [5-7]. One of the most commonly used polyol is the castor oil due its high hydroxyl numbers [6].

Another commonly used soy polyol is obtained from soybean oils. However the use of soy polyol based polyurethanes is limited due to lower mechanical properties. There are studies to reinforce biobased polyurethanes with glass fibers and hemp fibers to overcome the low mechanical properties [8, 9].

In this study, lignin was used as reinforcement for soy polyol based polyurethanes. The lignin (Protobind 2400 from ALM Private Limited, Hoshiarpur, Punjab, India) with a hydroxyl value of 400 mg KOH/g was blended with soy polyol with hydroxyl value of 166 mg KOH/g. Afterwards, the polyol blend was reacted with different isocyanates at 150ºC and cured for 8 hours. Three different isocyanates were used from Huntsman Chemicals, PMDI (polymeric diphenyl methane diisocyanate (pMDI, Rubinate M)), MDI (diphenyl methane diisocyanate, Rubinate 9511), and modified MDI (Rubinate 9271). Tensile testing was done to understand the ultimate strength, e-modulus and percent elongation of the materials synthesized.

The lignin was incorporated at 5 wt % in soy polyol based polyurethanes prepared with three different isocyanates. For all the polyurethanes, the lignin showed reinforcing effect.

The tensile strength was improved by 70%, 57%, and 118% for PMDI, MDI, and MMDI based polyurethanes respectively. The percent elongation values were 13.50%, 87.30%, and 105.00% respectively. Figure 3a and Figure 3b shows two different polyurethanes obtained with lignin and soy polyol reacted with different isocyanates representing different elongation values obtained.

42

bioplastics MAGAZINE [05/10] Vol. 5

Polyurethanes | Elastomers

Figure 3: Biobased Polyurethane with Lignin (left stiff type, right elastic type)

The lignin had significant effect for the improvement of modulus of elasticity (E-modulus) value of these biobased materials. For the PMDI based polyurethane, lignin incorporation at 5 wt % increased the E-modulus values around 12 fold. For the MMDI based polyurethane, the increase in the E-modulus values was 37 fold with the addition of 5 wt % lignin. In this study, it was shown that a new biobased polymer with various properties can be synthesized with polyols obtained from soybean oil and lignin. The biobased material has biological material content of 67.4 % and this group of polymers can find numerous applications. This discovery will enable wide usage of soy and other plant based polyols in the polyurethane materials due to reinforced properties.

The most important aspect of these findings is to find new applications for lignins. Lignins are generally produced as a side product and they are mostly burned and used as energy source at a low price. By this way, new value added products can be manufactured from lignin with reinforcing the soy polyol based polyurethanes. It is reported that these new value added products from lignin (price increasing from $100 to $1500 per ton) helps to decrease the price of bioethanol by creating new economic value [1].

References [1] M.N.S. Kumar, A.K. Mohanty, L. Erickson, M. Misra, J. Biobased Mater. Bioenergy 3, 1 (2009).

[2] W. J. Cousins, R. W. Armstrong,W. H. Robinson, J. Mater. Sci. 10, 1655 (1975).

[3] T. Elder, Biomacromolecules 8, 3619 (2007).

[4] S. Husic, I. Javni, Z.S. Petrovic, Compos. Sci. Technol. 65, 19 (2005).

[5] Sharma,V.; Kundu, P.P.; Prog. Polym. Sci. 33, 1199 (2008).

[6] Güner, F.S.; Yağcı, Y.; Erciyes, A.T.; Prog.

Polym. Sci. 31, 633 (2006).

[7] G. Oertel. Polyurethane Handbook, Hanser Gardner Publications; (1994), p1.

[8] J.P. Latere Dwan’Isa, A.K. Mohanty, M. Misra, L.T. Drzal, M. Kazemizadeh, J. Mater. Sci. 39, 2081 (2004).

[9] J.P. Latere Dwan’Isa, A.K. Mohanty, M. Misra, L.T. Drzal, M. Kazemizadeh J. Mater. Sci. 2004, 39, 1887.

Acknowledgements The authors are thankful to the Ministry of Research and Innovation (MRI) of Ontario, Canada for the post-doctoral research fellowship. Financial support from NSERC-Discovery Grants program individual (Mohanty) is greatly appreciated.

Arkema is acknowledged for donations of soy polyols.

H

H

H

C

N

C

N

H

H

O

O C

Isocyanate group R1

O

H

H

C

C

H

H

Polyol group

R2 OH

Lignin group

Figure 2: Biobased Polyurethane Chemical Structure with Lignin Incorporated

bioplastics MAGAZINE [05/10] Vol. 5

43

Polyurethanes | Elastomers

Unique Soft Bioplastics

I

n addition to TPE’s, TPU’s and masterbatches API S.p.A. now produces APINAT, the first and unique soft and biodegradable thermoplastic, which is now also available made from renewable raw materials

Article contributed by Marco Meneghetti, Laboratory & Bioplastics Product Manager

The Apinat family of soft biodegradable thermoplastic compounds has been available since June 2008. These products are recyclable and biodegradable under aerobic conditions in accordance with EN 13432, EN 14995 and ASTM D6400.

Paola Scopel, Technical Development, Polyurethanes

With the aim of offering a wider range of bioplastic materials that can help the reduction of CO2 emissions, API has just created a new formula based on renewable raw materials (from agricultural origin). The content of these renewable resources can vary between 15 and 40% of the total components.

API Applicazioni Plastiche Industriali S.p.A., Mussolente, Italy

The product is the result of a more comprehensive R&D project at the API laboratory which leads to the creation of a complete range of polymers derived from renewable raw materials, from non-food sources. Bioplastics such as Apinat can help commercial companies, associations, local municipalities and governments engaged in greenhouse gas reduction to achieve the targets set by the Kyoto Protocol by reducing the whole environmental impact of the products.

Bioplastics and Biodegradability It is of the utmost importance to point out once again that bio-based plastics are not always biodegradable and biodegradable plastics are not always biobased. Biodegradability is directly linked to the chemical structure rather than the origin of the raw materials. As a result, there are some special synthetic polymers which are certified as biodegradable: fossil raw materials can be used to produce biodegradable polymers and plastic products (oilbased bioplastics). This distinguishes them from conventional standard plastics which are neither biodegradable nor compostable. (e.g. PE, PP, PS, PET, PA, ABS, EVA or PVC).

