bioplastics MAGAZINE 02-2011 by bioplastics MAGAZINE

bioplastics

magazine

Vol. 6 ISSN 1862-5258

March / April

02 | 2011

FKuR plastics - made by nature!® Bio-Flex® multilayers – engineered to clarity!

Multilayer made from Bio-Flex® A 4100 CL / F 2201 CL / A 4100 CL, content of renewable resources approx. 70%!

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

Guest Editorial

dear readers Every 3 years the packaging industry packs its bags and arrives in Düsseldorf for the largest packaging show in the World – INTERPACK. 6 years ago European Bioplastics set up a small pavilion to introduce this new school of materials – Bioplastics – but it was very early days and the functional capability of the materials was quite limited. And, if I remember correctly, the show was also the soundingboard to assess the potential viability of a publication specifically aimed at our industry. Indeed, within a year the first issue of bioplastics MAGAZINE landed on our desks… 3 years later and our industry shared a larger pavilion with elements of the sustainable paper industry. The technical progress made by our industry was evident to see; the materials were starting to show evident technical progress with stands demonstrating a mixture of real commercial packs and developmental concepts. And now, in 2011, we‘re back here again; but this time the industry has grown sufficiently mainstream to find its way into the ‘normal’ halls. We’re following the same format of keeping our stands close together, so that partners and potential customers can find us in a kind of ‘one stop shop’. I anticipate we’ll all be showcasing the major technical and commercial progress made to date; what will be evident is that the products on show are increasingly showing ‘conventional’ plastic packaging performance albeit using materials that are either bioderived, biodegradable after use, or both. And at the same time we’ll be celebrating the 5th birthday of bioplastics MAGAZINE. Congratulations to Michael and the team and we’ll raise our glasses at the show to toast the next five years!!

Andy Sweetman Chairman – European Bioplastics

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bioplastics MAGAZINE [02/11] Vol. 6

The cover of this issue is laminated with metallised NatureFlex™ from Innovia Films, converted by Achilles Papierveredlung. Therefore the complete issue is still fully compostable ...

Cover

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

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

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.

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

Event Calendar 56 Glossary 58 Companies in this issue 62 Editorial Planner 2011 56

bioplastics MAGAZINE is read in 91 countries.

March/April

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

02|2011

ISSN 1862-5258 bioplastics magazine is published 6 times a year. This publication is sent to qualified subscribers (149 Euro for 6 issues).

bioplastics magazine

Tölkes Druck + Medien GmbH 47807 Krefeld, Germany Total Print run: 9,000 copies

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Editorial News Application News interpack Preview interpack ShowGuide Event Calendar Suppliers Guide

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Head Office

Mark Speckenbach, Julia Hunold

Layout/Production

Dr. Michael Thielen Samuel Brangenberg

Publisher / Editorial

Imprint Content

5 - 11

40 -45

26 - 37

32 - 33 59

Rigid Packaging

Bio-Alternative for HIPS Sheet 12

High-Performance Thermforming of Starch-Based Polymers 14

Clearing the Way for Wider PLA Use 16

Catering Products

Carousing for our Climate 18

Heat Resistant & Certified Compostable Utensils 20

Applications

Biodegradable Alternative to Leather 22

New Sustainable Bottle Initiative 24

World‘s First 100% Plant-Based PET Bottle 25

Materials

Improved PHA Production in Tobacco 38

Basics

Bioplastics in Packaging 46

Opinion

Comments regarding Cereplasts Symbol Competition

Martin Kumar Patel

Bioplastics in Israel 50

Personality

Politics

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News

Biopackaging for Beverages Compostable bottles present an increasingly attractive alternative to recycled PET for beverage companies, according to a new Drinks Biopackaging report from leading food and drink consultancy Zenith International. Biopackaging use in the combined markets of West Europe and North America rose by 47% in 2010 to over 100 million litres, but volumes remain small as a proportion of total volume. There is a clear need for government incentives if the market is to make a real step change, particularly in the area of drinks packaging. “While the environmental credentials of compostable bottles sit well with increasingly green-minded consumers, challenges such as price, separation from PET and composting facilities persist,” commented Zenith Senior Analyst Jenny Foulds. Zenith’s 2011 Drinks Biopackaging report finds that: Biopackaging does have potential to improve sustainability in beverage packaging. Increased retailer acceptance has helped compostable packaging become a mainstream opportunity. Whilst the economic downturn may have affected demand, interest in added value, convenience and eco-friendly products will return. Larger formats, such as 1.5 and 2 litre sizes or above, represent a relatively untapped segment. Growing interest in locally-available renewable crops may bring additional scope.

DRINKS BIOPACKAGING MARKET, 2006-10 Million litres

North America, West Europe

120 100

“Despite the difficulties, we foresee continuing strong growth in development projects. If the challenges can be answered, then volume can gain serious market share”, Jenny Foulds concluded.

The Report contains over 80 pages and is available for € 1500 or US-$ 2000 via Zenith’s website.

60 40

0 2006 2007 2008 2009 2010e

www.zenithinternational.com.

bioplastics MAGAZINE [02/11] Vol. 6

News

Another 5 Year Jubilee “Limagrain Céréales Ingrédients (LCI) are also celebrating five years – their five-year involvement with bioplastics,” explains Nathalie Gorce, Marketing Manager for biolice at LCI. “We will focus here on food packaging, a dynamic sector where innovation is an essential development. Long regarded as an accessory to the product inside, food packaging is now an important part of the production chain that connects the product to the consumer.” In addition to its role of protection and conservation of a product - and communication of brand image through package design - environmental awareness has become a key consideration in the development of a package, whether flexible or rigid. The market for bioplastics is one that is growing both in technological and commercial terms. The raw materials now available offer a wide range of high-tech options to meet the requirements of this market. Agricultural resources provide a renewable energy source that is one of the main alternatives to the use of oil-based resources for many applications. The use of biomass is also a driver for new products by providing new functionality. In this way, the development of bioplastics is part of the overall issue of sustainable development. LCI is at the heart of these market expectations and developments. “Our strength lies in our ability to combine the agricultural and environmental needs of farmers with the industrial and technological requirements of manufacturers,” says Nathalie. Biolice is an environment-friendly bioplastic that offers a high quality alternative to ordinary plastics for flexible applications such as bags, industrial films as well as rigid thermoformed and shaped extruded products - ideal for the packaging industry. After use and disposal it is broken down by micro-organisms and produces humus. In producing biolice, we work with our member farmers to control the production of the maize raw material from seed and have created a unique site where processing, storage and transformation into biolice granules are situated together to limit transport and protect traceability. Helping to develop the market for bioplastics allows us to work with customers to focus on important issues such as improving environmental protection - including limiting emissions of greenhouse gases that contribute to global climate change. It also helps to ensure economic growth, especially that of rural areas, by providing farmers with new market opportunities for their output - thus meeting our strategy of developing added value cereal crops for our farmer members. www.lci.limagrain.com

Frost and Sullivan Rewards BIOPAR Technology Based on the findings of the Best Practices research, Frost & Sullivan presents the Award in Starch Polymers Market to BIOP. “At BIOP they go an extra mile to clearly understand and design a product according to the needs of the consumers”, says Senior Research Analyst Dr. Sujatha Vijayan. She adds: “It distinguishes itself with a novel technology platform which is very promising”. The technology platform allows combining different polymers and starches in order to match best the properties and requirements the customer asks for. The success of the technology today shows clearly that BIOPAR® can do more. “We foresee the Biopar technology becoming world standard in starch polymers”, Frits P.E.A. de Jong, CEO of Biopolymer Technologies AG (BIOP) is convinced. “We are very pleased to be presented as the 2011 Award winner for the European Product Differentiation Excellence Award from Frost and Sullivan”, says de Jong “This recognition validates the outstanding performance of our bi-continuous-phase technology” www.biop.eu

bioplastics MAGAZINE [02/11] Vol. 6

News

iBIB2011 - The First International Business Directory Compostable Netting The main objective of the European ECOBIONET project is the market introduction of new products for the packaging of fresh food with the added advantages of biodegradability and environmental sustainability. This will enable manufacturers to minimize the environmental impact by reducing the generation of plastic waste. To achieve this, four companies from Germany, Belgium and Spain are working together with the research organisation AIMPLAS on the implementation of new materials and processes for biodegradable and compostable packaging nets. Partners are the German company Tecnaro, OWS from Belgium and the Spanish net producers Cristobal Meseguer and Ecoplas. The target markets are agricultural and shellfish products. Four different types of nets will be developed during the ECOBIONET project period: These will be oriented and non-oriented nets of two or three filaments in combination with plastic sheets. The nets will be manufactured in a conventional one-step extrusion melt-spinning process. As a specific objective, the biodegradable nets developed in the project must meet the requirements for the final application (packaging of agricultural and shellfish products). The nets must be mechanically comparable to the currently used nets based on polyolefins, and they must be cost-competitive. In addition the new nets must be completely biodegradable and compostable (EN 13432) in order to obtain the right to use the eco-label/compostable logo.

The market for bio-based plastics and composites continues to grow at double-figure rates and has now gained true international status. However, the new market functions based mainly on ‘insider-knowledge’ and therefore lacks transparency. The international business directory iBIB2011 comprises information on about 70 major companies, associations and R&D organisations from 17 countries on four continents. Publishers are the renowned nova-Institute and bioplastics MAGAZINE. The iBIB2011 will enable industrial suppliers and customers to reach out to one another. It will help companies to find the best bio-based solutions available worldwide within the sectors of bio-based plastics, composites and green additives. Via print and PDF versions the iBIB2011 will reach ten thousands potential customers. The print version will be distributed free of charge by the publishers and partners at trade fairs, exhibitions and conferences worldwide, the PDF version will be made available to a wide audience via email and websites. The online database with detailed index will help to reach a supplier in a most targeted way. At www.bio-based.eu/ iBIB a free and direct access to the database with more than 100 specific criteria is open to everyone. Also the full PDF version is available for free. Companies, associations or institutes are welcome to join the business directory at any time and will immediately be included in our online database. They will also automatically be included in the next print edition iBIB2012. www.bio-based.eu/iBIB

The European Commission is funding this project in the scope of the ‘CIP-Eco-Innovation’ programme. The partners are using and adapting compounds which were developed in a previous European CRAFT project, which was the basis of ECOBIONET. MT www.aimplas.es/proyectos/ecobionet

bioplastics MAGAZINE [02/11] Vol. 6

& J O I N T LY

P R E S E N T

THE SIXTH ANNUAL GLOBAL AWARD FOR DEVELOPERS, MANUFACTURERS AND USERS OF BIO-BASED PLASTICS.

Call for proposals Enter your own product, service or development, or nominate your favourite example from another organisation

Please let us know: does or development is and ce rvi se t, uc od pr e th an award 1. What velopment should win de or ce rvi se t, uc od 2. Why you think this pr on does ) company or organisati ed os op pr e th (or ur yo 3. What ge) and may also 500 words (approx 1 pa ochures and/or ed ce ex t no ld ou sh Your entry keting br graphs, samples, mar be The 5 nominees must be supported with photo ). ck ba ot be sent nn (ca ion tat en m cu do technical 30 second videoclip prepared to provide a m

ded fro try form can be downloa More details and an en ine.de/award www.bioplasticsmagaz

The Bioplastics Award will be presented during the 6th European Bioplastics Conference November 22/23, 2011, Berlin, Germany

supported by

News

BASF Starts Operations at Expanded Ecoflex Plant BASF has started operations at its expanded plant for the production of the biodegradable plastic Ecoflex®. Expansion of the existing plant in Ludwigshafen, Germany will increase production capacity for Ecoflex from 14,000 to 74,000 tonnes per year. At the same time, BASF will ramp up compounding capacity for Ecovio®, a derivative of Ecoflex (basically a compound of Ecoflex and PLA). “We are already successful in the market with our biodegradable polyester Ecoflex and the related innovation, Ecovio. The larger production capacities will enhance our position significantly,” said Dr. Wolfgang Hapke, president of BASF’s Performance Polymers division. “The capacity expansion will also enable us to respond even more effectively to our customers’ wishes.” Ecoflex is an aliphatic-aromatic copolyester (PBAT) that has the properties of conventional polyethylene but is fully biodegradable under industrial composting conditions in accordance with DIN EN 13432. Ecovio is a derivative of Ecoflex that is also biodegradable and that contains up to 75% renewable raw materials. Typical applications are shopping bags, organic waste bags, mulch films for agricultural applications, and food packaging. One of the latest innovations is Ecovio FS Paper, which is used to provide a biodegradable waterproof coating on the interior surfaces of paper cups and cardboard containers. MT www.basf.com

bioplastics MAGAZINE [02/11] Vol. 6

Events News

5 Years bioplastics MAGAZINE By now every reader should have discovered the secret of this issue’s unusual cover. bioplastics MAGAZINE is celebrating its 5th birthday. Five years and 25 issues (plus this one) show that we obviously hit the nerve of this emerging industry. And we think that interpack is the right place to celebrate this birthday. After all, it was at interpack 2005, at the first ‘Innovationparc Bioplastics in Packaging’ when founder, publisher and editor Michael Thielen was ‘infected by the bioplastics virus’. And less than one year later the first issue of bioplastics MAGAZINE was born. Now it’s time for a party, and so the team from bioplastics MAGAZINE would love to thank you and invite all our advertisers, contributors, readers, partners and critics that are coming to interpack to join us for a drink. On Friday, May 13th (we are not superstitious !) in the later afternoon hours, bioplastics MAGAZINE is going to sponsor a socalled ’Bar Bell’ with free cocktails, beer and other beverages at the booth of European Bioplastics, Hall 9, Booth 9E02. Come and have a drink with us.

Chinaplas Features Event on Green Plastics Nowadays, many countries request the manufacturers not only to consider the products‘ function and cost, but also to bear the responsibility of the environmental impact brought about by the products. China‘s 12th five-year plan‘s policies on energy saving and emission reduction, together with the introduction of various regulations on environmental protection, have led to the new challenges to the development of plastics and rubber industries. As Asia‘s no. 1 and the world‘s top 3 plastics and rubber trade fair, CHINAPLAS has fully demonstrated this major direction and paved the way for green plastics and rubber industries. CHINAPLAS 2011 will be held in the China Import & Export Fair Pazhou Complex, Guangzhou, PR China from May 17 to 20, 2011. Mr. Stanley Chu, Chairman of Adsale Exhibition Services Ltd, the show‘s organizer, stated that the show would continue last year‘s theme of ’Green Plastics - Our Goal - Our Future’ to cater to the market needs, and would disseminate the messages of ‘energy-saving’ ; ‘emission reduction’ ; ‘recycling’ and ‘biodegradable plastics’ through different exhibits and concurrent events. ‘Eco-friendly Plastics Conference’, one of the concurrent events, will gather renowned international and Chinese corporations and associations‘ representatives from the plastics and rubber industries to share the current hot topics and their insights. Invited organizations include the British Plastics Federation, the Society of the Plastics Industry, Inc., NatureWorks LLC, etc. As China is now the world‘s largest plastic product manufacturer and consumer, the research, production and application of biobased plastics and biodegradable plastics are important for the sustainability of the plastics industry in China. One of the topics of the conference, ‘The Challenge of Sustainability and the Applications of Bio-plastics and Degradable Plastics’, will discuss the standard and sustainability of biobased plastics and biodegradable plastics in USA, Europe, and Japan, its applications and market trend. Other topics of the conference are ‘Reduce Carbon Emission with Recycling Plastics Technology’ and ‘Achieve Energy Efficiency with Energy Saving Plastics Technology’.