Further to the question of biodegradation/compostability there are other degradation mechanisms (oxo-degradation, UV-degradation) acting on specially modified plastics with additives (oxo-polymers). Plastics with this kind of degradation mechanism are not biodegradable because it is not scientifically proven that they are completely assimilated by mircroorganisms as an energy source and that they do not leave toxic residues. They do not meet the standards set for biodegradability/compostability (EN 13432/EN

Fig. 3: Examples of hard/soft composite articles

Fig.: 1 - Biodegradation 120

biodegradation (%)

100 80 60

Apinat

40

Cellulose

20 0

0

10

20

30

40

50 Days

44

bioplastics MAGAZINE [05/10] Vol. 5

60

70

80

90

Polyurethanes | Elastomers

Fig. 2: Before degradation

Degradation in soil

14995). At present there are no standards or certifications for oxo- or UV-degradable plastics or plastic products.

According to EN 13432/EN 14995 standards, in order to be defined as biodegradable the material must degrade by at least 90% within 6 months (180 days). Figure 1 shows the biodegradability of Apinat (Apinat shown in blue, Cellulose used here as a reference - shown in green).

2. Grades and Properties Figure 2 shows the effect of the biodegradation of an Apinat plate under controlled composting conditions.

Apinat behaves in the same way as many other thermoplastic elastomers and does not degrade in air or water.

The evaluation of ultimate aerobic biodegradability of Apinat in an aqueous medium by measuring the evolution of carbon dioxide (according to a modified Sturm test, ISO 94391999) gives a value of less than 10% (i.e. non biodegradable).

The test is performed at 20-25°C in an aqueous medium containing microbes and mineral salts.

Apinat is different from most other biodegradable materials so far available on the market because it is exceptionally soft and is classified as an elastomer (Shore A scale). The hardness is in the range between 55-90 ShA (ASTM D2240) and flexural modulus 45-110 MPa (ASTM D790).

It possesses physical and mechanical properties which are very similar to the best traditional thermoplastics and it can be easily processed using all standard equipment for plastics (injection moulding, extrusion, co-extrusion and hard/soft overmoulding).

Compost at the end

substances, in full compliance with EN 13432 norm. These masterbatches are also compatible with other commercially available bioplastics.

3. A new ‘Green TPU’ API launches a new development in the TPU market, BIOAPILON 52 from renewable raw materials. This new family (not biodegradable) is a bioplastic with a renewable content of between 30 and 60% and can compete with traditional oilbased TPU in terms of quality and processability, opening the green future of plastics.

The product range now includes the BIO-APILON 52 DB series, which is a polyester TPU obtained from vegetable oil based polyols. Its hardness is in the range between 40 and 50 ShD (ASTM D2240) and the tensile strength is about 30-50 MPa (ASTM D638). The BIO-APILON 52 TB series, a polyether TPU, is obtained from vegetable oil based polyols.

The hardness of this type is in the range between 90 ShA and 50 ShD (ASTM D2240) and tensile strength was measured at 40-50 MPa (ASTM D638).

API has been a member of European Bioplastics since 2009. www.apiplastic.com

Fig. 4: Examples of hard/soft composite articles

Specific Apinat hard grades have been developed for coinjection/overmoulding applications. These products have a hardness between 35 and 85 ShD (ASTM D2240) and flexural modulus in the range 100-3000 MPa (ASTM D790). The final hard/soft product is completely biodegradable according to EN 13432:2000 and EN 14995:2006 norms (see Figures 3 and 4).

Apinat products are generally supplied in neutral colour pellets, however API SpA has also developed Apicolor B, tailormade colour masterbatches for the Apinat range. This is a special series of biodegradable and non-toxic masterbatches which does not contain heavy metals and other dangerous

bioplastics MAGAZINE [05/10] Vol. 5

45

Polyurethanes | Elastomers

Bio-based ‘Cold Weather’ Thermoplastic Elastomer Article contributed by Frederic L.G. Malet PebaxR Research Manager ARKEMA Serquigny, France

P

ebax® polyether block amides are plasticiser-free thermoplastic elastomers which belong to the technical polymer family. They are used in high value added applications, in particular top-level sports.

However, society’s growing demands in terms of performance required a total rethink of the polymer’s composition and hence the material’s physical structure. To achieve better performances, ARKEMA’s team turned to raw materials of renewable origin in order to formulate eventually a material with superior properties than the original material.

A few years ago, the partner with whom this development was carried out unveiled its new Hurricane long-distance ski boot at a tradefair.

Not only do these boots rigidify less at cold temperature than if they were based on the original material, but additionally the customer noted superior processability of the polymer, while keeping excellent impact strength in cold weather. The commercial launch was therefore a success.

In search of new performance Pebax is a range of thermoplastic elastomers; segmented block copolymers prepared by reacting together functionalised polyether and polyamide building blocks. However, it is only when Deleens et al. discovered that the tetra-alkoxide catalyst family was efficient for the reaction that production of high molecular weight materials could be achieved, leading to the introduction on the markets in the early 1980’s.

They own their unique properties to a phase-separated microstructure, with a hard phase consisting mostly of the polyamide blocks together with the soft phase consisting mostly of the polyether blocks. Since both blocks are chemically bonded by ester links, a complete macroscopic phase separation is thus prevented.

O

║ — C — (CH2)11 — N — | H

Polyamide 12

Polyehter

HO — CH2 — CH2 — CH2 — CH2 — O — H n Figure 1 Structure of Pebax copolymers based on PA12 and PTMG blocks

46

bioplastics MAGAZINE [05/10] Vol. 5

The winter sports shoe market is a market with increasingly extreme demands, in particular in competitive sports. Skiers expect new, much more rigid models that therefore help them control their movements more accurately and more effectively. However, increased rigidity must not mean loss of resistance at cold temperature for the boot. This compromise is not easy to achieve as increasing a material’s rigidity leads to reducing performance in the flexible phase, which contributes to this cold resistance.

The use of standard grades of Pebax can offer a good rigidity / cold resistance compromise, though this was not sufficient to accommodate increasingly extreme conditions. Indeed, the polyether blocks currently in use are oligomers of polytetramethylene glycol, with a very low glass transition temperature close to –80°C, and thus responsible for the remarkable mechanical properties at cold temperature. However, very rigid grades, therefore with low polyether content, will start to show some limit.

The rigidity of Pebax copolymers is closely related to the amount of soft polyether blocks present in the material. Thanks to Kerner and Jordhamo’s work, a model can be build up in order to follow the evolution of the rigidity

Polyurethanes | Elastomers

with the polyether content. One of the key parameters is the modulus of the corresponding polyamide homopolymer.

Among the possible polyamides, the odd ones, meaning having an odd number of carbons, do have peculiar properties, as the positioning of the amide groups in the chain is important for structural order and packing efficiency.

Among these polyamides, PA11 rapidly became the centre of our attention. Indeed, being an odd polyamide, its elementary lattice can theoretically lead to either a parallel or an antiparallel configuration of the chains with every amide group able to be engaged with another one through hydrogen bonds.