Special Events and New Zone Raise the Environmental Awareness To promote the message of environmental protection, the organizer will hold a record-breaking event – ‘Beating Record by Recycling Bottles’ during the show. More than 3,000 recycled bottles will be collected to create a plastics statue and create a new record in the Guinness World Record, with an objective to arouse the environmental awareness of the exhibitors and over 80,000 visitors at the on-site fairground. In addition, the organizer has newly established the ‘Bioplastics and Degradable Plastics Zone’, aiming to create an efficient and convenient platform for buyers who are looking for green manufacturing solutions. Exhibitors of this zone now include NatureWorks LLC, Kingfa, Biograde, Shenzen Ecomann, Hangzhou Xinfu, etc. www.ChinaplasOnline.com

bioplastics MAGAZINE [02/11] Vol. 6

Events

Delegates Voted for ‘Biomaterial of the Year 2011’ And the winner is Zelfo... For the fourth year running, an Innovation Prize from nova-Institute (Huerth, Germany) was awarded to the innovative biomaterials industry - bio-based plastics, natural fibre reinforced plastics and wood plastic composites. The aim was to recognize and reward innovative ideas in the biomaterials industry regarding material and product development and product launch. The competition seeks to encourage the development of new materials, along with suitable applications and markets for bio-based products. Sponsor of the ‘Biomaterial of the Year 2011’ was, as in the years before, the company Coperion (Stuttgart, Germany), one of the leading twin screw extruder producers. 14 companies followed the tender and five were nominated by a panel of judges composed of biomaterial experts. The final winners were elected by the 150 or more participants of the 4th International Congress on Bio-based Plastics and Composites in Cologne (15/16 March 2011), organized by nova-Institute. The three winners are: 1st prize: OMODO® GmbH, Germany: Zelfo® The ‘Cellulose Optimization Resource Efficient (CORE)’-technology up-cycles cellulosic and ligno-cellulosic waste without the addition of any chemicals, catalysts or binders to create Zelfo, a micro and nano-fibrillated cellulose fibre (MFC/NFC). Zelfo can be formed into finished objects (bio-composites), or used as a bio-additive to improve plastic or paper material characteristics. Biomass: Cellulose and ligno-cellulose biomass www.omodo.org

No. 2: Ecovative Design LLC, USA: EcoCradle EcoCradle is a low embodied-energy, compostable, protective packaging material that is literally grown into any custom shape and competes with petrochemical foams in terms of both performance and cost. The self-assembling bonds formed by mycelium (mushroom ‘roots’) produce this material as it grows around a substrate of regionally sourced agricultural by-products.

Zelfo layered CNC demo part (photo: Omodo)

Biomass: Agricultural by-products, fungus mycelium www.ecovativedesign.com

No. 3: ROQUETTE, France: GAÏALENE® Gaïalene is a new ‘high-performance’ range of bio-based plastics for packaging, which can compete in performance terms (mechanical, thermal, soft touch, etc.) with fossil-based plastics. Gaïalene resin is for lasting applications that currently use polyolefins, ABS and more technical polymers - with an excellent cost/efficiency profile. Biomass: Starch www.gaialene.com www.biowerkstoff-kongress.de

bioplastics MAGAZINE [02/11] Vol. 6

Rigid Packaging

Bio-Alternative for HIPS Sheet By Volker Siebott JC Hagen GmbH Vienna, Austria

Hips Sheet Grade - Supply Situation

bio-plast SHJ 700 thermoformed on Kiefel thermoformer

One might think that gas and oil exploration countries always have an ample supply of polymers. With a population of more than 71 million the supply situation is anything but balanced in the Islamic Republic of Iran. Besides a significant lack of refining capacities for petrol, Iran has also been a net importer of polystyrene resin in recent years. The country exports huge quantities of crude oil, in particular to Korea, and receives the refined products in return. Rather than expanding the refining capacities within the country a long term strategy led to the development of bio-plastics as an alternative industry. Based on corn starch and other renewable materials the plan will help to keep farmers employed and reduce the trend of urbanization which, at 68%, is already a major concern of the government. With an estimated population of 13.1 million the capital Tehran is the 21st largest city in world.

Development of a Biodegradable Alternative: SHJ 700 In 1999 the University of Tehran began developing a compound with the aim of replacing HIPS applications, in particular in sheet extrusion, with starch alternatives. The developments led to a compound called SHJ 700 with superior properties: the material is heat stable up to 120째C, microwaveable, dish washer proof and good for deep freezing. Yet the composition has a renewable content of 83%, primarily corn starch. Beeswax is a truly natural product but most likely never heard of as a plasticizer for sheet extruded products. The small content of non-renewable materials are calcium stearate, an ingredient of the food manufacturing industry (a hard surface coating for candies) and some biodegradable co-polyester. Other bio-polymer manufacturers are even working on this co-polyester to develop a bio-based version which would in future raise the renewable content of this composition even above 90%! The commercial compounding plant of SHJ 700 today has a nameplate capacity of 30,000 tpa. In total 12 decentralized factories operate sheet extrusion and thermoforming

bioplastics MAGAZINE [02/11] Vol. 6

Cellulose 6%

Bees Wax E901 2% Co-Polyester 10-12%

Renewable Resources 83%

Starch based on Corn 75%

Nonrenewable Resocurces 17% Calcium Stearate E572 5%

machinery all over the country. A range of more than 40 standard finished articles can be found in the market today. The main focus is on disposable and catering products such as hot and cold drink cups, bowls for soups, all kinds of fast food containers, plates and trays. Lately yoghurt cups and meat trays were also added and these bio-degradable thermoformed containers can be found in supermarkets for day to day packaging applications as well. The clear intention to cover export markets with bioplast compound led to the decision to establish a modern compounding plant in the Jebel Ali Free Trade Zone in the United Arab Emirates. Construction of the plant is almost complete, adding another 15,000 tpa capacity for sheet extrusion compound. Further expansions are planned in Turkey and Eastern Europe. To penetrate the European market, direct food contact certification according to 2002/72/EEC has been successfully applied for. Of course the compostablility according to EN 13432 is considered to be essential; bioplast SHJ 700 has been tested by Organic Waste Systems in Belgium and consequently been given the OK COMPOST award by AIB-VINCOTTE under number O 10-441-A . In order to successfully introduce bio-plast in Europe it was essential to prove that the compound was easy to process on standard plastic machinery. For this reason extended sheet extrusion trials took place at SML Maschinengesellschaft mbH in Lenzing, Austria. Roll stock with different thicknesses was subsequently thermoformed into cups, as well as trays, on Kiefel thermoformers. Cycle times achieved were well above 30 cycles per minute using HIPS and APET moulding techniques. This ensured that processors will not face additional investment for new moulds when thermoforming sheet made out of SHJ 700. An injection moulding grade of the SHJ700 series is also available â&#x20AC;&#x201C; applications are biodegradable cutlery, clips and hooks for horticulture, re-useable drinking cups, containers with lids, and others. www.bio-plast.com

bioplastics MAGAZINE [02/11] Vol. 6

Rigid Packaging

High-Performance Thermforming of Starch-Based Polymers By Uwe Heer Kiefel GmbH, Germany Anna Förster Plantic Technologies GmbH, Germany

ne field of application for bioplastics is thermoformed rigid packaging. Plantic® is a high-amylose starch-based material, introduced onto the market by Australian Plantic Technologies Limited in 2003. Thermoformable Plantic film is available in many colours and in thicknesses currently up to 450 microns.

Thermforming of Plantic: The optimum water-content of film material, which is approximately 12%, is negatively influenced during the thermoforming process by excessively high temperatures and by being heated for too long. As many of the conventional automatic roll-fed machines on the market often have no individual heater adjustment function, and are fitted with long-wave ceramic heaters, the results of the first tentative trials with Plantic were modest to say the least. The three-stage heating process to which the film material was subjected often resulted in pronounced dehydration (>0.5%) and increased brittleness of the thermoformed tray, particularly when automatic roll-fed machines fitted with a relatively slow-acting ceramic heater were used. Back in 2005, thermoforming machine supplier Kiefel from Freilassing, Germany, carried out trials with Plantic on a KMD 75 B machine, which helped the company reach the following conclusions: Heating with a standard quartz heater is possible It emerged that heating in a single stage was recommended if embrittlement of the material was to be avoided. The use of a heater with very high output and a very short wavelength (i.e. an induction heater) is recommended High-speed forming leads to results that are more uniform

bioplastics MAGAZINE [02/11] Vol. 6

The heating station must be fitted with an individual adjustment mechanism for each heater, along with a tracking device designed to measure directly the surface temperature of the film material. These trials showed that a high-performance machine can be used to process Plantic at similar speeds and forming temperatures as those used for materials such as PET. Given the polymer properties of Plantic film material however, deep-drawing performance is somewhat limited, compared to PET, when a normal thermoforming unit is used. Development work and experience on the part of Plantic in recent years have shown that deep-drawing performance can be further improved by using a very high output, shortwavelength IR heater. These findings were implemented in a practical manner at the end of 2008, when Kiefel installed a KMD 78 B Speedformer machine at the German Plantic factory in Schorba, with a view to optimising the processing of Plantic film material on a high-performance thermoforming unit. The KMD 78 B Speedformer machine supplied was equipped with the following features: 70 dry cycles per minute (instead of 55) 750-Watt quartz radiator (instead of the 500-Watt unit fitted as standard) One heating stage has been specially configured to operate with a very high output, short-wavelength IR radiator Motor-actuated expansion units downstream of each station Optimised intake system for fast filling of the tool with forming air

Rigid Packaging

Radiation intensity (relative units)

200

Visible light

UV 250

short

medium

long

Halogen 2600°C short-wave 2200°C

150

Fast microwave 2200°C Carbon 1200°C

100

microwave 900°C 50

0 1 2 3 4 5 Wavelenght µm

Measurement of film temperature during each cycle, including automatic temperature-tracking to ensure that processing always takes place within the optimum operating range The list of features also includes a modified heating station with special heating element, designed to make it easier for Plantic to ensure that high-quality output becomes standard, thanks to the company’s new Speedformer machine supplied by Kiefel.

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

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

The Plantic Company itself is meanwhile pushing the development of its film material in an effort to improve its ductility and make it suitable for use in an even wider range of applications. The use of a very short, but highly effective, heat-up zone makes it clear that a medium-wavelength heater (quartz radiator) or a short-wavelength heater (IR radiator) produces better results than a long-wavelength ceramic heater (see graphic showing wavelengths). It would definitely be desirable for the packaging sector to be able to ensure its share of the overall market by offering biopolymers as an alternative to mass-market plastics such as polystyrene, polyester and polyolefin (and particularly the polypropylene used in thermoforming). Efficient processing on virtually standard, automatic roll-fed machines, coupled with the technical properties of the film material itself, contribute to the likelihood of such alternative materials obtaining their fair share of use in thermoforming applications. Depending on local, country-specific conditions, the use of biopolymers can also be interesting from an economic point of view. www.kiefel.de www.plantic.com.au

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bioplastics MAGAZINE [02/11] Vol. 6

Rigid Packaging

Clearing the Way for Wider PLA Use Modifier that reduces brittleness, quiets film noise and reduces processing cost combats major growth restraints of the bio-based polymer

By Carol M. Casarino Global Technology Manager Packaging and Consumer DuPont Packaging and Industrial Polymers Wilmington, Delaware, USA

riven by consumer and industry demand for renewably sourced materials, consumption of bio-based polylactic acid (PLA) polymers has grown rapidly over the past decade. Applications have opened up in thermoformed packaging, cold drink cups, films for packaging and other uses, molded cutlery and other fields. To meet surging demand, polymer plants have sprung up in North America, Europe and the Asia-Pacific region. Yet for all its recent growth, PLA holds but a tiny fraction of total material use in packaging and other key application areas. The relatively short commercial history of PLA, the need for processors to learn how to handle it and the higher cost of PLA compared with petrochemical-based plastics are certainly important factors in PLA’s small market share. But inherent limitations of unmodified PLA polymers impose more telling constraints on its growth. Without modification, PLA polymers are brittle. Thermoformed packages, for example, can shatter, splinter or produce shards during die cutting from the web, or handling in the store or at home. In addition, films made of PLA are ‘noisy’, producing a crinkly sound when handled that consumers find objectionable. Other limitations arise in processing in the areas of thermal stability and energy consumption.

Fig. 2. Modifier maintains excellent contact clarity while greatly increasing toughness of thermoformed PLA packages.

Approaches to overcoming the shortcomings of PLA include the use of additive modifiers and modification of the polymer itself. This article focuses on an ethylene copolymer modifier that DuPont introduced in 2007 with the primary mission of enhancing PLA’s toughness but that has proven to reduce processing costs, too. Called DuPont™ Biomax® Strong 120 modifier, the ethylene copolymer works extremely well as a toughener. Just a 1 % loading produces a nine-fold improvement in the flexural fatigue resistance of amorphous PLA sheet (Figure 1). In crystallized sheet, dramatic reductions in brittle behavior are also seen. Oriented PLA sheet also gains in toughness with the ethylene copolymer modifier. In addition, the modifier produces major improvements in elongation and impact strength with loading levels of just a few percent. Shattering and shards rarely occur in PLA packages made with 1 to 5% of DuPont Biomax Strong. The ethylene copolymer produces outstanding toughening effects while maintaining excellent contact clarity. A leading manufacturer of thermoformed produce containers is taking

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Rigid Packaging Reducing Brittleness Fig. 1. Biomax strong sharply improves flex crack resistance of PLA sheet. Tests were conducted with 305 to 380 mÂľ thick cast PLA sheets. 1800 AMORPHOUS

1600

(b)

CRYSTALLIZED SHEET

1400 1200 1000 800

advantage of that feature in containers such as that shown in Figure 2.

600

Recent tests have proven that this additive overcomes another PLA limitation specific to packaging films, namely the crinkly noise that has limited its acceptance for applications such as snack bags. Preliminary testing of monolayer PLA films shows that the ethylene copolymer reduces such noise even at just a few percent loading (Figure 3). Furthermore, by combining PLA containing the modifier with layers of flexible materials, itâ&#x20AC;&#x2122;s feasible to design PLA-based packaging structures that produce no more noise than conventional packages.

200

Processing advantages

400

Noice Reduced Fig. 3. Modifier tones down crinkly sound of monolayer PLA film. 35 30 25 20 dB 15 10 5 0

Less energy for processing Fig. 4. Modifier reduces PLA processing cost with lower energy consumption.

http://biomax.dupont.com

Specific Energy (kg/hr-kW)

9 8 7 6 5 4 3 2 1 0

PLA Control 2% Biomax Strong 5% Biomax Strong

Improved thermal stability Fig. 5. Modifier sharply reduces thermal degradation of PLA during processing. 104 BIOMAX STRONG 100 in PLA2002D Shear Viscosity at 55 1/s [Pa-s]

In summary, the use of DuPont Biomax Strong 120 overcomes limitations in toughness, noise and processing efficiency that are holding back widespread replacement of conventional petrochemical-based plastics by bio-based PLA in packaging.

0% 2% 5% 7% Biomax Strong Loading

Another processing benefit is enhanced thermal stability. The addition of just 2 to 5 % modifier to PLA produces major improvements in thermal stability (Figure 5). That can pay off with greater use of regrind during extrusion.

Another processing plus for DuPont Biomax Strong is ease of use. Supplied as pellets, it is readily blended with PLA at the extruder or molding machine using conventional metering equipment, without the need for a separate masterbatch compounding step.

1% 5% 17%

Loading of Biomax Strong

Processing benefits of DuPont Biomax Strong 120 come in two areas. One is that during extrusion, it melts quickly and acts as a lubricant in the solids conveying sections of the screw. That can result in an increase of up to 21 % in extruder energy efficiency with only 2 % by wt. loading (Figure 4).

Improved thermal stability combined with the increase in elongation provided by the toughening modifier could also help expand the use of PLA in extrusion coating, which uses relatively high processing temperatures. There are also potential improvements in heat-seal performance and reduced neck-in during extrusion coating, but further testing is required for proof.

103

102 102

103 104 Residence Time (sec)

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Catering Products

Carousing for our Climate By Ute Breidbach Product Manager Central Europe Huhtamaki Alf, Germany

his was a motto of the traditional ‘Rose Monday Parade’ in Cologne, Germany a carnival parade which attracts more than a million people every year.