Depending on the cooling procedure, crystals will either have a hexagonal arrangement or triclinic one. Usually, both are co-existing. A very interesting phenomenon is that the triclinic phase can change into a pseudo-hexagonal one under thermal or mechanical stress. Thus, the amount of energy needed to perform the crystalline transition will decrease the energy dissipated within the material, thus explaining the outstanding strain hardening behaviour of PA11 vs. PA12. In the case of PA12, an anti-parallel configuration of the chains is only observed because of the even number of carbon and the extra twist of the chains, necessary to optimise hydrogen bonding, leads to a Îł-monoclinic structure. On a mesoscopic scale, the two materials exhibit noticeable differences: ringed spherulites can be observed for PA11, whereas coarse spherulites are the typical form for PA12.

The next step was then to try and see whether it was possible to transpose the remarkable mechanical properties to a multi-segment block structure comprising a PA11 block with a very low molecular mass.

1500 1250 Traction Modulus (MPa)

The modulus of polyamide homopolymers increases with the amide / methylene ratio. Indeed, a higher concentration of amide groups will lead to higher crystallinity and hence a more rigid material. Unfortunately, melting point of the material will also increase, together with moisture uptake and density. Absorption of water will have a significant impact on mechanical properties, for instance the modulus of PA6 can be reduced by half under moist conditions. Increasing the density does not help towards designing lighter materials for demanding athletes. Another hurdle is that the solubility parameter of polyamide increases with the amide / methylene ratio, increasing the gap with the solubility parameter of the polyether, leading to a higher enthalpy of mixing. Mixing of the two blocks will thus be more difficult, leading to slower polymerisation, if any.

1000 750 500 PEBAXÂŽ Rnew 70R53

250

PEBAXÂŽ 7033

0

0

10

20

30

40

50

60

70

80

Figure 2 Evolution of the traction modulus of Pebax copolymers depending on polyether content

PA12

PA11 Figure 3 Differences in the crystallite structure between PA12 and PA11.

bioplastics MAGAZINE [05/10] Vol. 5

47

40

Stress (MPa)

30

Having an amide / methylene ratio very close to PA12, and thus very similar solubility parameter, allowed the polymerisation of PA11 based Pebax copolymers to run as smoothly as with PA12 based ones.

20

10 PEBAX® Rnew 70R53 PEBAX® 7033 0

0

50

100

150 Strain (%)

200

250

300

Figure 4 Tensile test at 23°C of 70 Shore D hardness Pebax, based on PA12 (7033, blue) and PA11 (70R53, green)

When cold properties were assessed, a major differential in the ductile – fragile transition could be noted for one of the most rigid grade, having a Shore D hardness of 70, with a shift by almost 10°C.

140

Resiliency (kJ/m²)

120 100 80 60 40 PEBAX® Rnew 70R53

20

PEBAX® 7033 Temperature (°C)

Figure 5 Impact strength (notched Charpy) depending on temperature for 70 Shore D Pebax grades based on PA12 (blue) and PA11 (green).

Comparison of Normalized Fossil Energy Requirement -29%

120

Normalized fossil Energy

100

100

97

71

69

60 40 20 0

7033

70R53

Industrial Scenario 1

Normalized Equivalent CO2 emissions

7033

70R53

Industrial Scenario 2

Equivalent CO2 emision

120.0

-25%

100.0

-32%

100

80.0 60.0

75

74 50

40.0 20.0 0.0

7033

70R53

Industrial Scenario 1

7033

bioplastics MAGAZINE [05/10] Vol. 5

70R53

Industrial Scenario 2

Figure 6 Eco-profile of 70 Shore D hardness Pebax based on PA12 (7033) or PA11 (70R53).

48

All these results mean that the cristallinity of PA11 blocks in Pebax is the same as that of the homopolymer and the gain in mechanical strength was validated successfully in very demanding ski boot applications, hence the development of a new eco-designed range.

An Eco-designed product

0

80

Moreover, the substitution of PA12 blocks by PA11 blocks in the Pebax formula did lead to significant improvement of the mechanical properties. Indeed, as can be seen during a tensile test, PA11 based Pebax show greater elasticity, with no observation of yield. Creep resistance is also improved.

On top of its mechanical advantages, PA11 has also the particularity to lean on the chemistry of Amino-11, which is a unique monomer produced from natural vegetal oil. This natural vegetal oil comes from a non-edible crop, castor oil, and thus does not compete with food production. The use of a PA of renewable origin indeed allows a significant improvement in the environmental balance of Pebax, as shown below.

The graph on the left quantify the environmental gain from the synthesis of the Pebax Rnew 70R53 grade, containing about 89% carbon from renewable origin. Calculated ‘from cradle to granules’ according to ISO 14040-14043, the two calculations (scenario 1 and scenario 2) correspond to two industrial production lines. It can be seen that using this innovation helps reduce the amount of fossil energy required for the synthesis by 29% (compared to the same product but made from fossil materials), and the amount of CO2 equivalent released by 25 to 32%.

What about subsequent developments ?

It should be noted that, although the polyamide rigid block has been successfully replaced by a block of renewable origin, the same does not apply to the flexible block. For the latter, there was no renewable alternative to PTMG when the project was launched. To gain the few remaining percents, studies are now looking into the substitution of PTMG by a bio-sourced grade. www.arkema.com

Polyurethanes | Elastomers Figure 1: Image of a transparent film (30 µm) produced with Pearlthane® ECO.

density and maintains equivalent top mechanical and thermal properties like standard petrochemically-based TPU. And is suitable for a wide range of processing techniques (injection moulding, extrusion, compounding etc.).

At K’2010, Merquinsa will highlight several new commercial applications in consumer, footwear and industrial markets.

Bio TPU Film Application Example

Same Performance just Greener…

www.merquinsa.com

Article contributed by Maria Josep Riba, Bio TPU Application Development Manager Merquinsa SL, Montmeló (Barcelona), Spain

T

he challenge faced today by manufacturers subject to consumer pressure driven by sustainable forces and the current trend of use of bio-based materials, is to offer end consumers a bioplastic that not only provides 100% recyclability and other environmentally-friendly benefits, but also complies with demanding technical requirements.

A clear example of a renewably-based material achieving both is Merquinsa´s Bio TPU (thermoplastic polyurethane).

First-to-market Bio TPU at K’2007, Merquinsa received the prestigious Frost & Sullivan 2008 Global Thermoplastic Urethane (TPU) Product Innovation Green Excellence of the Year.

Bio TPU contributes up to 40% less global warming emissions with its manufacturing process compared to that of standard 100% petrochemically-based TPU. It features low

The new Bio TPU product ranges –Pearlthane® ECO & Pearlbond® ECO- developed by Merquinsa with a bio content ranging from 20% to 90% (carbon content according to ASTM D 6866) expand the limits of high performance elastomeric materials allowing for their use in different moulded or extruded TPU parts; even in applications processed under the most demanding conditions such as the extrusion of blown films or T-die extrusion.

The Pearlthane, Pearlcoat® and Pearlbond TPU product ranges (comprising both TPU from renewable sources as well as standard 100% petrochemically-based TPU) are easily adhered to coextruded polar substrates, such as PVC, ABS, PC, leather, cotton and polyurethane foam. Apart from offering high chemical resistance and UV protection, other advantages of Bio TPU include excellent abrasion resistance and a wide range of service temperature (from -45ºC a +110ºC), depending on the grade.

Extruded Bio TPU is highly transparent so as to comply with even the most stringent requirements regarding transparency (see fig. 1).

Renewable-sourced Bio TPU Pearlthane ECO not only offers the same benefits as standard TPU, it is also a sustainable option based on fully recyclable material (see fig. 2).

Pearlbond ECO D900 is a Bio TPU grade which offers an environmentally-friendly sustainable solution for film manufacturers and among other advantages offers: Excellent adhesion to difficult substrates, Fast crystallization speed (allowing for high productivity results), OEKO TEX Class I compliancy, and very good thermoplasticity.

Conclusion Bio TPU has a bright future because of its simple and sustainable value proposition: “Same Performance, just Greener”. Merquinsa will continue to invest in new sustainable technologies for a better world.

Pearlthane® ECO D12T95 120

Figure 2: Bio TPU from renewable sources is fully recyclable.

Tensile retention (%)

100 80 60 40 20 0

0

25

50

75 Recycled amount (%)

50

bioplastics MAGAZINE [05/10] Vol. 5

100

125

Polylactic Acid

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

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

Think. Invest. Earn.

Uhde Inventa-Fischer GmbH Holzhauser Strasse 157–159 13509 Berlin Germany Tel. +49 30 43 567 5 Fax +49 30 43 567 699

Visit us at

Uhde Inventa-Fischer AG Via Innovativa 31 7013 Domat/Ems Switzerland Tel. +41 81 632 63 11 Fax +41 81 632 74 03

Hall 8a Booth G 32

www.uhde-inventa-fischer.com

Uhde Inventa-Fischer

Basics

Basics of Bio-Polyolefins

—

H | C — | H

H | C — | H n

A

s it has almost become a habit, let’s start our ‘basics’ article with a look into Wikipedia: A polyolefin is a polymer produced from a simple olefin (also called an alkene with the general formula CnH2n) as a monomer.

For example, polyethylene (C2H4)n (PE) is the polyolefin produced by polymerizing the olefin ethylene H2C=CH2. Polypropylene (PP) is another common polyolefin which is made from the olefin propylene. In some cases PE is produced as a copolymer using butene, hexene or octene as comonomer.

Polyethylene Polyethylene or polythene (IUPAC name polyethene or poly(methylene)) is the most widely used plastic, with an annual production of approximately 80 million metric tons (2008). Its primary use is within packaging [1]. And in bioplastics MAGAZINE 01/2008 Dr. Thomas Isenburg wrote: Polyethylene is a plastic material that has been known for more than 100 years. It is found in millions of applications from simple film, through containers, to toys or technical components such as plastic fuel tanks for cars.

Polyethylene

Polyethylene was discovered by the chemist Hans von Pechmann in 1898. In 1933 polyethylene was successfully produced, at a pressure of 1400 bar and a temperature of 170°C, at the ICI laboratories. For a large scale industrial process these conditions were, however, difficult to produce and were highly energy intensive. In 1953 polymer chemistry saw a major breakthrough. The chemists Karl Ziegler and Giulio Natta succeeded in synthesising polyethylene from ethylene at normal pressure using catalysts.

Plastic Fuel Tank made from bio-PE (Photo: Courtesy Braskem)

H H \ / C ═ C / \ H H

Ethylene

52

bioplastics MAGAZINE [05/10] Vol. 5

Ethylene So it all starts with ethylene…

Ethylene is a chemical intermediate used to produce many different products, besides polyethylene (PE), for example polyethylene terephthalate (PET), polyvinyl chloride (PVC), and polystyrene (PS) can be named. Its current world production capacity is around 115,000 tons per year, mainly (>98%) through the petrochemical route based on steam cracking (thermal pyrolysis) of petroleum liquids (naphtha, condensate, and gas oils) and natural gas feedstocks (ethane, propane, and butane).

However, before the boom of petroleum started in the early 1950s, ethylene was produced from ethanol. Interestingly, the first report that was published in the literature about the catalytic dehydration of ethanol to ethylene dates from 1797.

Applying the catalytic dehydration of ethanol to produce ethylene is again becoming more and more important. Especially in Brazil, with the building of large-scale plants motivated by the Brazilian sugarcane based ethanol competitiveness and by the low carbon footprint of the product obtained by this route. Just a few weeks before publication of this issue of bioplastics MAGAZINE Braskem started the manufacture of polyethylene on a large scale based on Brazilian renewable ethanol.

Article contributed by Antonio Morschbacker Responsible for Green Polymers Technology Braskem S.A. São Paulo, Brazil and Michael Thielen

Ethanol We all know very well that bio-ethanol has been used as engine fuel since the beginning of the last century. In the mid 1970s, the Brazilian National Alcohol Program led to a significant increase in the Brazilian ethanol capacity.

About thirty years later the United States started to grow their capacity very fast so that eventually they became the world leader in manufacture. With 23 billion liters (USA) and 21 billion liters (Brazil) in 2007 these two countries are currently by far the global leaders in ethanol production. In the meantime the Brazilian production reached 25 billion in 2009 and 28 billion estimated for 2010.

Under optimal climate conditions, like in tropical regions, sugarcane is relatively inexpensive to grow. Sugarcane offers a high agricultural productivity and relatively simple harvest methods. The growing season for sugarcane (6 to 7 months) is longer than that of other crops. It is harvested year by year during at least four years with no necessity to plant it again during this cycle. The poor mechanical harvesting methods of about 10 years ago are much more efficient today and still do not emit carbon dioxide in consequence of the sugarcane burning. In Brazil, the water requirement for its production is to a large extent rainfed. The World Bank and the FAO have confirmed that Brazilian ethanol has not raised sugar prices significantly and that it is the only biofuel competitive with petroleum-based diesel or gasoline and which saves greenhouse gases [2]. And once again it needs to be explained: In Brazil the rainforests are in the north of the vast country, whereas most of the the sugarcane plantations are in the southeast. In addition, land and climate in the north – the rainforest area - aren’t appropriate for sugarcane production (see bM 04/2009).