The organisers of the Cologne carnivals parties and parades contributed not only to the safety of these events, but also to active climate protection by using a million (beer) tumblers made from Ingeo™ PLA. These BioWare™ tumblers took to the stage when safety reasons led to the banning of glasses and bottles from the party premises in the city centre. They are made from 100 % renewable sources and can boast of a superior carbon footprint compared with conventional plastic cups.

Especially at big events and in stadiums and arenas, safety comes first: no event organiser wishes to take the risk of incised wounds through shards. Heavy drinking vessels or bottles can easily be turned into projectiles when the mood rises. This prompted the authorities of Cologne to ban bottles and glasses from the city centre between ‘Weiberfastnacht’ (women’s carnival day) on 3rd March until the end of the carnival season on 8th March. The Cologne Carnival Committee and the city authorities decided to not only to embrace the carnival revellers, but to do the environment justice, too, by using tumblers made from Ingeo PLA at the carnival parades. The organisers had already seen excellent results with these cups last year when they were used in the field for the first time. Says Markus Ritterbach, President of the ‘Committee Cologne Carnival’, an incorporated society: “We used bio plastic cups at the Cologne carnival in 2010 and they stood the test. These cups are not only safe to use and hygienic, they also help protect the environment“. The production of the raw material for BioWare- tumblers generates far less greenhouse gases than the production of conventional plastics. Compared to amorphous PET for example, PLA generates 75 % less GHG emissions, and uses 56 % less non-renewable energy.

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Huhtamaki Germany, the plastic processor, uses locally sourced water power from the river Moselle for the production of the final BioWare-tumbler, which can easily compete with conventional PET cups in every respect: shape, looks and function. It is hygienic, safe and a good flavour and aroma barrier. A major aspect today is the search for alternatives to products based on mineral oil: the scarcer mineral oil becomes, the more crucial it becomes to use it diligently and with caution. Developing alternatives wherever possible, is the mission today. Andreas Hees, Sales Manager at Huhtamaki comments: ”Ingeo PLA clearly is the raw material of the future for Huhtamaki. Increasingly excessive deflections in fossil fuel based plastics result in an increasingly unpredictable business for participants in the market. Fossil deposits are finite. Even if it is possible to tap a few more oil fields: time and effort for their exploitation are mounting up. Nevertheless, there is and there will be considerable demand for practical and hygienic service packaging. We are well prepared for this demand, thanks to our Bioware-Range.“ Production and usage of products are one side of the coin – disposal is the other.

CO2-reduced carnival When the beer is downed, the tumbler is not supposed to be simply cast aside, in spite of its bio label: “We would like to see that all the cups are being disposed of into the special bins we set up during Carnival” Markus Ritterbach explained in the run-up to the parades. In 2010 the committee and Huhtamaki initiated a pilot project for the chemical recycling (or feedstock recycling back to lactic acid) of the cups, in order to gain food grade PLA from the process. Tumblers were supposed to be collected in mono-fraction bins. However, the street carnival atmosphere proved stronger: mono-fraction collection cannot be guaranteed under these extreme conditions.

Catering Products

The carbon footprint was in the focus of the event organisers in other aspects, too: “Each vendor was only supplied once a day during the carnival season, as less trips per delivery mean lower CO2-emissions“ Markus Ritterbach emphasises. Logistics were handled by a central wholesaler who supplied all the shops environmentally sound. Andreas Hees summarises: “Our BioWare-tumblers contributed to another relaxed and merry Carnival season in 2011 with parades in untroubled party mood. Considering that you come across our tumblers in many stadiums and arenas and that they were used for e.g. the catering at the World Climate Conference in Copenhagen 2009, I can ascertain that our spadework begun in 2004 is now bearing fruit: The message catches on with consumers.“

(Foto J. Badura, Köln Festkomitee Kölner Karneval)

A different direction was taken in 2011: All litter from carnival parties and parades was collected by the public cleansing service and fed to thermal utilisation: “BioWaretumblers made from PLA only release the amount of CO2 accumulated from the atmosphere by the plants used for its production“ reminds Andreas Hees.

www.huhtamaki.com

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Catering Products

Heat Resistant & Certified Compostable Utensils By Aseem Das Worldcentric Palo Alto, California, USA

Table 1 – Typical Composition of Starch Based Non Compostable Utensils Material Carbohydrate

Relative Weight % 51.2

PP Random Copolymer

34.0

Calcium Carbonate

5.4

Wax Volatiles

7.2 2.5

orld Centric, a leading manufacturer of compostable food service products, recently revamped its line of biodegradable utensils to ensure full compostability. Their TPLA™ (70% non-GMO PLA and 30% Talc) utensils are carbon neutral, heat resistant up to 93°C (200°F) and certified compostable by BPI according to ASTM D6400. With all the compostable resins available in the market, it would seem that it would be relatively easy to manufacture disposable utensils which are heat resistant to 85-100°C and also fully compostable. However, until recently there have been hardly any truly compostable, heat resistant and affordable utensils available (at least in the American market). PLA, the most widely used bio-polymer used for food service disposables is only heat resistant up to 50°C and utensils made from PLA are not suitable for hot drinks and food. Many suppliers in USA have been selling their utensils marked as compostable or biodegradable, when they are actually neither. The most common resin still being used for manufacturing utensils is a starch based resin mixed with polypropylene (PP) or polyethylene (PE), yet being sold as biodegradable. The resin is cheap due to the high content of PP and PE and the use of this and other similar resins is a great disservice to end users, composting facilities and the field of bioplastics. Composting facilities find out that the utensils made from these types of resins do not biodegrade, have to be sifted out and put in the landfill. End users are fooled, articles are written about non-biodegradability of biodegradable utensils and the whole bioplastics industry gets a bad name. World Centric commissioned several studies to determine the plastic content and hence the compostability of widely available utensils in the American market. These studies were carried out by reputable, independent laboratories and were done in Nov-Dec of 2009. Eleven heat resistant utensils manufactured by different manufactures were tested and all had PP content between 30-70%. Table 1, shows a typical composition profile of the starch based non-compostable utensils.

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Catering Products

The samples were analyzed using Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). FTIR analysis showed that for most of the starch based utensils the FTIR spectrum had absorbances associated with PP, carbohydrate, calcium carbonate and a wax-based additive. DSC analysis (Figure 1) showed a weak melting point at 74°C, associated with a melting point of the wax-based additive and a second thermal transition centered at 157°C associated with melting point of PP resin. TGA analysis (Figure 2) showed main decompositions of 47.4% associated with carbohydrate-based material and 31.7% associated with the PP resin. Even after one year of these studies, non-biodegradable utensils are continuing to be sold as biodegradable, with still only few manufacturers of heat resistant compostable utensils certified by BPI. However, most of these BPI certified manufacturers are still continuing to sell non-compostable utensils as ‘sustainable’ and made from plant starch or corn starch material, without explicitly indicating that the utensils have PP content in them or that they are not compostable. This leads to further confusion by end-users and composting facilities, thinking that these plant starch based utensils are also compostable. World Centric overriding goal is to ensure complete compostability in all of its food service products. They only manufacture compostable products and their TPLA line of compostable utensils are heat resistant, affordable, high quality and aesthetically pleasing. All of World Centric products are also carbon neutral, with offset purchases for raw materials to final delivery. “Our mission has always been to be at the forefront of environmental and social responsibility” said Aseem Das, CEO World Centric. “The studies highlight the need for our peers to closely examine their manufacturing processes and messaging to ensure the compostability of their products.” www.worldcentric.org

Figure 1 – DSC thermogram for a typical starch based non-compostable utensil

Figure 2 – TGA thermogram for a typical starch based noncompostable utensil Editor’s Note: bioplastics MAGAZINE has copies of at least ten independent lab analysis reports substantiating the statements in this article. Here are some anonymized quotations from these reports: Report 1: It is the conclusion of this analysis that the material used to manufacture the BRAND XYZ Sample XYZ cutlery was a blend of 57.1% polypropylene (PP) block copolymer and a low molecular weight carbohydrate, such as dextrin. Report 2: BRAND-XYZ biocompostable utensils were analyzed by LAB-XYZ. We found 96 wt% of the BRAND-XYZ material was insoluble in hot acidic water. The infrared spectrum of the insoluble BRAND-XYZ material indicates that it is polystyrene. Report 3: PP block copolymer 39,4% Report 4: PP homopolymer 40.5% Report 5: PP homopolymer 34.0 Report 6: We found 73 wt% of the BRAND-XYZ material was insoluble in hot acidic water. The infrared spectrum of the insoluble BRANDXYZ material indicates that it is isotactic polypropylene yarn. Report 7: PP block copolymer 36.9% Report 8: PP homopolymer 42.9% Report 9: PP homopolymer 42.2% Report 10: PP homopolymer 60.1% MT

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Applications

Biodegradable Alternative to Leather By Farida Bocchese API S.p.A. Mussolente (Vicenza), Italy

PINAT® is an innovative family of recyclable biopolymers with a certified level of biodegradability and a verified content of renewable resources.

These bioplastics are the result of constant research and development at API SpA, a leading Italian producer of thermoplastic compounds. Apinat brings together API’s dedication to providing high-quality, great-looking products with outstanding performance and their commitment to safeguarding the environment. Starting from bioplastics Apinat, there was the idea to realize a range of bio-materials which would meet the everincreasing demand for environmentally friendly products in the footwear and synthetic leather industries. This philosophy led to the formation of a partnership between API and Fiscagomma S.p.A., leading Italian producer of synthetic leather and finished products as an alternative to leather. The stated aim of the partnership was to reduce the use of solvents while exploring the possibility of using raw materials which would provide the fashion industry with a viable, more environmentally friendly alternative to thermoplastic polyurethane (TPU). The project was not without its difficulties and significant limitations which required a determined effort in research and development. The project aimed to identify and industrialize a new mono-component product with the following characteristics: ensure that the minimum number of technological and process changes would be necessary thus providing our clients and end users with an innovative product without needing to invest in costly machinery upgrades and replacements;

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guarantee that the end product adequately met the needs of the end user; the working processes needed to remain the same as the traditional methods used to work synthetic leather in TPU. The culmination of this project was the launch of a new product: ‘APINAT BIODEGRADABLE ECO-LEATHER series’ Super soft Workable both using coagulation and transfer coating processes Heat burnishable. The first application of Apinat Biodegradable EcoLeather occurred in the bookbinding industry leading to the development of product line AURORA by Fiscagomma Spa. The Aurora material is obtained using Apinat Biodegradable Eco-Leather on supports of non-woven. The biodegradable eco-leather series Aurora has already been chosen by leading global manufacturers of stationery. In addition to the bookbinding industries, Apinat Biodegradable Eco-Leather series can be used in some of the most advanced high-quality footwear, clothing and packaging industries. API company will present Apinat Biodegradable EcoLeather at Techtextil exhibition in Frankfurt/Main, Germany from 24 to 26 May 2011 in hall 4.1, stand C74. www.apinatbio.com

Applications

New Sustainable Bottle Initiative

his year is looking even greener for Odwalla Inc., a company of the Coca-Cola group based in Halfmoon Bay, California, USA. The natural health beverage company recently announced plans to transition all of the brand‘s single-serve bottles to PlantBottle™ packaging, HDPE (high density polyethylene) made completely out of plant-based materials and 100% recyclable, in March 2011.

The new Odwalla package will help The Coca-Cola Company to reduce dependence on nonrenewable resources. For example, the potential annual CO2 emission reduction from the use of plant-based material, instead of petroleum, to make Odwalla‘s PlantBottle packaging is equal to a savings of almost 1.5 million liters (400,000 gallons) of gasoline for driving a car. “Plants do such a good job of making our juice, Odwalla hired them to help make our bottles,“ said Alison Lewis, President, Odwalla. “Doing good things for the community and building a business with heart are core guiding principles of Odwalla‘s vision. PlantBottle packaging is just the latest step in our continued commitment to the environment.“ Combined with Odwalla‘s Plant A Tree Program, which has planted over 300,000 trees in the last 3 years, and Odwalla‘s Bloom Energy Fuel Cell technology commencing at Odwalla‘s plant in Dinuba, California - which reduces the plant‘s carbon footprint by 35% while supplying 30% of the plant‘s energy needs - PlantBottle packaging is the latest step in Odwalla‘s efforts and innovations to reduce dependence on nonrenewable resources. The HPDE PlantBottle packaging consists of material derived from molasses and sugarcane juice. It has the same performance as traditional HDPE bottles: no differences in shelf life, weight, composition, appearance or recyclability.

Being asked about a potential confusion arising from the recently introduced name ‘PlantBottle’ for this new HDPE bottle, Dr. Klaus Stadler of Coca-Cola Europe said to bioplastics MAGAZINE: “We now have two packaging types using plant-based materials. We have our plant-based PET package which was launched in 2009. This recyclable PET plastic package uses up to 30% by weight plant-based materials (for the mono ethylene glycol component) and is compatible for use with a wide-range of our products, including our sparkling beverages and many of our stills. And we are also working to innovate a plant-based solution to the other element of PET plastic which is terephthalic acid (TA). In 2010 we introduced over 2.5 billion Plant-Bottle PET packages in the marketplace globally and we expect to double that volume in 2011.” Concerning Odwalla he added: “HDPE is a great plastic for our Odwalla juices, but it is not acceptable for carbonated beverages because it has higher gas permeability. It also is not ideal for bottled waters because it is not ‘crystal clear’ - it is translucent. There is only one material used to make PE: ethylene. Ethylene can be made today from renewable materials from sugar cane-based ethanol, so it can be 100% from renewables, or to a minimum of 96% to be precise. However, we have very little HDPE in our system, but for Odwalla this made sense. The material is produced by Braskem using Brazilian sugarcane. We are also exploring options with Braskem (like bio-based closures). We realize the possible confusion likely to be created by this given a recyclable HDPE bottle with nearly 100% plant-based material versus a PET bottle with up to 30%. Due to the amount of PET we are using, our main focus remains on PET and building out a bPET (bio-PET) infrastructure. MT www.thecoca-colacompany.com

bioplastics MAGAZINE [02/11] Vol. 6

Applications

World‘s First 100% Plant-Based PET Bottle

epsiCo, headquartered in Purchase, New York, USA, announced in mid march it has developed the world‘s first PET plastic bottle made entirely from plant-based, fully renewable resources, enabling the company to manufacture a beverage container with a significantly reduced carbon footprint, thus again building upon its heritage as an innovator and leader in environmental sustainability.

spokesperson responded that with PepsiCo’s latest scientific breakthrough, they have ‘cracked the code’ on transforming biomass into terephthalic acid. However, given that patents are currently pending, they are unfortunately not at liberty for the time being to discuss details of the process. bioplastics MAGAZINE will continue and try to get details latest for the bottle/blow moulding issue (July/August).

PepsiCo‘s ‘green’ bottle is 100% recyclable and far surpasses existing industry technologies. The bottle is made from bio-based raw materials, including switch grass, pine bark and corn husks. In the future, the company expects to broaden the renewable sources used to create the ‘green’ bottle to include orange peels, potato peels, oat hulls and other agricultural byproducts from its foods business. This process further reinforces PepsiCo‘s ‘Power of One’ advantage by driving a strategic beverage innovation via a food-based solution.

PepsiCo will pilot production of the new bottle in 2012. Upon successful completion of the pilot, the company intends to move directly to full-scale commercialization.