Sugarcane (Photo: Courtesy Braskem)

Braskem Green PE Plant (Courtesy Braskem - Photo by Mathias Cramer)

If a sugar source, mainly sugarcane juice and molasses (as in Brazil) and hydrolyzed starch from corn grains (as in the United States) is fermented, ethanol can be obtained. In some regions other crops can be used, such as potato, wheat, manioc, and sugar beets. The use of hydrolyzed cellulose and hemicellulose from low-cost biomass is a potential way to obtain cheaper ethanol but until now this technology is under development and its commercial production started at the end of the last year in a small unity [3].

To produce the ethanol through fermentation, sugar is extracted from sugarcane by crushing the raw cane with water to extract the sugars (mostly sucrose). In a similar

bioplastics MAGAZINE [05/10] Vol. 5

53

Evaporation

Furnace

Cruede ethylene

Ethanol

Aqueous NaOH

Water

Light contaminants

Chemical grade ethylene

Raw ethylene

Polymer Grade Ethylene

Steam

Aqueous effluent REACTION

QUENCH

Caustic effluent

Heavy contaminants

SCRUBBING

DRYING

DISTILLATION AND STRIPPING

Representation of a generic process diagram of an ethanol-based ethylene plant.

way, starch is obtained from corn by dry milling, then slurried with water, and hydrolyzed to glucose. The resulting solution of fermentable sugars obtained by both ways is fermented typically in batch or fed-batch by Saccharomyces cerevisiae yeast to produce a broth with 6 to 8% by weight of ethanol. The fermentation of the sugarcane juice is quite simple, because it can be fermented directly, and faster, taking in general less than 16 hours.

By distilling the broth containing ethanol hydrated ethanol, about 93% by weight, is produced. The stillage, the bottom by-product stream of the distillation, is rich in nitrogen and potassium and is commonly recycled to the sugarcane crop by a practice called ferti-irrigation.

Energy for the process A large amount of lignocellulosic material is also produced from the sugarcane feedstock. For an average yield of 80– 85 metric tons per hectare and 14% by weight of sugars, it produces, and in addition, 28% by weight of dry lignocelluloses fibers as bagasse and leaves. These fibers can be used to supply renewable heat and electricity to the ethanol process.

Cosmetic Bottle (Courtesy Braskem)

Its surplus of about 20–40% is used normally to co-generate renewable electricity to the grid and may also be used in other processes when integrated with the ethanol manufacture. If in the future the hydrolysis of hemicelluloses and celluloses would be economically competitive these fibers may be used as an additional source of sugars.

As a consequence of these many aspects the energy balance of the sugarcane based ethanol is very favorable.

This number is obtained dividing the fossil fuel energy input required by the entire manufacturing process, since the crop plantation, by the energy content of the biofuel output. For the Brazilian sugarcane ethanol the input/output energy balance is 1:9, while for the US corn ethanol this relationship is 1:1.5.

Ethanol to Ethylene To generate ethylene from ethanol, you simple need to take the water out (dehydration).

C2H5OH → C2H4 + H2O Well, in real life, it is not that simple.

The dehydration of alcohols, mainly ethanol, has been studied during the last centuries with different technologies and using a large variety of catalysts such as alumina, silica, silica-alumina, zeolites, clays, metal oxides, phosphoric acid, and phosphates.

While older technologies were based on supported phosphoric acid, later activated alumina became predominant as a catalyst.

The dehydration reaction is endothermic which means that energy has to be put into the process. The most accepted mechanism for the ethanol dehydration considers a simultaneous reaction: 2 CH3CH2OH → CH3CH2OCH2CH3 + H2O → 2 H2C=CH2 + H2O Ethanol

Ether

Ethylene

Water

2 CH3CH2OH ─────────────── → 2 H2C=CH2 + 2 H2O Ethanol

Ethylene

Water

Diethyl ether is considered an intermediate and not a byproduct. Its formation is favored mainly between 150°C and 300°C, while ethylene formation is predominant between 320°C and 500°C.

54

bioplastics MAGAZINE [05/10] Vol. 5

A simplified generic process diagram of an ethanol-based ethylene plant, based on an isothermal or an adiabatic process, is represented by the schematic on the left.

The first of the commercial plants to produce ethylene from ethanol was built and operated at Elektrochemische Werke G.m.b.H at Bitterfeld in Germany in 1913. It was a very small-scale plant that used alumina catalyst in isothermal conditions to produce ethylene for the preparation of pure ethane that was used in refrigeration. From 1930 until the Second World War, ethanol dehydration plants were the unique source of ethylene in Germany, Great Britain, and the United States. The process based on supported phosphoric acid was the basis for very primitive plants for all polyethylene production in England until 1951

Sustainable Banco Imobiliario, a sustainable version of the Monopoly game (Courtesy Braskem)

Polypropylene While the production of biobased polyethylene is now starting on industrial scale, biobased polypropylene is still under development.

Polypropylene is a plastic used in a wide range of everyday products, from food containers, drinking straws, and water bottles to washing machines, furniture, and car bumpers. It is the second most widely used thermoplastic with a global consumption in 2008 of 44 million metric tons. The market is estimated to be USD 66 billion, with an annual growth rate of 4%.

Today, polypropylene is primarily derived from oil, but Braskem produced in 2008 in bench scale what is considered the first biobased polypropylene of the world. At the end of 2009, Braskem and the Danish company Novozymes started a partnership to develop a green alternative based on Novozymes’ core fermentation technology and Braskem’s expertise in chemical technology and thermoplastics. The initial development phase will run for at least five years.

Conclusion

[1] www.wikipedia.org [2] Morschbacker, A. Bio-Ethanol Based Ethylene.

Journal of Macromolecular Science®, Part C: Polymer Reviews, 49:79-84, 2009 [3] www.inbicon.com www.braskem.com

First products from bio-PP shown at BioJapan 2008.

Carpet made of PP homopolymer fibers and stretch blow moulded bottles made of bioPP random copolymer with bio ethylene (Courtesy Braskem)

Whilst biobased polypropylene is still a development project, biobased polyethylene is a reality and is already available on industrial scale in grades of high density (HDPE) and linear low density (LLDPE).

To make it very clear: Biobased polyethylene (and, once available polypropylene) are NOT biodegradable. On the contrary: biobased PE and PP do not at all differ from petroleum based polyolefins. They have the same chemical structure and can be polymerized the same way. The same grades (film, injection or blow moulding etc) can be created and so on.

The only difference is the origin of the carbon. Biobased polyolefins consist of renewable carbon. This can be tested and proven by the radio carbon method (12C versus 14C) as described in ASTM 6866.

bioplastics MAGAZINE [05/10] Vol. 5

55

Personality

Mark Verbruggen bM: When and where were you born?

MV: I was born in a little town close to Antwerp, Belgium, in July 1959. bM: Where do you live today and since when?

MV: I’ve lived in the US for nearly 10 years now. bM: What is your education?

MV: I received a PhD in aerospace engineering from the University of Delft, the Netherlands, although I never worked in an aerospace company. bM: What is your professional function today?