“This breakthrough innovation is a transformational development for PepsiCo and the beverage industry, and a direct result of our commitment to research and development,“ said PepsiCo Chairman and CEO, Indra Nooyi. “PepsiCo is in a unique position, as one of the world‘s largest food and beverage businesses, to ultimately source agricultural byproducts from our foods business to manufacture a more environmentally-preferable bottle for our beverages business – a sustainable business model that we believe brings to life the essence of Performance with Purpose.“

“As You Sow applauds PepsiCo‘s innovative packaging design,“ said Conrad Mackerron, Senior Program Director of ‘As You Sow’, a San Francisco-based foundation, which promotes corporate social responsibility through shareholder engagement. “By reducing reliance on petroleum-based materials and using its own agricultural scraps as feedstock for new bottles, this advancement should deliver a double win for the environment and PepsiCo.“ With this development – as stated in the press release PepsiCo continues its leadership position in environmental sustainability and driving progress against the global goals and commitments it announced in 2010 to protect the Earth‘s natural resources through innovation and more efficient use of land, energy, water and packaging. – (PRNewswire) MT www.pepsico.com

Combining biological and chemical processes, PepsiCo has identified methods to create a molecular structure that is identical to petroleum-based PET (polyethylene terephthalate), which results in a bottle that looks, feels and protects its product identically to existing PET beverage containers. bioplastics MAGAZINE asked PepsiCo for details on the production route for biobased therephthalic acid. A

Indra Nooyi bioplastics MAGAZINE [02/11] Vol. 6

interpack Preview

rom May 12 to 18 the World’s biggest packaging trade fair will again invite visitors to Düsseldorf, Germany. For the third time in a row, European Bioplastics and Messe Düsseldorf present a large group exhibition about ‘Bioplastics in Packaging’. The first two bioplastics shows with more than 10,000 trade visitors each, sold-out exhibition space and a high interest of public and media give evidence of the importance of sustainable technologies for bio-based and compostable packaging.

On the following pages bioplastics MAGAZINE gives a detailed preview on ‘Bioplastics in Packaging’, this year in hall 9. In addition to the short notes you will find a centerfold with a floorplan of hall 9 in the middle of this issue. This will be complemented by a special web-based service at www.bioplasticsmagazine.com. Here you will find additional information and files for download.

For interpack 2011, European Bioplastics teams up with strong partners and co-exhibitors from the bioplastics industry to create an experienceable industry representation. Together, the cooperation partners showcase the benefits and the dynamically developing status of the bioplastics industry in the pioneering packaging sector. The European Bioplastics stand will function as an information hub for the bioplastics exhibitors, introduce visitors to the wellknown partners, and will guide all visitors through the ‘bioplastics world’. An attractive presentation of the industry - live: The bioplastics stage at the European Bioplastics stand constitutes the platform to present the bioplastics industry‘s impressive innovations and developments - daily! www.european-bioplastics.org 9E02

The Fachagentur Nachwachsende Rohstoffe e.V. (FNR) is promoting the use of agricultural resources on behalf of the German Federal Ministry of Food, Agriculture and Consumer Protection (BMELV). FNR is the central coordinating agency in Germany for the funding of research, development and demonstration projects. However, its tasks also include providing information and advice to a wide range of different target groups as well as supporting the market introduction of products made from renewable resources. Besides the diverse information about the whole field of renewable resources, especially about bioplastics, FNR shows the biopolymer database created from the Fachhochschule Hannover and M-Base on its booth. Farmer ‘Hubert’ explains sustainability to children

www.fnr.de 09F01

The products from Biopla factory are made from an annually renewable resource – PLA, which is made from corn. All Biopla PLA products are certified to EN13432, ASTM D6400-99 and similar standards to be 100% biodegradable and 100% compostable. At interpack 2011 Biopla will showcase products such as a Corn Cup: The process of manufacturing the 100% PLA cup uses 68% less energy, produces 65% fewer carbon emissions and conserves water, making the corn cups a substantially greener option than a traditional plastic mug. All of Biopla’s Bio-bags and Bio-films are made from PLA, compostable, biodegradable and renewable. In addition, Biopla not only offer finished products, but they also produce PLA raw material themselves. Various grades of PLA are available for injection moulding, thermoforming and blown film. www.2wplastic.com 9H12

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interpack Preview Sidaplax is an innovative, international film manufacturer and distributor with over 60 years of experience in the plastic film industry. With four distribution centres, two ISO certified manufacturing plants, and a location in Gentbrugge, Belgium, the company is perfectly positioned to meet their customers just-in-time plastic film requirements anywhere in the world. As the manufacturer and distributor of EarthFirst速 PLA film, an annually renewable product, Sidaplax have the opportunity to offer an environmentally friendly alternative to the petrochemical based films available on the market today. EarthFirst is a biopolymer film and is certified as compostable in line with the DIN EN 13432 and ASTM D6400 standards. EarthFirst films are replacing a number of conventional films in the marketplace. Offering excellent shrink characteristics, high natural dyne level, heat sealability and a high MVTR, EarthFirst is an ideal product for the flexible packaging, shrink sleeve label, lamination and windowing markets. Those who are looking for a truly environmentally friendly product will see innovation in action in D端sseldorf. www.sidaplax.com 09D14

bioMat速 by Pro-Tech and natura packaging stand for a sustainable relationship with their environment and for the conservation of resources. The companies are able to offer an alternative to conventional materials by virtue of their many years of experience in this area. They cooperate closely with their partners worldwide in order to promote new developments, and their specialists are continuously working on ecological product improvements. As raw materials the companies use polylactic acid, plant starch, plant oils, plant fibres and many other resources. In conjunction with partners, films for flow-pack and for thermoforming applications, as well as nets, trays and bags, are produced. Besides these standardised products, it will of course always be considered if customized solutions are needed. All products are demonstrably fully compostable, as guaranteed by European composting standard DIN EN 13432, to which all products are certified. Furthermore, through ISO 9001, 14001 and 22000 standard it is ensured that the products are suitable for use in food packaging. www.biomat.info www.naturapackaging.com 9D04

Xylophane is an efficient barrier against oxygen, grease and odour. A thin layer of Xylophane in the packaging material can prolong the shelf life of many foods and industrial products. Examples of suitable end-use are the packaging of oxygensensitive dairy products, greasy snacks or pet foods, as well as aromatic products such as spices and coffee. Xylophane consists of the natural carbohydrate xylan plus food contact approved additives in order to have customised properties for different areas of application. Xylan is one of the most abundant naturally occurring carbohydrates, but despite this fact, it has until now not been used in industrial applications. Xylan can be isolated from agricultural by-products, such as cereal hulls and husks. Xylophane can be combined with other packaging materials such as paper, cardboard and plastics. Xylophane is applied onto another material layer by dispersion coating. www.xylophane.com 09F10

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interpack Preview Add ultimate functionality to your extruded thin and rigid PLA films and molded PLA parts with Sukano’s innovative biobased masterbatches and polymer alloys. Sukano’s Biopolymer product line consists of PLA based bioplastics grafted with Sukano technology. In this process the PLA polymer is enhanced by specific additives to ensure it can be processed and used like oil based plastics in many applications. Sukano bioconcentrates are highly concentrated masterbatches based on biopolymer carriers. Sukano offers biobased slip/antiblock, antistatic, UV masterbatches, nucleating agents and impact modifiers and a broad range of biobased optical masterbatches. Sukano® Bioloy biobased alloys endow PLA with impact strength, durability, and easy processibility for semidurable applications. Sukano bioconcentrates and Sukano Bioloy are fully compostable on an industrial scale and feature a biobased carbon content of up to 100%. www.sukano.com 09H16

Bio4Pack from Haaksbergen, The Netherlands, is proud to present a new generation of bio-packaging. During the interpack 2011 the company Bio4Pack shows new high-end barrier-packaging with the biggest amount of renewable resources. “With this product line we open a new range of packaging solutions for products which need to be packed with a high oxygen barrier like sausage, cheese, meat and coffee, “says Patrick Gerritsen, General Manager of Bio4Pack. All products of Bio4Pack are made from raw materials with a high content of renewable recourses which comply fully with European standard EN 13432 and US standard ASTM D6400. The product range comprises PLA, Flow wrap, Natureflex™, sugar cane products and starch based products. www.bio4pack.com 9H10

Headquartered in Finland, Huhtamaki is the first company to launch a complete range of compostable foodservice packaging under the trade name BioWare. Biodegradable BioWare products generally consist of the renewable resource PLA or are starch-based. All BioWare materials are compostable and certified to DIN EN 13432. Its range of products includes single-use drink cups, plates, containers and cutlery. In addition, Huhtamaki Films offers, with its two decades of experience in biodegradable film production, a variety of thin and thick films. At interpack Huhtamaki Films will present its holistic concept with regards to its sustainable film developments. “We consider every available option which contributes to a better environment. REDUCE, REUSE and RECYCLE are as important key drivers as the REPLACEment of fossil based raw materials by renewable resources. For that reason we always consider the best possible solution depending on the customer’s needs and applications.” www.huhtamaki-films.com 9E03

PolyOne’s polymer solutions expertise allows them expand the potential for biopolymers into application areas formerly out of reach. Their global capabilities in color and additive concentrates, thermoplastic elastomers, and specialty polymer compounding allow them to develop an ever-widening range of bio-related sustainable solutions for applications from healthcare to transportation, packaging to electronics, and alternative energy to appliances. In addition to polymer solutions, PolyOne also offers a new generation of bio-based plasticizers for a wide range of applications. At the Interpack fair, PolyOne will feature a new line of additive masterbatches which is especially tailored to improve the transparency and opaque impact resistance of PLA as well as the processing needs of biodegradable films. www.polyone.com 09E17

bioplastics MAGAZINE [02/11] Vol. 6

interpack Preview BIOSPHERE is a company specializing in bioplastic resins. Falling oil reserves and growing demands for a greener environment are opening the door to the new potential provided by biomass-produced plastics. Bioplastics can and will replace current plastics for numerous applications and trigger the emergence of new areas of use.

Minima Technology Co. Ltd. has built its research and development centre to include a broad range of mechanical options which give prospective clients flexibility when discussing environmental options. A family of like-minded companies in different fields of processing expertise assist Minima Technology with manufacture is required. The options available include:

Biosphere is pushing this advance in the fields of research and development, technical applications and the whole marketing chain for new generations of bioplastic products. Thus Biosphere develops Bioplast resins with five major products covering a wide number of both rigid and flexible product applications with high mechanical properties and similar to crude oil based thermoplastic materials:

Extrusion

Flexible applications: Film for bags, flexible packaging for food and non-food

Injection moulding

Rigid applications using thermoforming Injection moulding applications

Biosphere pursues a number of missions: Developing new technical and industrial applications Improving manufacturing processes Providing technical and commercial expertise

Printing Conversion Resin compounding Thermoforming Blow moulding

Physical/Chemical foaming Minima Technology Co. Ltd. has the ability to assist in the consultation, supply or manufacture, Implementation and after sales servicing of environmental programs whether it be large or small, to achieve the goal of a better environment for all. With global partners all around the world we are in the strongest position to assess and assist in most eventualities. www.minima-tech.com 09G08

Delivering advice and support Giving the right response to each partner and contact worldwide www.biosphere.eu 09D18

bioplastics MAGAZINE [06/11] Vol. 6

interpack Preview

KINGFA SCI. & TECH. CO., LTD is Asia’s largest and first stock-market listed company in the modified plastics industry. ECOPOND® 100% biodegradable plastics developed by Kingfa with independent intellectual property rights is up to internationally most stringent standard: EN13432, ASTM 6400 and AS 4736. Besides, Ecopond has successfully passed tests (OWS, Belgium) to prove that Ecopond leave no toxic material after it is fully degraded under the action of microorganisms. Potential applications comprise: Green packaging: shopping bag, food wrap film Organic waste collection: trash bag, leaf & yard bag Catering: One off tablewares Agriculture: mulching film/string At interpack Kinfga will exhibit PLA-based Ecopond Flex262&Flex-64D; Starch-based Ecopond Flex-162; 100% biodegradable and compostable shopping bag, trash bag, one-off tableware and agricultural mulching film and string made from Ecopond. Ecopond is 100% biodegradable and compostable. It can be processed on traditional PE blown film and processing machines. The material show controlled storage and shelf life and offers excellent mechanical property, ideal for film blowing/vacuum forming/cast molding. www.ecopond.com.cn 9D13

Innovia Films is a major international producer with production sites in the UK, USA, Belgium and Australia. Innovia’s transparent, metallised and coloured films are sold to converters, brand-owners and end-users around the globe. They become part of the packaging, labelling or overwrap solution for some of the world’s best known brands across a wide variety of everyday consumer goods including confectionery, perfume, cheese, tea, shampoo, tobacco, soft drinks and biscuits. NatureFlex™ is Innovia’s award winning, compostable, cellulose-based film, which will be showcased alongside the full range of substrates. The focus of Innovia Films at this year’s Interpack is on two signature brands of NatureFlex™ and Propafilm™ and how the six key themes of Barrier, Compostable, Digital, Life Cycle Assessment (LCA), Renewable and Seal Integrity relate to these. The spotlight will also be on Innovia’s increased BOPP coating capacity, environmental improvements since the introduction of their new cellulose production line in 2009 and the launch of the new corporate website with added functionality www.innoviafilms.com 09G03

In line with their strategic vision of becoming the world leader in sustainable chemicals by 2020, Brasilian company Braskem will present at Interpack its line of I’m green™ biopolymers. These 100% renewable source polyolefins show a very favorable carbon footprint throughout the entire production cycle. With excellent technical performance and processability, these biopolymers can be used to make packaging for food, cosmetics, personal care and cleaning products, as well as other uses, with significant reductions in greenhouse gas emissions in all these applications. In September 2010, the the leading producer of thermoplastic resins in the Americas and world’s largest producer of biopolymers inaugurated a green polyethylene plant in Triunfo, Rio Grande do Sul with production capacity of 200,000 tonnes per year. Braskem’s green polypropylene plant with capacity of 30,000 tonnes/year is scheduled to start production in 2013. www.braskem.com 10D88

bioplastics MAGAZINE [02/11] Vol. 6

interpack Preview Grace Biotech Corporation will introduce its GRABIO range of product lines. Grabio uses a unique and innovative biochemical technology method to create biodegradable and compostable starch plastics from renewable resource material. The new Grabio extruding grade materials can be used to produce agriculture products such as seedling pots, seedling trays, plant pot etc. by thermoforming. These products are completely compostable. Furthermore, the biodegradation will not leave any residue or toxic effects in soil or plants. Grabio biodegradable agriculture products can save farmers a great deal of time, labour and expense in the retrieval and disposal of discarded mulch and pots. Grabio film grade material for bags and other film products conforms to EN 13432 and ASTM D6400 compostable standards, and had received Aib Vincotte and DIN Certco compostable certificates. With its good physical strength and easy to process features, Grabio film product is a good replacement alternative to conventional plastic bags in the fast emerging global trend of plastic bag ban. www.grace-bio.com.tw 9F06

Folienwerk Wolfen GmbH (FWG), Germany, as a manufacturer of custom-made rigid polyester films started manufacturing PLA (polylactic acid) films as early as in 2003. The optical properties of their films made from this biodegradable polymer produced from renewable sources can easily compete with other polyesters, and experts at FWG are conducting extensive research to further improve the thermal and mechanical stability of PLA films. But there is more to biopolymers than just PLA. In collaboration with their suppliers FWG have developed films from a range of biopolymers for lots of individual applications. www.folienwerk-wolfen.de 09J26

bioplastics MAGAZINE [06/11] Vol. 6

Visit PolyOne at Hall 08b / G46 ask about our new durable biopolymers

9 C20-2

VTT Technical Research Centre of Finland

9 C24-2

Plastiroll

9 D04

Natura Verpackungs GmbH

NOTAUSGANG

9 A24/B23 Mondi

HALLE 10

Hall 09

NOTAUSGANG

Hallenmeister

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ANL Plastics

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Rodenburg Biopolymers

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EINGANG NORD

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Sidaplax

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POLINAS BIO

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BIOSPHERE

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Bollore

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European Bioplastics

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Huhtamaki

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DIN CERTCO

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BIOBAG INTERNATIONAL

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Kaneka

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Shenzhen BrightChina

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PACOVIS

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PolyOne

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Xylophane

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AGRIPLAS

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Synprodo

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Plantic

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Wentus Kunststoff

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MANN + HUMMEL

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Mitsubishi Chemical Europe

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MINIMA Technology

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Biostarch Technology Europe

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Innovia Films

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Natureplast

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Folienwerk Wolfen

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A real sign of sustainable development. www.novamont.com

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Sukano

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NatureWorks

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biopla Products factory

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Grace Biotech

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BASF

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Fachagentur Nachwachsende Rohstoffe

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9 D24/E23 Taghleef Industries

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BIO4PACK P.O. box 26 | 7480 AA Haaksbergen The Netherlands

ShowGuide

T +31 26 495 48 | F| +31 (0) 5975 26 495955 59 76 +49(0) 5975 955909457 F +49 9458 E info@bio4pack.com | W www.bio4pack.com

Hall 07

07aB11/C30 Sleever International

Hall 10

10B45

Anton Debatin

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Kisico

10D88 BRASKEM

7.1 D07-5

Cromex

10E85 Icimendue

7.1A36

Tianjin Greenbio

7.2A26

VELOX

7.2A39

DICS Korecopack Company

Entrance North

EN1 / 05

Itene

Hall 11

11F42 Easypack 17A03

Zhejiang Zhongcheng

Bioplastics Consulting Tel. +49 2161 664864 info@polymediaconsult.com www.polymediaconsult.com System + Know-how

E c o l o g i c a l Pa c k a g i n g M a t e r i a l s

MANN+HUMMEL ProTec Halle 9 Stand G10

Umweltschonendes Materialhandling von PET und PLA aus einer Hand von der Einzelkomponente bis hin zum vollständigen Handlingsystem: Trocknen

Kristallisieren

SOMOS

Fördern

Dosieren

Mischen

Schneiden

MANN+HUMMEL ProTec GmbH - www.mh-protec.com

WELCOME TO VISIT US AT STAND: 9C24-2

interpack Preview

Novamont, the leading Italian company in the bioplastics sector will present at interpack its innovative applications in Mater-Bi, the completely biodegradable and naturally compostable bioplastic. Mater-Bi, Novamont‘s main product, guarantees a resistance and strength very similar to traditional plastics. It is derived from renewable resources of agricultural origin, thereby reducing the emission of greenhouse gases and saving consumption of energy and non-renewable resources. Mater-Bi thus enables a complete ‚virtuous circle‘: raw materials of agricultural origin are returned to the soil by way of biodegrading and composting processes without the production of pollutants. Among the breakthrough products which Novamont will be putting on display at booth will be clingfilm, Naturene (see picture), and bubble film. www.novamont.com 09 G01

Polylactide (PLA) and Polycaprolactone (PCL) biopolymer material supplier Shenzhen Brightchina Industrial Co. Ltd founded in 2002, started research, production and sales of PLA and PCL. In the city of Xiaogan (Hubei province) Brightchina has its own 300,000 square metre environmentally-friendly industrial park, with a capacity of 5000 tons for PLA and 3000 tons for PCL. They have branches in Guangzhou, Shanghai, Tianjin and Wuhan, with joint ventures in Hong Kong and Hungary. PLA supplied by Brightchina has been successfully used in injection applications such as toys, electrical housings, forks and spoons etc. Other applications, like film blowing, sheet producing and fibre making are also proved to work perfectly well. Brightchina PLA can meet the requirements of EN13432 and ASTM D6400. With the slogan “Better Nature Better Life” Shenzhen Brightchina welcomes visitors to their booth at interpack to present their latest innovations. www.brightcn.net 09E09

Biodegradable plastic bags represent one way to a hygienic and energetically sensible disposal of bio-waste. With their help more compost can be gained via industrial composting plants. This is why BASF does not only show shopping bags but also biowaste bags made from its biodegradable plastics Ecovio® F and Ecovio FS. The new grade Ecovio FS Film contains an even higher content of renewable materials than its well-known predecessor Ecovio F Film. Paper cups coated with Ecovio FS Paper, a new Ecovio grade specifically developed for paper coating, will also be on display. Via classical extrusion coating lines known from PE-processing, paper can be coated with a thin biodegradable film made of Ecovio FS Paper. When inline-coating the paper with this fully biodegradable plastic, the customer can now manufacture paper cups or paper boxes for food that offer improved resistance against liquids without losing their option to be recycled in the normal paper recycling process. www.basf.com 09F04 and 10B43

bioplastics MAGAZINE [02/11] Vol. 6

interpack Preview NatureWorks will showcase a host of packaging and other products made from Ingeo™ biopolymer. This product gallery will be similar to the one at the UN Conference on Climate Change in Cancun, Mexico, with a heightened emphasis on packaging including: yogurt from Stonyfield Farm, division of Danone; fresh food packaging from Walmart; and snack food flexible packaging from Snyder’s of Hanover, Frito-Lay, and Target. Booth staff will deliver information to attendees on the latest developments in Ingeo biopolymer flexible and rigid packaging. Cradleto-cradle reuse through lactic acid recovery programs both in Europe and in the United States will also be discussed. Bottled water from Italian firm Sant’Anna in the distinctive green Ingeo bottles will be given to visitors at the booth. Huhtamaki will be supplying Ingeo cold cups and paper cups with an Ingeo film moisture barrier. DS Fibers is supplying NatureWorks with Ingeo exhibition carpet for the booth. In a separate booth, Taghleef will be showing its Ingeo based films. www.natureworksllc.com 09H15

Taghleef Industries, the worldwide leader in bi-oriented polypropylene films, believes in responsible packaging and considers this as part of its DNA. The new range of BoPLA films, manufactured at the Ti plant in Italy using Ingeo™ polymers from NatureWorks and marketed under the brand NATIVIA™, includes transparent and metalized heat sealable films, from 20 to 50 microns, for a number of flexible packaging applications ranging from flexible packaging for fresh produce, bakery, confectionery, snacks, hygiene, health & beauty care to lidding films, labels, stationery. All Nativia films are compostable according to EN 13432 norms, and achieved the 4-star BIO BASED certificate from Vinçotte. Examples of Nativia applications will be shown at the Taghleef Industries booth in hall 9 and presentations will be also given at the European Bioplastics stage. www.ti-films.com 09D24/E23

Plastiroll, Ylöjärvi, Finland premieres new, multilayer biodegradable films at interpack, which open a new era of bio-films for instance for fresh food packaging. Films are characterised by high transparency and excellent mechanical properties, as well as by very good grease and gas barrier properties, and by good water resistance. Several properties of this biodegradable barrier film can be tailored according to the customer requirements, by combining several biomaterials. Transparent bio-films are made of bio polymers certified according to EN13432, and are also GMO-free. Plastiroll produces biodegradable films since 1997. www.plastiroll.fi 09C24-2

Rodenburg Biopolymers, Oosterhout, The Netherlands, will be present on the Interpack show demonstrating the third generation of the patented bioplastic Solanyl®. On the exhibition stand visitors will find the newest developments and applications made with Solanyl as well as the possibility to discuss new opportunities and ideas. Solanyl is a bioplastic based on reclaimed starch of the potato processing industry, therefore it does not compete with the food chain. Solanyl is suitable for various processing techniques for example injection moulding, sheet extrusion/thermoforming and profile extrusion. For each technique different standard grades are available. For specific client requirements Rodenburg can, in close cooperation with the client, develop tailor made grades. www.biopolymers.nl 09D08

bioplastics MAGAZINE [06/11] Vol. 6

interpack Preview

Multilayer made from Bio-Flex® A 4100 CL / F 2201 CL / A 4100 CL

FKuR has launched a new transparent, flexible biopolymer. Called Bio-Flex® F 2201 CL this material contains a high amount of renewable resources and, in line with the other resins in the Bio-Flex family, can be processed easily on standard LDPE blown film lines and converting equipment. This brand new grade has a renewable resource content of approximately 60%. Its mechanical properties exhibit a high elongation and flexibility along with good puncture resistance. Consequently Bio-Flex F 2201 CL can ideally be used to adjust the properties of all the available Bio-Flex family resins. However, due to its limited sealing strength, Bio-Flex F 2201 CL should always be used as a mid-layer in a co-extruded structure. As a result of its mechanical properties it is the perfect partner for Bio-Flex® A 4100 CL in a transparent 3-layer combination. Bio-Flex A 4100 CL is a clear but stiff material with properties comparable to PP. The combination of these two transparent grades offers superb and unmatched clarity for a biodegradable blown film available today while maintaining a very high content of renewable resource material. This is between 60 - 80% depending on the variation of polymers of the final structure. As both polymers are clear, the transparency of a 20µm film, for example, is close to 91% (light transmission figure). The toughness and high tear resistance are the result of the core Bio-Flex F 2201 CL layer and the renewable content of a 20 micron 3-layer structure with a layer ratio of 20 / 60 / 20 (%) is around 70%. Using such a structure, this film is ideal for VFFS applications. www.fkur.com 09F14

bioplastics MAGAZINE [02/11] Vol. 6

MANN+HUMMEL ProTec will present the latest, most up-todate technologies and systems in the areas of material drying, crystallization and condensate separation in the drying process. Exemplary for the new generation of stationary material drying systems, a SOMOS® D 200 dry air dryer (air flow rate 200 m3/h) will be presented at Interpack. A new, powerful controller (MH 25) now controls the triggering of the dew point-constant dry air with the D-dryer. In combination with additional design innovations it leads to a significantly more flexible application of the dryers. The SOMOS D 200 dryer presented at the trade fair can be, for example, ‘expanded’ from nominally 200 m3/h up to 500 m3/h by adjustment in control technology. The systems engineering presented at interpack and proven many times for PET treatment in the meantime, is in principle also suited for the treatment of biopolymers such as PLA (polylactide) and is currently being tested in operation in pilot projects. www.mh-protec.com 09G10

Other companies exhibiting at interpack, that are involved in bioplastics but who were unfortunately unable to provide us with detailed information in time for this issue are: Mondi VTT Technical Research Centre of Finland ANL Plastics Medkonpack Polinas Bio Bollore DIN Certco Biobag International Kaneka Pacovis Zhejiang Hangzhou Xinfu Biostarch Technology Europe Mitsubishi Chemical Europe Wentus Kunststoff Plantic AGRIPLAS Synprodo Natureplast Sleever International Kisico Cromex Tianjin Greenbio Velox Dics Korecopack Company Anton Debatin Icimendue Easypack Zhejiang Zhongcheng Itene

9A24/B23 9C20-2 9D06 9D10 9D15 9D20 9E04 9E06 9E07 9E15 9F08 9G06 9G09 9G15 9G16 9G18 9H11 9H19 07aB11/C30 7.1 B02 7.1 D07-5 7.1A36 7.2A26 7.2A39 10B45 10E85 11F42 17A03 EN1 / 05

Materials

Improved PHA Production in Tobacco Research Furthers Potential for Biobased Plastics and Chemicals in Non-Food Bioenergy Crops

etabolix, Inc. from Cambridge, Massachussetts, USA recently announced the publication of its most recent scientific achievements in the development of advanced genetic engineering approaches to achieve high levels of polyhydroxyalkanoate (PHA) in non-food biomass crops. The plastid genome of the research crop tobacco was engineered using Metabolix’s multi-gene expression technology, resulting in fertile transgenic plants producing PHA at levels of up to 9% of the total plant weight. PHA levels of up to 17% were found in leaf tissue. Metabolix’s engineered tobacco plants produce ten times more PHA bioplastic than previously published reports for tobacco. These findings continue to demonstrate the Company’s ground-breaking scientific capabilities and continued progress on using new tools to improve its programs to develop advanced biomass crops as biorefinery feedstocks. A detailed scientific paper entitled ‘High levels of bioplastic are produced in fertile transplastomic tobacco plants engineered with a synthetic operon for production of polyhydroxybutyrate’ was published online in Plant Physiology, a peer-reviewed journal from the American Society of Plant Biologists, on February 16, 2011. The article also appears in the April 2011 print edition of the journal focused on plastid biology and can be downloaded as complete pdf file from www.bioplasticsmagazine.com/201102 (as long as provided by the original publisher)

PHAs are a family of renewable polymeric carbon storage materials, which have a broad range of industrial applications as performance, biodegradable bioplastics and as renewable starting materials for the production of a number of existing specialty and commodity chemicals. As polymers, PHA bioplastics offer excellent performance in use and have the unique ability to biodegrade in a wide range of environments including compost, soil, wetlands, marine and anaerobic digestion facilities. As a starting material for the production of renewable chemicals, PHAs offer exceptional, highly efficient, low cost recovery and conversion opportunities for the production of a number of specialty and commodity chemicals. By producing PHAs directly in biomass crops, Metabolix plans to further improve the cost benefits, lifecycle performance and scale potential of renewable resourcebased industrial products. “The demonstration of this new approach to increase PHA production in the model biomass crop tobacco is an important milestone in further demonstrating the scientific and technical capabilities of the Company in the crop science field. This also represents continued progress towards our longer term objective for the biomass crop program and the recognition of our research by a peer-reviewed journal,” said Dr. Oliver Peoples, Chief Scientific Officer and vice president of Research and Development at Metabolix. “This work provides us with important new data and tools for the production of PHAs in plants as we continue to develop other targeted commercial crops including switchgrass.” www.metabolix.com

TEM-picture of PHA granules in tobacco (Photo: Dale Callaham, Central Microscopy Facility of the University of Massachusetts in Amherst) 38

bioplastics MAGAZINE [02/11] Vol. 6

Application News

Denitrification Biopellets Reef Interests, an innovative provider of home aquarium systems located in the Netherlands, is launching a biodegradable product based on Telles’ Mirel™ DP9002 for managing waste generated in aquariums and marine environments. The product will be sold throughout the U.S., Europe, Russia, China and other key markets. Nitrates generated as waste products from fish foods and other sources can rapidly build up in fish tanks, overpowering the denitrification organisms. By activating existing microbes that are present in the aquarium, Mirel initiates a more efficient denitrification process that helps improve water quality. “Keeping waste products such as nitrate and phosphate under control is often a difficult task, which requires expensive and complex filtration systems,” said J.P. ten Klooster, Chief Executive Officer at Reef Interests. “We found that the Mirel solution provides long term and efficient control of nitrate levels.” “Mirel continues to open up a number of new market opportunities for Telles, from compost bags to packaging solutions, and now marine applications including denitrification,” said Bob Engle, Telles general manager. “With Reef Interests, we are bringing an efficient and long-lasting denitrification solution to consumers in the home aquarium market. By creating a safe and highly effective process for water denitrification, Telles will work with its partners to expand Mirel’s applications for marine environments.” Mirel is biodegradable in marine environments in accordance with ASTM D7081 for marine-biodegradable non-floating plastics. This standard specification, along with the standard method ASTM 6691 for determining aerobic biodegradation of plastic materials in the marine environment, was developed at the U.S. Army Natick Soldier Research, Development and Engineering Center (NSRDEC) in Natick, Massachusetts, with support from the U.S. Navy and the Waste Reduction Afloat Protects the Sea (WRAPS) Program. Metabolix has worked with NSRDEC using Mirel PHA to help qualify the biodegradation of water-resistant yet marine-biodegradable bioplastics. www.reefinterests.com. www.mirelplastics.com.