MV: I am president and CEO of NatureWorks LLC. bM: How did you ‘come to’ bioplastics?

MV: In 2008, I was president of North American carbon fiber operations for Teijin, a shareholder in NatureWorks.

The managing board of directors asked me to become CEO of NatureWorks. Bioplastics and carbon fibers are both fast growing businesses that need very large asset bases - and of course big plants.

So I joined NatureWorks in the summer of 2008. Teijin left the joint venture a year later because NatureWorks no longer fit into its business portfolio. bM: What do you consider more important: ‘biobased‘ or ‘biodegradable‘?

MV: Actually, what we consider most important is first enabling a compelling family of consumer products which perform well in use - that has to be a given! Now, with that established, from an environmental point of view, biobased (the renewable aspect, and the ultra low carbon footprint that this yields) is most important to governments, brand owners, retailers, consumers and environmental organizations because it’s a common denominator across every single market segment we sell into. Compostability is important, but secondary, and much specific to certain end-markets. Ingeo is compostable, which makes it ideal for food contaminated service ware and packaging for instance. bM: What is your biggest achievement (in terms of bioplastics) so far?

MV: Simply put, it’s the diversity of the end markets into which we sell Ingeo – and in turn, what this means about the strength of our business – as evidenced by NatureWorks coming out of the global recession in better financial shape than when the downturn began. To realize that we kept all our customers on board through the economic downturn is

a clear proof point of the value proposition offered by Ingeo plastics and fibers. bM: What are your biggest challenges for the future?

MV: Our biggest challenge short term is to create economy of scale throughout the value chain. On the upstream side, we are proud to have a 140.000 tons Ingeo capacity, but it is even more important today to work on the economy of scale of the downstream processes, the compounding and converting (film, nonwovens etc), thus to achieve competitive costing all the way thru to finished consumer products.

In the longer run, the challenge will in bringing to bear different feedstocks (e.g. incorporating cellulosic feedstocks into the biopolymer production in an economic way), and in sorting out what the 2nd and 3rd generation of biopolymers will look like. On this last point, I always emphasize that NatureWorks is not a ‘One-Trick-Pony’ i.e. Ingeo will not represent ‘PLA-only’ and NatureWorks, will look different in 2020. bM: What is your family status?

MV: I am happily married to my wife Stephanie Balest.

When we first met, she found my last name impossible to pronounce so she decided to keep her maiden name. She lives in Knoxville, Tennessee, where she runs two restaurants.

We have no children, making our weekends a little easier. bM: What is your favourite movie?

MV: Comedy: The Big Lebowski by the Coen brothers in 1998. bM: What is your favourite book?

MV: I do not really have one due to lack of time - but I enjoy reading The New York Times, which is my connection to the world outside bioplastics. bM: What is your favourite (or your next) vacation location?

MV: While we would love to spend more time in Europe, we usually cannot spend more than 4 or 5 days together for a vacation. Then we really enjoy going to Florida or the Bahamas - and we strictly stay away from telephones! bM: What do you eat for breakfast on a Sunday?

MV: Traditionally American with a slight European touch.

Growing up in Belgium, we often had soft-boiled eggs for breakfast as well as lots of chocolate. Up to this day, I stick with both for my Sunday breakfast. If I can be in Knoxville for the weekend, Stephanie makes the greatest omelettes bM: What is your ‘slogan’?

MV: FOCUS - see, keep and travel a clear and straight path towards the big picture! bM: Thank you very much.

MT

56

bioplastics MAGAZINE [05/10] Vol. 5

Opinion

Sustainability Counts Through the Life Cycle

By Heeral Bhalala Coordinator, Sustainable Biomaterials Collaborator Institute for Local Self-Reliance Washington, DC , USA

F

ossil-fuel-derived plastics are non-renewable, often threaten public health, have devastating impacts on marine life, and increase reliance on imported fossilfuel-based feedstocks in many countries. The development of bioplastics holds great promise to mitigate many of these sustainability problems by offering the potential of renewability, biodegradation, and a path away from harmful additives. They are not, however, an automatic panacea.

Harvesting of forest biomass can be done in ways that jeopardize the health of the forest and ecosystem. Modern industrial agriculture creates a host of health, environmental, social issues including the use of genetically modified organisms (GMOs) in the field, toxic pesticides, high fossil fuel energy use, and the loss of family farms. Farming can also degrade water and soil quality and endanger natural habitat and biodiversity. Increased demand for agricultural products may well exacerbate problems posed by modern agriculture while increasing pressure on ecologically sensitive land and raising food security concerns. The manufacture, use and discard of products made from bioplastics can also result in hazardous emissions, particularly if the bioplastic is mixed with fossil fuel-based chemicals. While many bioplastic products are certified compostable, challenges remain in developing the collection services and the composting infrastructure to ensure products are actually composted at the end of their intended use. At the same time, some bioplastic products may be recyclable but similarly lack the necessary infrastructure, while posing concerns for existing recycling systems.

The Sustainable Biomaterials Collaborative (SBC) is a network of organizations working together to spur the introduction and use of biomaterials that are sustainable from cradle to cradle. The Collaborative seeks to advance the development and diffusion of sustainable biomaterials by creating sustainability guidelines, engaging markets, and promoting policy initiatives. It is broadly focused on the entire lifecycle of biomaterials from production in the fields, to green manufacturing, to product use, and recycling or composting

58

bioplastics MAGAZINE [05/10] Vol. 5

at the end of product life. We define sustainable biomaterials as those that: (1) are sourced from sustainably grown and harvested cropland or forests, (2) are manufactured without hazardous inputs and impacts, (3) are healthy and safe for the environment during use, (4) are designed to be reutilized at the end of their intended use, such as via recycling or composting, and (5) provide living wages and do not exploit workers or communities throughout the product lifecycle.

Starting at the Source An assessment of the sustainability of bioplastics begins at the source, looking at how feedstocks are grown and harvested. While bioplastics are made from a wide variety of agricultural and forest-based materials, most of the bioplastics available today are derived from corn and other commodity crops, crops that have clear and significant impacts on our natural environment. But agriculture can also improve water and soil health, provide refuge and food for wildlife and increase biodiversity and economic prosperity for farmers, their families and communities.

The SBC is working to further develop and implement an innovative market-based approach that allows bioplastic users to support environmental stewardship on agricultural lands. The Working Landscapes Certificates (WLC) program is currently focused on corn-based plastics, but could expand to other feedstocks. WLCs are a purchasable offset for companies presently using bioplastics that want to support sustainable farming practices. This payment is used to financially support farmers who agree to raise the crop under prescribed sustainability criteria. For corn this means not using GMO seed, eliminating carcinogenic chemical and atrazine use, and other practices that promote better environmental quality.

The program is now poised for major expansion.

Negotiations are nearly complete with a major national company to grow the WLC program over five-fold this year with more growth in later years.

Opinion

Steps to Best Practices for Each Life Cycle Stage 1) Biological Feedstock Production a) Eliminate hazardous chemicals of concern b) Avoid use of genetically modified seeds c) Conserve, protect and build soil d) Conserve nutrient cycles e) Protect air and water access and quality

Making the Product By paying attention to the principles of green chemistry, manufacturers can increase process safety to protect worker health, and minimize hazardous emissions into the environment. Biobased producers could avoid problematic blends that contain large quantities of petroleum plastic, thus easing reclamation of the product. Avoiding persistent, bioaccumulative, and other toxic chemicals is important.

Consider use of nanomaterials with caution as not all have been comprehensively tested for health or safety impacts.

f) Promote biological diversity g) Reduce impacts of energy use h) Reduce transportation impacts i) Develop and certify a comprehensive sustainable agriculture plan j) Protect workers

2) Processing and Manufacturing a) Support sustainable feedstock production

Design for Recovery Bioplastics are just another burden on the landfill unless they are recovered for recycling or composting. In the US, waste incineration is broadly opposed, while anaerobic digestion for methane recovery is becoming more widely accepted. Without the technology and infrastructure in place to handle discarded biobased products, bioplastics are likely to end up trashed rather than recovered. While the composting infrastructure is developing, systems for recycling bioplastics are virtually non-existent and have many challenges to their widespread implementation. For example, who will capitalize the equipment to sort PLA from PET? Will compostable plastic bags contaminate the recycling of conventional polyethylene bags? Product labeling is a critical issue to inform citizens how best to handle products once used. Biodegradation in the marine environment is also increasingly being recognized as important.

b) Reduce impacts of energy use c) Avoid problematic blends and additives and encourage recycling d) Maximize process safety and minimize hazardous emissions e) Continuous improvement f) Protect workers

3) Product Distribution and Use a) Reduce quantity used b) Avoid unhealthy exposures c) Create opportunities for sustainability education d) Label material content e) Prefer local

Industry Challenge Developing the technology and markets for sustainable bioplastics will require time. The Collaborative has defined a progression of intermediate steps towards reaching sustainable biobased products (see sidebar ‘Steps to Best Practice‘). We encourage companies to evaluate their current practice and make public commitments toward these goals. Please visit our website for more information.

4) End of Product a) Ensure safe and rapid biodegradation b) Design product for recycling or composting c) Producer and converter industry participate in planning for complete life d) Protect workers

www.sustainablebiomaterials.org www.workinglandscapes.org

Source: Guidelines for Sustainable Bioplastics, www.sustainablebiomaterials.org, 2009

bioplastics MAGAZINE [05/10] Vol. 5

59

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 p42]

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 p42] 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 p34, bM 01/2007 p38]]

60

bioplastics MAGAZINE [05/10] 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.

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

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] 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

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.

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.

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.

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 [05/10] Vol. 5

61

Suppliers Guide 3.1.1 cellulose based films

1. Raw Materials 10

20

30

40

50

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

60

70

80

90

Showa Denko Europe GmbH Konrad-Zuse-Platz 4 81829 Munich, Germany Tel.: +49 89 93996226 www.showa-denko.com support@sde.de 1.1 bio based monomers

100

110

120

130

140

PURAC division Arkelsedijk 46, P.O. Box 21 4200 AA Gorinchem The Netherlands Tel.: +31 (0)183 695 695 Fax: +31 (0)183 695 604 www.purac.com PLA@purac.com 1.2 compounds

150

160

170

180

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

190

200

210

220

230

240

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

260

270

62

bioplastics MAGAZINE [05/10] Vol. 5

Telles, Metabolix – ADM joint venture 650 Suffolk Street, Suite 100 Lowell, MA 01854 USA Tel. +1-97 85 13 18 00 Fax +1-97 85 13 18 86 www.mirelplastics.com

1.3 PLA

Shenzhen Brightchina Ind. Co;Ltd www.brightcn.net www.esun.en.alibaba.com bright@brightcn.net Tel: +86-755-2603 1978 1.4 starch-based bioplastics

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

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

Sukano AG Chaltenbodenstrasse 23 CH-8834 Schindellegi Tel. +41 44 787 57 77 Fax +41 44 787 57 78 www.sukano.com 3. Semi finished products

INNOVIA FILMS LTD Wigton Cumbria CA7 9BG England Contact: Andy Sweetman Tel. +44 16973 41549 Fax +44 16973 41452 andy.sweetman@innoviafilms.com www.innoviafilms.com 4. Bioplastics products

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

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

3.1 films Jean-Pierre Le Flanchec 3 rue Scheffer 75116 Paris cedex, France Tel: +33 (0)1 53 65 23 00 Fax: +33 (0)1 53 65 81 99 biosphere@biosphere.eu www.biosphere.eu

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

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

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

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

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. +385 31 7005 011 Fax +385 31 705 012 info@ecocortec.hr www.ecocortec.hr

1.5 PHA

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

4201 Woodland Road MK46 5FP Circle Pines, MN 55014 USA Tel.: +44 1234 714 477 Tel. +1 763.225.6600 Fax: +44 1234 713 221 Fax +1 763.225.6645 sales@aandofilmpac.com info@natur-tec.com www.bioresins.eu www.natur-tec.com ®

250

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

Taghleef Industries SpA, Italy Via E. Fermi, 46 33058 San Giorgio di Nogaro (UD) Contact Frank Ernst Tel. +49 2402 7096989 Mobile +49 160 4756573 frank.ernst@ti-films.com www.ti-films.com

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

Suppliers Guide Simply contact:

Tel.: +49 02351 67100-0

6.2 Laboratory Equipment 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

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

suppguide@bioplasticsmagazine.com

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

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.