First Biodegradable Toothpaste Tube Tectubes from Åstorp, Sweden introduces the world’s first truly biodegradable toothpaste tube made from FKuR’s bioresins. The company is a global partner in tube production. They produce more than 300 million tubes yearly, from their factories in Sweden and North America. Tectubes injection mould, extrude and print the various parts of the tube. The tube itself stands out due to its excellent mechanical properties. “Using bio resins for such an application was a challenge for us. We needed to have compatibility between the different parts, and match them together with good conversion properties”, says Johan Barkentin, project leader at Tectubes, Sweden. ”By using FKuR’s expertise and range of sustainable bioplastics we were able to reach a very satisfactory solution”, he says. The result of this development is a toothpaste tube made from natural products. Stefan Lundbladh Swedish manager of toothpaste maker Allveggie pointed out: ”It is important for us to emphasize our ecological awareness and send a signal. By using bioplastics we can fulfil our wish to have an overall environmentally friendly solution.“ All of the raw materials which have been used are biodegradable. Allveggie produces toothpaste made from natural substances. Also, the product is considered as Fair Trade and does not exploit nature or people. Bjarne Högström, FKuR’s sales representative for Scandinavia, stated that “This development shows the versatility of biopolymers and how far biopolymers have progressed with respect to processability and final characteristics.” Bioplastics are an own class of polymers, which have properties comparable to conventional polymers, but are made from renewable resources or enable the biodegradability of the products made from this material. MT

www.tectubes.com www.fkur.com

bioplastics MAGAZINE [02/11] Vol. 6

Application News

No More Tickly Hairs – Thanks to PLA Are you familiar with the problem of tiny clippings of hair falling onto your face when you go to the hairdresser? You will certainly agree with us, that this is most annoying, especially when the hairs tickle your eyes and your nose. As a solution the Austrian hairdresser Edinger had the amazing idea of developing, in collaboration with an Austrian bioplastic retailer Novitech®, an innovative product called FacePro®, which is designed to protect the client’s face from clippings of hair. So how does FacePro work? FacePro is a shield made of PLA, with an adhesive stripe on the back to adhere to the client’s forehead and so protecting the face from tiny, tickly hairs. Furthermore it was very important for Edinger as well as Novitech to offer a product which is made of an ecofriendly, eudermic material - for the simple reason that FacePro is a throw-away product. The percentage of renewable material (maize) in FacePro is around 93%. Sales figures show that it works! From August 2010 to January 2011 Novitech sold around 1,000 packages of FacePro each containing 50 shields (equivalent to around 30,000 metres of PLA). MT www.novitech.at

Toys - Made 100% from Bioplastics “My heart is in eco-plastics” says Markus Swoboda, mechanical engineer who one year ago had the confidence to found another company besides his well-established engineering enterprise. This is how BioFactur was born - dedicated to supplying children’s toys that parents can hand to their little loved ones without thinking about any risk that one normally has to face with regard to plastic toys – which are put millions of times into the mouths of children whilst having fun with them. BioFactur’s products are mainly based cotton cellulose, but also on other ingredients such as starch obtained from maize and potatoes, wood or vegetable oils from rapeseed or sugar. And, most importantly, they fulfill both of the fundamental demands of bioplastics, i.e. made from sustainable raw materials and being completely and verifiably ecologically degradable - biodegradable in the case of BioFactur’s products that in addition are CO2-neutral. Optimistically looking further ahead, BioFactur is sure to find a firm niche in the worldwide plastics market (currently running at about 260 million tonnes) even though the sustainable and almost healthy bioplastics products from BioFactur are up to 30% more expensive compared to conventional plastic toys. People feel different when sitting near the playground and having a drink from a cup that is made from the same family of future-oriented bioplastics as the toys their children are playing with. This belief strongly demonstrates BioFactur’s attitude towards all our futures and underlines the seriousness of their commitment. CJ www.biofactur.de

bioplastics MAGAZINE [02/11] Vol. 6

Application News

Multipack Yogurt Cups Beginning in October 2010, global organic yogurt leader Stonyfield Farm (headquartered in Londonderry, New Hampshire, USA), replaced all of its petroleum-based multipack yogurt cups with cups made from Ingeo™ PLA, giving consumers a yogurt cup they can feel as good about as they do the yogurt inside. The new cups are a first for the dairy industry and reduce the package’s greenhouse gas emissions by 48%. All new Ingeo-based multipack cups look and feel exactly like the petroleum-based yogurt cups they replace and now carry a ‘This Cup is Made From Plants’ stamp on the bottom. MT www.stonyfield.com www.natureworksllc.com

Biodegradable Beach Toys Zoë b Organic, a distributor of BPA-free, organic products for babies and kids from Winston Salem, North Carolina, USA has selected Mirel™ bioplastic for America’s first line of biodegradable beach toys. Mirel was the material of choice for Zoë b Organic’s new beach pails, cups and shovels for toddlers because it is the only durable bioplastic on the market that is proven to biodegrade in a marine environment. “Consumers are increasingly seeking more products that fit with their desire for healthier lifestyles, and forward-thinking brand owners, including distributors like Zoë b Organic, are responding by turning to biobased and biodegradable materials that are made from renewable sources,” said Bob Engle, Telles general manager. “Mirel’s biobased solutions provide an alternative to petroleum-based resins that offers brand owners a way to meet corporate sustainability goals and further differentiate product offerings.” “As a mother of three young children, I am concerned about the number of stray plastic shovels and beach buckets that inadvertently wash up on the shore,” said Valerie Lecoeur, president and founder of Zoë b Organic. “Our line of Zoë b Organic beach products made with Mirel represents a cultural shift in toy manufacturing. With Mirel’s ability to biodegrade in water and other environments, Zoë b Organic is making smarter beach toys that are healthier for our kids and our planet.” MT www.zoeborganic.com www.mirelplastics.com

New Line of Kitchen Utensils Propper from Rain am Lech, Germany recently introduced a new line of kitchen utensils made from the fully degradable bioplastic PROGANIC® again proving the versatility and heat stability of this much talked about bioplastic. At Ambiente 2011 (Frankfurt, Germany) Propper unveiled stylish kitchen utensils as well as the new kitchen herb pot ‘My Proganic Garden’. This decorative yet functional pot includes a smart watering system and comes with a pair of multi-blade herb-scissors. The new line of kitchen utensils is made from 18/8 quality stainless steel with removable Proganic handles. Proganic is dishwasher safe, wear-resistant and CO2 neutral. Unlike conventional bioplastics this award-winning biopolymer is heat resistant up to 100°C. Proganic compounds consist of PLA and PHA plus natural waxes and minerals. This material processes on standard injection molding and extrusion machinery and molds/tooling. Heat resistance is to 110°C, and it is food safe and UV resistant. Additionally It is durable, with a modulus of 4300 N/mm2, higher than that of ABS or PS, and a Charpy impact strength that falls between that of those two standard plastics. Proganic already has had the material certified to DIN 14851/2 for home composting, so there is no need to dispose it to a commercial composting facilitity. www.propper.de

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Application News

Green Dust Bag

Earth’s Best Diapers

With a variety of over 1000 different vacuum cleaner models worldwide, finding the right dust bag has been a challenge for consumers for many decades. To make life easier for consumers Electrolux from Sweden has developed the standard s-bag® in collaboration with Philips. s-bag GREEN is a high-tech innovation and the first dust bag in the world using Ingeo™ biopolymer. s-bag Green is made from completely renewable sources, with Ingeo PLA fibers, natural rubber, and recycled cardboard. s-bag Green has up to 50% longer lifespan than paper dust bags and is TÜV certified.

In a continued effort to provide a healthier alternative for babies and a cleaner, safer world for them to grow up in, Earth’s Best® proudly introduces Earth’s Best TenderCare® environmentally friendly disposable diapers. Earth’s Best are a product of The Hain Celestial Group, Inc, Boulder, Colorado, USA.

In summer 2010, Electrolux gathered plastic from the world’s oceans and turned it into a number of vacuum cleaners. The initiative – “Vac from the Sea” – aims to bring attention to the issue of plastic pollution and at the same time combat the scarcity of recycled plastics needed for making sustainable home appliances. MT www.electrolux.com www.natureworksllc.com www.electrolux.com/vacfromthesea

Made from Ingeo™ fibers, a man-made fiber created from NatureWorks’ PLA, the production of Earth’s Best TenderCare Disposable Diapers offers a lower carbon footprint than traditional petroleum based diapers. Also chlorine free, made with non-bleached materials offering a soft, non-toxic, super absorbent inner panel, breathable sides and moisture barrier cuff. Available in five sizes, each with refastenable, velcro-like tabs, these diapers provide a perfect, comfortable fit for babies and ease of use for parents. Earth’s Best TenderCare Disposable Diapers are chlorine-free, latex-free, dye-free and perfume-free, and provide the ultimate comfort for babies. MT www.earthsbest.com www.natureworksllc.com

‘Nucycle’ Developed by NEC, the ‘Nucycle’ plant based formulation illustrates the NEC Group’s unique material development technology and capabilities. Nucycle significantly expands the application of Ingeo PLA bioplastics into products where performance features such as durability, safety, and high levels of flame retardancy are of paramount importance. Life cycle analysis (LCA) demonstrates that ‘Nucycle’, with high Ingeo bio-content (75%~ plant based) offers significant carbon footprint reduction, lowering CO2 emissions ~50% compared to the petroleum-based polycarbonate/ABS blends used in the past. With the development of Nucycle, the NEC group plans broad commercial implement across its PC business in 2010. Future NEC group focus is on actively promoting and supporting progress toward non food based cellulosic feedstocks. MT www.nec.com www.natureworksllc.com

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Application News

Bioplastic for Printers and MFPs

New Line of Compostable Bags

OKI Data Corporation, an OKI Group company specializing in the printer business, recently announced it will introduce a bioplastic part consisting of at least 25% (by weight) of plant-based renewable biomass resources in all its printers and MFPs. Products manufactured from March 2011 onward will incorporate bioplastic, marking the first effort among OKI Group companies to use bioplastic in products.

Telles, Lowell, Massachussetts, USA recently announced that Lakeside Plastics Ltd., an innovative film converter headquartered in British Columbia, Canada, will be launching a compostable bag product line based on Mvera™ B5002, a compostable film product made from a proprietary blend with Mirel™ bioplastics.

OKI Data is currently active in 120 countries, selling approximately 1.1 million printers and MFPs annually. Today’s introduction of bioplastic is expected to reduce its annual CO2 emissions by three tons. “Plant-based renewable bioplastics reduce environmental impact by reducing CO2 emissions and the petroleum resources consumed,” said Harushige Sugimoto, President of OKI Data. “OKI Data is proactively developing products and technologies to reduce environmental impact. The company has long considered using bioplastic in its printers and MFPs. However, compared to traditional plastic, bioplastics offer formidable challenges in the areas of flame resistance, strength, heat resistance, and formability.” The bioplastic announced today is based on PLA and offers enhanced flame resistance, strength, heat resistance, and formability, as well as high transparency and ease of processing, qualities that allow use of the product to form elements ranging from exterior components to mechanical parts. It is widely used in stationery, electrical home appliances, and office equipment. OKI Data is firmly committed to reducing its CO2 emissions, having set a goal to cut emissions by 6% relative to 2007 levels by 2012. Introducing bioplastics is one of the ways it intends to achieve this goal. Where possible, the company plans to replace traditional petroleum-derived plastics with plant-based renewable bioplastics in its future printers and MFPs. MT www.okidata.com

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Lakeside Plastics has been working with Telles to produce compostable trash liners, lawn and leaf, and kitchen compost bags. The new product line of bags will use Mvera B5002 film material, enabling consumer yard waste and organics diversion to industrial composting. “We are very excited with the superior performance of Mvera B5002 film in terms of strength, rapid composting ability, and that it meets or exceeds ASTM standard D6400 for compostable plastics,” said Stuart MacDonald, chief operating officer with Lakeside. “As we commit to manufacturing compostable bags for the burgeoning North American market, we are confident in doing so with Mvera B5002, that our product line will have wide appeal to the consumer and industrial compost bag segments alike.” “Through Lakeside, we are bringing a tough and faster composting film material to the market,” explained Bob Engle, Telles general manager. “Mvera B5002 film for compost bags has the strength that consumers are asking for. With the rapid composting and D6400 certification to a thickness of 288 µm, Mvera is an excellent material choice for both consumer and commercial organic waste diversion needs.” MT www.lakesidepackaging.net www.mirelplastics.com.

Basics

Bioplastics in Packaging By Harald Kaeb Founder narocon Berlin, Germany

Fig. 1:First Coca-Cola, then Volvic – soon a megatrend? PET bottles with bio-based content and rPET (Photo CocaCola)

Fig. 2: Multilayer-film for demanding products are only avaliable since a short time (here combination of starchblend and cellulose films (Photo Innovia Films)

Fig. 3: Compostable Deep Freeze (Material FKUR) (Photo: McCain)

Plastics in Packaging As a general rule, in western industrial nations about 50% of all goods are packaged in plastic. More than one third of the world’s plastic is used for this purpose – which represents almost 100 million tonnes of plastic packaging. The constantly increasing market is dominated by the polyolefins (PE, PP) and PET. Plastic packaging is lightweight, and can offer tailor-made solutions for almost any product. It is also relatively cheap: in the food business the packaging often makes up less than 10% of the product price. Super, successful products – and not just at first glance. Packaging is basically just as important as the stuff it holds. Food that is senstive to rough handling, such as pears or strawberries, would hardly be able to withstand long transport routes, and an iPad would find it difficult to withstand the way in which it may be treated by the customer when he is on the move. Buying easily perishable foodstuffs with no packaging could be a health risk – and not only in summer. Without the protection provided by packaging a lot of products would not even reach us. They would either be unsafe from a health point of view, or they would be many times more expensive. Despite these contributions made to our standard of living the consumer’s view of plastic packaging is surprisingly negative. Is this a lack of gratitude? No! At least not only that! With the increasing use of packaging the associated problems are also increasing. Because it is so difficult to close the loop the waste disposal sites worldwide are full of packaging plastics. Being lightweight also means easy to throw away: in the environment, in the oceans, we find packaging everywhere. And even though the litter problem lies in people‘s unacceptable behaviour it is aggravated by the fact that plastic is very slow to degrade. In many countries there is also no collection and recovery system, or what they do have is inadequate. The extravagant way that we treat finite resources is highlighted to us every day by the household rubbish bin, which is often half full of plastic packaging. Only about 10% of the EU’s 50 million tonnes of plastic is mechanically recycled or reclaimed after use. 15% is reclaimed as an energy source (incineration). Only bottles and industrial foil have a high recycling rate (40%) and most packaging plastics fail to reach a 10% recycling rate. Europe is nevertheless well placed when global comparisons are made. But it also shows that making new plastic products from waste or used material is difficult and expensive because of the mix of materials and the contamination – if it can be done at all! Today plastic packaging is still made predominantly from petroleum. A good 4% of the world’s petroleum is used in the production of about 240 million tonnes of plastic, of which packaging accounts for some 40%.

Fig. 4: Globally controversely discussed … albeit not so much when made of bioplastics (Photo: Novamont)

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The drawbacks of conventional plastics were a significant factor in driving the general development of bioplastics. Bioplastics are expected to at least offer some improvement,

Basics if not a total solution to the well-known problems. This means that bio-packaging should conserve fossil resources and be capable of being recycled. On top of which it should be capable of fulfilling the tasks that conventional plastic packaging does so well.

Production processes Bioplastics can be processed using practically all of the current technologies for plastics processing. Packaging plastics are, as a rule, always thermoplastics which are supplied as granules that can be plasticised during processing. Thin film or sleeving from 10 to 60 microns can be blown, thicker film can be calendered or extrusion moulded. Deep drawing (or thermoforming) is used to produce containers, such as plastic cups or trays. If the film is welded pouches can be produced. Nets, as often used for fruit or vegetables, are made by fibre extrusion or are woven. Injection moulding is the process used for thick walled or complex components such as buckets or caps and closures. Bottles are produced by blow-moulding a plastic preform or parison. Causing the material to foam and produce a soft or hard foam is usually achieved by expelling a previously introduced low boiling point liquid. This allows the production of soft trays for particularly sensitive small products or protective housing for larger heavier products. When processing mono-materials, products are made that generally meet simple requirements, e.g. pouches. Multiple materials are used and brought together during the process to usefully combine their properties. Depending on the demands of the application the mechanical properties, resistance to oxygen and water vapour, and gas barrier, as well as gloss, printability or feel can be modified and optimised. Combinations of paper board and plastics are widely used in the packaging business. The board gives then pack shape and rigidity and plastic gives it its barrier properties making it, for example, waterproof or greaseproof. Applications include compostable tubs and cups for ice-cream and drinks. The plastic film is either laminated (glued) or melted directly onto the board in an extrusion process. Multilayer films are produced by laminating single thin sheets of film or by co-extrusion. Double or treble thickness films are still the exception. Plastic processing offers huge opportunities for product optimisation – both technical and economic. The polymer materials have been made much easier to process and use by the introduction of processing aids, additives and colorants. Packaging is often designed and made for a specific product. They are made economically viable by minimising material usage at the same time as maximising the level of protection that they offer, and maximising the speed of their manufacture. Before a PLA yoghurt cup reaches the supermarket shelf it has to go through complex, technically difficult stages in the production chain. The manufacture of the pot, and food safety standards, are part of this. Filling the pot with yoghurt under sterile conditions and making an airtight seal when applying the lid, which has to be easy to peel off at a later date, are stages that must be able to be

carried out at high speed, and which cause us to think of the demands placed on the material and other components (glue, additives, colorants, labels), and on the product designer. A plastic shopping bag which itself weighs almost nothing but which can safely be used to carry home five bottles of a good wine, is a small but high-tech product. If the product also has to be biodegradable there are even more criteria to meet in order to conform to the appropriate standards.