10.2 Universities

For Example:

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

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

10 35 mm

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

20

30 35

Sample Charge:

4.1 trays

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

5. Traders

8. Ancillary equipment

5.1 wholesale

9. Services

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

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

35mm x 6,00 â‚Ź = 210,00 â‚Ź per entry/per issue

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

6. Equipment 6.1 Machinery & Molds

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

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

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

COMPOSTABLE PACKAGING TECHNOLOGIES

EcoWorks

ÂŽ

• 100% BIODEGRADABLE • 100% COMPOSTABLE

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

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

10. Institutions 10.1 Associations

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

Q U A EXCELLENCE I T Y

w w w. C o r t e c V C I . c o m BPI - The Biodegradable Products Institute 331 West 57th Street, Suite 415 New York, NY 10019, USA Tel. +1-888-274-5646 info@bpiworld.org

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

SY

BioPlastics 2010.indd 1

ST

VIRO

NMENT

AL

EM REGISTER

ED

( & ) ( , - %

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

bioplastics MAGAZINE [05/10] Vol. 5

63

2/1/10 9:11:30 AM

Companies in this issue Company

Editorial

A&O Filmpac AIB Vincotte Alesco API Arkema Avianca BASF Bayern Innovativ Bio4Pack bioplastics24 Biotec Boselle E. & Cie. BPI Braskem Britney Spears Brückner C.L.A.S.S. Cabopol Cereplast Chinaplast Clariant Clarifoil Coperion Cortec Daimler DSM DuPont EconCore Ecor EMS GRIVORY European Bioplastics Fama Jersey FAS Converting Fasal Wood Fashion Helmet FH Hannover Fischerwerke FKuR Fraunhofer PAZ Fraunhofer UMSICHT Frizza Fujitsu Gattinoni GEHR Kunststoffwerk Grace Bio Green Gran Hallink Huhtamaki ICO Staionery Manufacturing Innovia Films Inst. for Self-Relienace Kikkoman Lei-Tsu Lificolor

31 40

Next Issue

62 40, 44 14, 30, 46 23 5, 38

62 41 62 28

28 16, 17 5, 7, 31, 52 22 6, 31 16 30 22

63 19 34

62 49

40 22 30 62, 63 5 32 32 24, 26 22 32

34 29, 63

16 63 39 18 39 5 6, 27, 33 20

63 2, 62 63

16 27 17 40 62 34 63 62 27 62 58 12 17 33

Company

Editorial

Limagrain Céréales Ingrédients Mann + Hummel M-Base Merquinsa Michigan State University Minima Technology Murasaki Natureplast NatureWorks Natur-Tec NEC NGR Recycling Machines Nordic Fashion Association nova Institut Novamont Phoenix Packaging Group Plastic Suppliers plasticker Polymediaconsult PolyOne President Packaging Procter&Gamble Proganic PSM Purac Rizieri Robert-Bosch Roll-o-Matic Saara Lopokorpi Saida Sezersan Shenzen Brightchina Sidaplax Sukano SUPLA Sustainable Biomaterials Collaboration Synbra Taghleef Industries Tandus Teijin Telles ThermHex Waben Tianan Biologic Toyota Transmare TU Braunschweig Uhde Inventa-Fischer Universität Stuttgart University of Guelph Wei Mon Wirkstoffgruppe Wuhan Huali (PSM) Zhejiang Hangzhou Xinfu Pharmaceutical

39 32, 50 63 62 12 37 16, 17, 18, 19, 23, 56 62 21 36 16 10, 22, 38 23

33

34 21 1, 62, 68 62 6 63 34 63

5 13, 27 15, 62 7, 62 18 5 36 16

34, 63 63

22

38 39 58 37 6, 31 17 12 37 24

62 62 34, 62

62

62, 67 62

26 62 5 34, 51, 63 6 42 57, 63 63 15 36

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

Publ.-Date

Editorial Focus (1)

Editorial Focus (2)

Basics

Fair Specials

Nov / Dec

Dec. 06, 2010

Films / Flexibles / Bags

Consumer Electronics

Recycling

K‘2010 Review

bioplastics MAGAZINE [04/10] Vol. 5

Advert 62 63

Month

New: 64

Advert 62

Follow us on twitter: http://twitter.com/bioplasticsmag

Like us on Facebook: http://www.facebook.com/pages/bioplastics-MAGAZINE/103745406344904

bioplastics MAGAZINE [04/10] Vol. 5

65

Event Calendar

Event Calendar Oct. 11-13, 2010 5th Annual Biopolymer Symposium The Westin Tabor Center Denver, Colorado, USA

Nov. 22-24, 2010 Agricultural Film 2010 Fira Palace Hotel, Barcelona, Spain www2.amiplastics.com

www.biopolymersummit.com

Oct. 13-15, 2010 19th Annual BEPS Meeting POLYMERS AND THE ENVIRONMENT: EMERGING GREEN TECHNOLOGIES & SCIENCE Sheraton Centre Toronto Hotel Toronto, Ontario, Canada www.beps.org

Oct. 18-20, 2010 Sustainable Cosmetics Summit Paris / France www.sustainablecosmeticssummit.com

Oct. 19-21, 2010 EuropaBio‘s 3rd annual European Forum for Industrial Biotechnology 2010 Sheraton Grand Hotel & Spa, Edinburgh, Scotland www.efibforum.com

Oct. 26-28, 2010 4th International Conference on Technology & Application of Biodegradable/Biobased Plastics (ICTABP4) Shang Hai Tongji University (Jiading Campus), Shanghai, China www.degradable.org.cn

Oct. 27 - Nov. 03, 2010 Visit us at K‘ 2010 - International trade Fair No.1 for Plastics & Rubber Worldwide Booth 7C09, Düsseldorf, Germany www.k-online.de

Oct. 28 - 30, 2010 Bioplastics Business Breakfast (@ K‘2010) Three meetings - succinct and to the point before the fair doors open www.bioplastics-breakfast.com

November 11, 2010 Biopolymers: Perspectives – Technologies – Markets Cooperation Forum, Visit of Companies and Institutes Herzogschloss Straubing, Bavaria/Germany

Dec. 1-2, 2010 5th European Bioplastics Conference Hilton Hotel, Düsseldorf, Germany www.conference.european-bioplastics.org

Feb. 01-03, 2011 Bioplastics - Reshaping an Industry Cesar‘s Palace, Las Vegas; USA www.reshapinganindustry.com

April 12 - 13, 2011 4. BioKunststoffe 2011 Tagungsveranstaltung Hannover www.hanser-tagungen.de

March 29-30, 2011 Bioplastics Compounding and Processing 2011 International conference on the profitable use of bioplastics Hilton Downtown Miami, Miami, Florida www2.amiplastics.com

May 1-5, 2011 ANTEC® 2011 Sponsor: Society of Plastics Engineers Boston Marriott Copley Place and Hynes Convention Center Boston, MA USA www.antec.ws

Sept. 25-29, 2011 8th European Congress of Chemical Engineering and 1st European Congress of Applied Biotechnology (together with ProcessNet Annual Meeting 2011 and DECHEMA‘s Biotechnology Annual Meeting) Berlin, Germany www.dechema.de

Oct. 17-19, 2011 GPEC 2011 (SPE‘s Global Plastics Environmental Conference) The Atlanta Peachtree Westin Hotel, Atlanta, GA, USA www.4spe.org

www.bayern-innovativ.de/biopolymere2010

Nov. 16-17, 2010 The Second China (Shenzen) International Exhibition and Forum of Biological Plastic Great China International Exchange Square Shenzen, China www.szhowell.net

66

bioplastics MAGAZINE [05/10] Vol. 5

You can meet us!

Please contact us in advance by e-mail.

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