Compostability as a functional advantage It was no accident that the biological degradability and compostability of bio-packaging were important goals right from the beginning of their development. These new functionalities for plastics are still key factors today in the shape, and promotional messages, of most of the commercialised products. The message was the perceived ability to compost organic waste and bio-packaging together in a cost-effective way. If this packaging was produced from renewable resources the loop would be closed, as in nature’s model. Food residues in the packaging make the recycling of conventional plastics rather difficult, but not for ‘organic recycling’. This idea was taken up and seriously researched for almost 20 years – from the very first packaging product. The door was finally opened by the compostable bio-waste bag which was followed by the first simple foil packaging. Biodegradable polymers can be thermoplastically processed into thin-walled film. Short shelf-life foods, mainly fresh fruit and vegetables, are typical products that can be packaged in a compostable pouch. At home the food waste and packaging can all be taken together for composting. In the distribution chain it is not necessary to separate unsaleable, rotting produce from its packaging if the produce is to be composted. A further advantage is the fact that compostable bioplastics keep produce in a fresh condition for longer, so making them saleable for longer and thus more cost effective. This results from high water vapour permeability, which however also limits to a certain extent the range of applications. Serviceware made from bioplastics has followed a comparable route. Whether we are talking about drinks cups, plates, knives, forks and spoons, or plastic shopping bags – nowadays all of these products are available in a compostable form. They are used at sports venues and events, on the road, in aircraft or on the train. Everywhere in the world this type of application, using single-trip products, is taking on an increasing importance. Where the product waste can be properly sorted on the spot, e.g. in aircraft (see bM 05/10) or at open air festivals (see bM 06/10), composting is an efficient method to use. Experts however say that anaerobic fermentation is better because compost and also a source of energy - bio-gas – is obtained. There is hardly any packaging format in the world that creates more controversy than the disposable plastic bag. No other plastic product is gaining such attention from politicians and legislators. Rapidly biodegradable bags could, during household refuse collection, help towards a better separation of organic and other waste – an important prerequisite for

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Basics efficient recycling and reduced greenhouse gas emissions. Single trip and multiple trip plastic bags are also quickly produced using almost all bioplastics. In Europe they are already available in many food stores and supermarkets. The dominant bioplastics here are a compostable starch based material and PLA compounds. Easy to recycle bio-PE has also recently proven very successful. The ‘plastic bag war’ is being fiercely waged, and is using weapons such as the ecobalance and environmental arguments. For the bioplastics industry the plastic shopping bag is a major communications tool thanks to its high profile and the enormous quantity being produced. It is joining the race as the new favourite.

We can also make bottles and durable products Technological developments have driven the emergence of a wide range of bioplastic packaging solutions. Biobased polyolefins have unleashed a real flood of packaging innovations for branded articles. Big companies in particular decide on ‘green’ solutions, and often launch their premium brands in such bio-packaging right from the beginning. Coca-Cola started in 2009 in the USA with partially biobased PET bottles for their main brand - Coca-Cola itself, and its iconic packaging design. Volvic followed a year later with water bottles in Europe. Only a few weeks ago the Heinz food group announced that it would be converting its 500 ml ketchup pack to bio-PET, in association with Coca-Cola. The companies focus in their advertising message on the plantbased content and the recyclability. So we now have not only PET and rPET, but also bio-PET, and soon bio-rPET. Danone in France decided in February to use bio-HDPE bottles for their Actimel yoghurt drinks. Procter & Gamble will use bio-PE for their Pantene shampoo bottles. Drop-in approaches where an already well-established polymers, or some parts of it, are converted from a fossil origin to renewable resources, is already popular with manufacturers. At the moment we do not have much information on consumer reaction. There can however be certain risks when switching to biopackaging. Unlike the ‘drop in’ solutions, for new bioplastics such as PLA, PHA, cellulose or starch-based materials, there was a costly programme of development and application trials necessary to be able to change over to a completely new package. A learning process which, at the beginning, above all needed money and plenty of patience. Meanwhile the number of products on the market is now truly vast. Optimisation is in full swing, newcomers are taking advantage of the work done by the pioneers, but the pioneers are still a step ahead. PLA drinks packaging in particular has had to navigate some rough seas and fight off challenges. A small number of manufacturers still use this material, including the well-known Italian company Fonti di Vinadio (Sant‘Anna) that supplies still water in PLA. The Danone subsidiary StonyField in the USA uses PLA yoghurt pots – more than a decade after the first trials in Germany the material is being

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given a new lease of life. And the PepsiCola subsidiary Frito Lay is not running away from the difficulties of launching PLA packaging for SunChips in the USA. The loud crackling noise, which the consumers seemed to object to, has now been stopped. The many and varied technical hurdles had all been overcome, but nobody even thought about a noise problem! Biodegradable polymers are above all used for short shelflife products. Combinations of materials and multilayer film today allow the manufacture of packaging for longer shelf life products that place an increased demand on the aroma barrier, such as muesli or tea. Bio-packaging has also caught the attention of the cosmetics industry. Jars or tubes are technically quite possible to produce but the required extended shelf-life of moist/oily products represents another high hurdle in addition to the aroma barrier. A combination of natural cosmetics and bio-packaging would be just as acceptable as ecologically produced foodstuffs – in fact this merger is already enjoying some success.

How do we move on? Packaging made from bioplastics today still has a very small market share, although there are no precise statistics. The use of biodegradable and/or bio-based polymers in this sector of industry is estimated by the author to be around 100,000 tonnes worldwide (2010). Growth rates are at least 20% per annum. There is growth in all product sectors and for all of the bioplastics The packaging industry finds itself in a real upheaval, which is largely influenced by the ‘sustainability’ megatrend. This is being demanded by the consumer, and additionally by governments as a major factor in their resources and global climate policies. Ways of measuring sustainability of packaging (such as Walmart’s ‘Sustainability Scorecard’) are already being established by the big retail chains and are exerting pressure on their whole supply chain. Trendsetters in the food industry see sustainability as a chance to establish for themselves a better position in a competitive market. If you ask Coca-Cola, Procter & Gamble or Danone, then in future packaging materials must be bio-based and/ or produced from recycled material – and in all cases must be themselves suitable for recycling. Energy consumption and CO2 emissions must be minimised. And all this without having a negative impact on the costs or the specific function to be filled by the packaging in question. Bioplastics thus have excellent prospects of taking advantage of a high level of market pull. But the demands, and the hurdles, are still high. The author is the founder of narocon innovation consulting for green chemistry and bioplastics (since 1997) and political adviser of European Bioplastics. The chemist (PhD) was Chairman of the Board of this industry association from 1999 through 2009.

Basics Bio-Packaging Development: Pioneers and historic achievements The first semi-commercial packaging trial was a joint effort of ICI (today AkzoNobel) and Wella (today owned by Procter & Gamble). Wella`s ‘Sanara’ shampoo bottle was made of PHB and sold in a very small quantities already in 1990. The begin of packaging bags commercialisation could be marked by the first field trial of Novamonts compostable MaterBi biowaste bags in Fürstenfeldbruck, Germany 1992. That might have been ‘the mother’ of all starch material bags. 1994 was the year of the Olympic Games in Lillehammer where starchbased cups were used for catering – the kick-off for many more ‘olympic cups’ to follow.

Fig. 5: For many cosmetics packaging application bioplastics solutions are available. Including bottles and labels (Photo: Sidaplax)

Danone launched the world‘s first yoghurt cup made from Cargill-Dow‘s (today NatureWorks) PLA in 1998 in Germany - sold a few months only. Their US daughter Stonyfield dairy did it again starting October 2010. The seedling logo and compostability mark of IBAW (now European Bioplastics) was designed by a student and launched in 1998. Back in 2000, the UK retailer Sainsbury‘s launched a fully compostable packaging with breakthrough biodegradable trays on some of their organic produce. Their adoption and public commitment to bioplastics raised the profile of biopackaging worldwide.

Fig 6: Compostable Net Bag (Photo: FKuR)

Nitted and extruded nets for fresh fruit and vegetables were first introduced first by Novamont in 2001. The 100,000 household field trial in Kassel, Germany revealed that compostable plastic packaging waste can be separately collected by consumers and recycled through composting in municipal plants without loss of compost quality (2003). As a consequence a privileging packaging legislation was set up to promote compostable bio-packaging in Germany 2005 - 2012 – the first of its kind. US based water distributor Biota developed the world‘s first compostable water bottle made of PLA and launched it in 2004.

Fig. 7: Selection of packaging from compostable film (Photo: Sainsbury’s)

A laminated bilayer film of MaterBi and Natureflex film was used the first time for the Jordan‘s Muesli in UK 2005. 23 exhibitors showed their bioproducts in the special exhibition ‘Innovationparc Bioplastics in Packaging’ to the global business - the first time at interpack in 2005. By the way the initial spark for bioplastics MAGAZINE. 2007 Braskem announced its green polyethylene from bioethanol project and went on-stream at a 200.000 tpa scale in 2010. 2009 Coca Cola launched their PET plant bottle with up to 30% biomass content for some of their main brands in parts of the US.

Fig. 8: PLA trays with lids (Photo: natura)

First compostable triplex film for Boulder Canyon chips using high barrier metallised NatureFlex film to provide shelf life requirements in 2010. 2011 Danone begins to pack their premium brand Actimel drink yoghurt in bio-based HDPE bottles in France. (Author’s choice. Not necessarily complete or historically warranted)

A German language version is abailable at www.bioplasticsmagazine.com/201102

Dr. Harald Kaeb (Photo: European Bioplastics) bioplastics MAGAZINE [02/11] Vol. 6

Opinion

Comments regarding Cereplasts Symbol Competition By Hasso v. Pogrell European Bioplastics

uropean Bioplastics, in general, supports the idea of creating a logo for bioplastics for use in the US market. Eventually, if it should achieve similar recognition as the recycling symbol, it would be a boost for the entire bioplastics sector.

However, there are a few issues concerning this particular competition initiated by Cereplast for a bioplastics logo that one needs to be aware of: According to the invitation to tender, bioplastics would be defined as plastics produced (in parts) of renewable raw material. Compostability and (mechanical) recyclability are seen as mere additional attributes to be displayed in respective variations of the general symbol. Given this, the question that will soon arise is: When will a product be considered to be made of bioplastics, i.e., what will the minimum share of renewable raw material have to be for a material to be defined as ‘bioplastic’? Furthermore, the details of the measurement of the biobased content are not clearly defined in the call for tender: Is the 14C method to be used? Or is the logo aiming to display the total biomass content (like, e.g., the Coca Cola Plant Bottle)? According to the US standard ASTM 6866, both methods could be used to display the wording ‘biobased content’ on a product. The importance of the latter question should not be underestimated. Long and dynamic discussions – at least in Europe – show that both methods have their merits but also some weak points. While the radiocarbon analysis is relatively simple to conduct, it does not say anything about other possible biogenic elements, e.g. hydrogen, oxygen, nitrogen, etc. contained in a product. This can lead to cases, where, according to the 14C method, the combination of a 100% biobased material with a fossil-based one will result in a product with a biobased factor far below the share of the natural material in proportion of the entire product. Not least for this reason have large brandowners decided to label the entire biomass (‘plant based’) fraction on their product instead of only the share of biobased carbon, which would reduce the displayed biobased figure. Assuming that the issue of biobased carbon vs. biomass is eventually clarified, the question will come: How is the logo awarded? Will a mere lab test be sufficient? An easy thing to do using the 14C method, but it has the distinctive disadvantage that it lacks independent verification. Or will there be third-party certification by an audited certifying body? This approach would increase the credibility of the claim but also make the labelling system more expensive and complicated. At least in Europe, the demand for quality certification is considered to be quite high. Finally, existing labelling schemes for biobased products, including biobased plastics, have to be taken into account, e.g. the recently launched USDA label for biobased products that extends beyond the US public procurement scheme and can also be applied to a wide range of biobased products voluntarily. European Bioplastics endorses the development of communication and labelling platforms for (biobased) bioplastics in order to become more visible in the market - as a matter of fact, EuBP itself has been very active in this field. Eventually however, a common approach would be the most beneficial solution for the industry. European Bioplastics would therefore very much welcome the initiation of a stakeholder dialogue.

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Personality

Martin Kumar Patel bM: Dear Mr. Patel, when and where were you born?

To conclude, I consider biobased more important today than biodegradable.

MP: I was born in Donaueschingen, Germany but spent the first seven years of my life in Ghana, West Africa. When I was 7 years old (in 1973), I moved to Germany together with my parents (Indian father, German mother).

bM: What is your biggest achievement (in terms of bioplastics) so far?

bM: Where do you live today and since when? MP: Today I live in Utrecht, Netherlands, where I have lived happily since 2000.

bM: What is your education? MP: After my training in chemical engineering (at Karlsruhe University, Germany) I did most of my Ph.D. research at the Fraunhofer Institute for Systems and Innovation Research Karlsruhe but I completed my thesis at Utrecht University.

bM: What is your professional function today? MP: Since 2001 I have been assistant professor at the Department of Science, Technology and Society at the Copernicus Institute at Utrecht University.

bM: How did you ‘come to’ bioplastics?

bM: What are your biggest challenges for the future? MP: Helping to find ways to channel creativity, personal drive and regulation into technological solutions that are sustainably sound – sound as transitional solutions and ideally, sustainable for the longer term. We need to offer means and methods for assessment which become broadly accepted and used. We need to contribute to a culture of transparency and openness – for reasons of trust and because it needs to go fast. Big changes are required but we will only get there if we are convincing!

bM: What is your family status? MP: I am happily married to an Italian scientist, who left the sunny South of Italy to move to the rainy and cloudy Netherlands.

MP: It was actually a part of my Ph.D. thesis in which I studied options to reduce energy use and greenhouse gas emissions related to the chemical industry. I was fascinated by bio-based chemicals but I also studied the contribution of incremental process improvements and of recycling. When I started working at Utrecht University, I seized the opportunity to further develop this topic in research and in teaching.

MP: It’s not really a movie – more a documentary film showing Pablo Picasso at work. He paints and completely repaints, on the same canvas. What creativity and what perfectionism.

bM: What do you consider more important: ‘biobased’ or ‘biodegradable’?

bM: What is your favourite (or your next) vacation location?

MP: Packaging accounts for 40% of all plastics used. Recycling is working out for some packaging applications (e.g. PET bottles) but is very challenging for some others (e.g. packaging films). For the latter, a biodegradable solution would be desirable if combined with digestion for recovery of the embodied energy (in the form of biogas) and soil improvement (valuable carbon and potentially some fertilizing ingredients). For the remainder, durable biobased plastics are a convincing solution under the condition that they are applied in a responsible manner - and the same holds true for their waste management.

MP: I am not alone here but I believe that I have contributed to the awareness that there is a need for environmental accountability. A bio-based product is not great just because it is made from biomass. It really needs to be better in terms of its environmental profile, but it also needs to be economically viable (and socially acceptable). We need a culture of checking out these things before it is too late, i.e. ideally at the R&D stage.

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bM: What is your favourite movie?

bM: What is your favourite book? MP: Saint Exupery’s ‘The little prince’.

MP: One day, I would like to visit the South of India.

bM: What do you eat for breakfast on a Sunday? MP: Polysaccharides and pectins in the form of Butterzopf (a plaited bread loaf with butter - and jam) made by my mother..

bM: What is your ‘slogan’? MP: “‘here is nothing as powerful as an idea whose time has come’ (Jules Verne).

bM: Thank you!

Politics

Plastics and Industry Israeli firms are committed to universally accepted quality standards and excel at meeting niche market needs. Israel is unique in having free trade agreements with the European Union, the United States and Canada, EFTA countries, as well as Mexico and Turkey. Most other countries have granted Israel MFN status (Most Favoured Nation). Israel’s vigorous R&D programs, its expertise in advanced technologies, and its strengths in computer-aided design and manufacture have been adopted by the plastic products industry. The result is a vibrant exportoriented enterprise offering innovative, high quality products.

Bioplastics in Israel By Inbar Avner JOLYBAR Montefiore Natanya, Israel

Products The Israeli plastics market manufactures agricultural products (23% of industry sales), infrastructure and construction related products, household and consumer items, engineering and high-tech components, medical consumables and packaging products (16% of industry sales). The latter is of particular interest to the biopolymer market. Reflecting global trends that increasingly embrace plastics, but that also address environmental concerns, Israel’s packaging industry works aggressively to develop solutions that meet consumer interests and regulatory demands while fulfilling customers’ requirements for quality, reliability and cost.

Legislation A few major steps have recently taken place in Israeli legislation: Israeli Standard IS 6018 – A non-obligatory standard which follows EN 13432 and ISO 17088 is being implemented. Packaging Law - Submitted by the Ministry of Environmental Protection, this law imposes direct responsibility on manufacturers and importers in Israel to collect and recycle the packaging waste from their products. The immediate outcome of the above has been extensive development and proactive steps by major market chain retailers, food and pharmaceutical producers and packaging converters. This means not only R&D activity, but also includes some pilot tests, adopting bio-based and biodegradable replacements for existing items.

Waste management in Israel – Figures: Waste in Israel has been growing at an average annual rate of 3%-5%. Some 5.4 million tons of municipal solid waste are generated in Israel each year. Every resident in Israel generates an average of 1.6 kilos of waste daily. The weight of packaging waste in Israel is estimated at a million tons per year. Recycling targets: By 2014 manufacturers and importers will be required to recycle 60% of the total weight of the packaging of the products they sell or import each year. Producers will have to comply with annual recycling targets according to type of material: glass, water and cardboard 70%, metal 65% and plastic 40%.

bioplastics MAGAZINE [02/11] Vol. 6

Waste collection, sorting systems and ‘end of life’ solutions: In Israel, today, there are only a handful of private companies able to handle massive shipments of wet waste, as the new regulation will soon dictate. The government has created incentives and funds to support and encourage new investments in such facilities, with the aim of having the appropriate infrastructure in place once new waste management regulations are implemented. The above companies, and some newcomers that have spotted the opportunity, are currently examining new investments in the areas of receiving and processing the expected growth in wet waste collection, through energy recovery systems (incineration), anaerobic digestion systems for producing gas, and coerced composting. The Israel Recycling Organization‘s main bottle recycling factory Aviv, is able to add an NIR stream that can sort PLA and bio-based containers. EU recyclers would be more than willing to purchase the bottles for resale to the industry after processing, however, there will be no investment before local production switches to more significant quantities (more than 1.5% of the total collected containers and bottles).

Major players in the Israeli biopolymer market In order to maximize market potential, special cooperation between Kafrit Industries (1993) Ltd. and Jolybar Ltd. has been created. The Kafrit Group, a worldwide leader in masterbatch manufacture and compounding, has broad experience in the development and marketing of unique solutions; together with Jolybar, a leader in the biopolymer market with extensive access to potential customers and a strong marketing position, have jointly developed the first multipurpose bio-based compound – Ecomp®. The Ecomp grades that comply with EN13432 and ASTM D6400 standards are mainly based on NatureWorks IngeoTM and Limagrain Biolice® as well as other biopolymers and additives. Ecomp grades have already been tested and commercially used in blown film, injection moulding and blow moulding applications, and furthermore provide perfect technical performance, high efficiency and positive cost-effective figures. Well-known Israeli manufacturers such as LOG - Plastic Products Company (1993) Ltd, A.M.G. Manufacturing & Marketing of Plastic Sheets L.T.D and Plastnir Ltd., have already applied Ingeo and Ecomp in their commercial production and others are in the final stages of trials and approvals. Possible applications are films for packaging (including multi-layer and high barrier pouches), mineral water bottles, cosmetics and pharmaceutical containers, cosmetics and hygiene tubes, injection moulded components and compostable and durable products. The biopolymers activity in the Israeli market is growing rapidly, providing a fertile market for activity by other companies, such as FKUR, Novamont, Biotech and Telles. www.kafrit.com www.jolybar.com www.ecojo.co.il

bioplastics MAGAZINE [02/11] Vol. 6

Event Calendar

Event Calendar April 12-13, 2011 4. BioKunststoffe 2011 Hannover, Germany

May 23–24, 2011 5th Bioplastics Markets The Langham, Hong Kong

www.hanser-tagungen.de

www.cmtevents.com

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

Mai 25, 201 Bioplastics: (Reactive) Compounding and Related Industrial Applications Best Western Horizon Hotel, Ghislenghien, Belgium

www.antec.ws

Mai 3-4, 2011 Siñal Exhibition 2011 Trade fair devoted to the non-food applications of agricultural resources Chalons en Champagne, France www.sinal-exhibition.fr

May 9-10, 2011 ecoPack systems Düsseldorf, Germany

http://www.materia-nova.com/documents/news/MateriaNova_conference.pdf

June 6-10, 2011 19th European Biomass Conference and Exhibition ICC Berlin - International Congress Center Berlin - Germany www.conference-biomass.com

June 27-29, 2011 bioplastek 2011 An Interactive Forum on Bioplastics Today and Tomorrow The Waldorf-Astoria, New York City, USA www.bioplastek.com

Sept. 25-29, 2011 8th European Congress of Chemical Engineering and 1st European Congress of Applied Biotechnology Berlin, Germany

www.ecopack-conference.com

May 12-18, 2011 interpack 2011 Düsseldorf, Germany

www.dechema.de

interpack.com

Oct. 17-19, 2011 GPEC 2011 (SPE’s Global Plastics Environmental Conference) The Atlanta Peachtree Westin Hotel, Atlanta, GA, USA

Mai 15, 2011 Bioplastik: Verpackung der Zukunft? Empa, St. Gallen, Saal C 3.11

www.4spe.org

www.empa.ch

May 16-18, 2011 Plastics & BioPlastics Modification Hilton - Chicago O’Hare Airport, Chicago, IL, USA www.innoplastsolutions.com

May 18-19, 2011 International Conference of the European Industrial Hemp Association Wesseling near Cologne, Germany www.eiha.org

May 18-19, 2011 Eco-friendly Plastic Materials and Machinery Conference Concurrent event at Chinaplas 2011 China Import & Export Fair Pazhou Complex, Guangzhou, PR China www.chinaplasonline.com

Nov. 22-23, 2011 6th European Bioplastics Conference Maritim proArte Hotel, Berlin, Germany www.european-bioplastics.org

Feb. 1-2, 2012 STOP’s 1st Global Conference Los Angeles, California, USA www.stopoceanplastics.org

Feb. 20-22, 2012 Innovation Takes Root 2012 Omni ChampionsGate Resort in Orlando, Florida, USA www.innovationtakesroot.com You can meet us! Please contact us in advance by e-mail.

Editorial Planner 2011 Month

Publ.-Date

May/Jun 06.06.2011

Edit/Ad/Deadl. Editorial Focus (1)

Editorial Focus (2)

Basics

Fair Specials

13.05.2011

Beauty & Healthcare

Thermoset

PHA (update)

interpack Review

End-of-Life Options

Jul/Aug 01.08.2011

08.07.2011

Bottles / Blow Moulding

Sep/Oct 04.10.2011

09.09.2011

Fibers / Textiles / Nonwovens Paper Coating

Algae

Nov/Dec 05.12.2011

11.11.2011

Films / Flexibles / Bags

Film-Blowing

bioplastics MAGAZINE [02/11] Vol. 6

Consumer Electronics

Stretch Blow Moulding

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bioplastics MAGAZINE [02/11] Vol. 6

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]]

bioplastics MAGAZINE [02/11] Vol. 6

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 [02/11] Vol. 6

Suppliers Guide 1. Raw Materials 10

100

110

120

130

140

150

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

Kingfa Sci. & Tech. Co., Ltd. Gaotang Industrial Zone, Tianhe, Guangzhou, P.R.China. Tel: +86 (0)20 87215915 Fax: +86 (0)20 87037111 info@ecopond.com.cn www.ecopond.com.cn FLEX-262/162 Biodegradable Blown Film Resin!

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

Division of A&O FilmPAC Ltd 7 Osier Way, Warrington Road GB-Olney/Bucks. MK46 5FP Tel.: +44 1234 714 477 Fax: +44 1234 713 221 ® Natur-Tec - Northern Technologies sales@aandofilmpac.com 4201 Woodland Road www.bioresins.eu DuPont de Nemours International S.A. Circle Pines, MN 55014 USA 2 chemin du Pavillon Tel. +1 763.225.6600 1218 - Le Grand Saconnex Fax +1 763.225.6645 Switzerland info@natur-tec.com Tel.: +41 22 171 51 11 www.natur-tec.com Fax: +41 22 580 22 45 plastics@dupont.com Telles, Metabolix – ADM joint venture www.renewable.dupont.com 650 Suffolk Street, Suite 100 www.plastics.dupont.com Lowell, MA 01854 USA Tel. +1-97 85 13 18 00 1.1 bio based monomers Transmare Compounding B.V. Fax +1-97 85 13 18 86 Ringweg 7, 6045 JL www.mirelplastics.com Roermond, The Netherlands Tel. +31 475 345 900 Fax +31 475 345 910 info@transmare.nl PURAC division www.compounding.nl Arkelsedijk 46, P.O. Box 21 1.3 PLA Tianan Biologic 4200 AA Gorinchem No. 68 Dagang 6th Rd, The Netherlands Beilun, Ningbo, China, 315800 Tel.: +31 (0)183 695 695 Tel. +86-57 48 68 62 50 2 Fax: +31 (0)183 695 604 Fax +86-57 48 68 77 98 0 www.purac.com Shenzhen Brightchina Ind. Co;Ltd enquiry@tianan-enmat.com PLA@purac.com www.brightcn.net www.tianan-enmat.com 1.2 compounds www.esun.en.alibaba.com 2. Additives / bright@brightcn.net Secondary raw materials Tel: +86-755-2603 1978

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

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 3.1.1 cellulose based films

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

1.4 starch-based bioplastics 160

170

180

API S.p.A. Via Dante Alighieri, 27 36065 Mussolente (VI), Italy Telephone +39 0424 579711 www.apiplastic.com www.apinatbio.com

190

200

210

220

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

230

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

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

The HallStar Company 120 S. Riverside Plaza, Ste. 1620 Chicago, IL 60606, USA +1 312 385 4494 dmarshall@hallstar.com www.hallstar.com/hallgreen

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 3.1 films

240

250

260

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

270

bioplastics MAGAZINE [02/11] Vol. 6

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 Sonja Haug Zweibrückenstraße 15-25 91301 Forchheim Tel. +49-9191 81203 Fax +49-9191 811203 www.huhtamaki-films.com

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

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

Suppliers Guide Simply contact:

6.1 Machinery & Molds

Tel.: +49 02351 67100-0 suppguide@bioplasticsmagazine.com

Eco Cortec® 31 300 Beli Manastir Bele Bartoka 29 Croatia, MB: 1891782 Tel. +385 31 705 011 Fax +385 31 705 012 info@ecocortec.hr www.ecocortec.hr

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

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

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

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

5.1 wholesale 6. Equipment

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.

For Example: Molds, Change Parts and Turnkey Solutions for the PET/Bioplastic Container Industry 284 Pinebush Road Cambridge Ontario Canada N1T 1Z6 Tel. +1 519 624 9720 Fax +1 519 624 9721 info@hallink.com www.hallink.com

Roll-o-Matic A/S Petersmindevej 23 5000 Odense C, Denmark Tel. + 45 66 11 16 18 Fax + 45 66 14 32 78 rom@roll-o-matic.com www.roll-o-matic.com

MANN+HUMMEL ProTec GmbH Stubenwald-Allee 9 64625 Bensheim, Deutschland Tel. +49 6251 77061 0 Fax +49 6251 77061 510 info@mh-protec.com www.mh-protec.com 6.2 Laboratory Equipment

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

Uhde Inventa-Fischer GmbH Holzhauser Str. 157 - 159 13509 Berlin Germany Tel. +49 (0)30 43567 5 Fax +49 (0)30 43567 699 sales.de@thyssenkrupp.com www.uhde-inventa-fischer.com 8. Ancillary equipment 9. Services

4.1 trays 5. Traders

nova-Institut GmbH Chemiepark Knapsack Industriestrasse 300 50354 Huerth, Germany Tel.: +49(0)2233-48-14 40 Fax: +49(0)2233-48-14 5

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

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

Wirkstoffgruppe Imageproduktion Tel. +49 2351 67100-0 luedenscheid@wirkstoffgruppe.de www.wirkstoffgruppe.de 10. Institutions 10.1 Associations

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

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

10 35 mm

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

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

30 35

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

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

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

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

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

bioplastics MAGAZINE [02/11] Vol. 6

Companies in this issue Company AIB Vincotte Agriplas AIMPLAS AkzoNobel Alesco ANL Plastics Anton Debatin API As You Sow BASF Bio4Pack Biobag International BioFaktur Biograde BIOP Biopla Biosphere Biostarch Technology Europe Biota Biotech Bollore Boulder Canyon BPI Braskem British Plastics Federation Cereplast Chinaplas CMT Coca-Cola Cortec Cristobal Meseguer Cromex Danone DICS Korecopack Company DIN Certco DuPont Easypack Ecomann Ecoplas Ecovative Design Electrolux European Bioplastics European Plastics News Fachagentur Nachwachsende Rohstoffe FAS Converting FH Hannover Fiscagomma FkuR Folienwerk Wolfen Fonti di Vinadio Fraunhofer UMSICHT Frost & Sullivan Grace Bio Hallink Hallstar Hangzhou Xinfu Heinz Huhtamaki ICI Icimendue Innovia Films Itene JC Hagen Jolybar Jordan‘s Kafrit Kaneka Kiefel Kingfa Kisico Limagrain Céréales Ingrédients Log Plastics Mann + Hummel

bioplastics MAGAZINE [02/11] Vol. 6

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M-Base McCain Medkonpack Metabolix Michigan State University Minima Technology Mitsubishi Chemical Europe Mondi narocon natura Natureplast NatureWorks Natur-Tec NEC nova-Institut Novamont Novitech OKI Data Omodo Organic Waste Systems Pacovis PepsiCo Philips Plantic Plastic Suppliers Plasticker Plastiroll Plastnir Polinasa Bio PolyOne Procter & Gamble Propper Pro-Tech PSM Purac Reef Interest Rodenburg Biopolymers Roll-o-Matic Roquette Saida Sainsbury‘s Schotland Shenzen Brightchina Showa Denko Sidaplax Sleever International SMC Maschinengesellschaft SPI Stonyfield Sukano Synprodo Taghleef Industries Tecnaro Tectubes Telles The Hain Celestial Group Tianan Biologic Tianjin Greenbio Transmare Uhde Inventa-Fischer University of Tehran Utrecht University VELOX VTT Technical Research Centre of Finland Wei Mon Wella Wentus Kunststoff Worldcentric Wuhan Huali (PSM) Xylophane Zenith International Zhejiang Hangzhou Xinfu Zoë b Organic

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