bioplastics MAGAZINE 02-2012

02 | 2012

ISSN 1862-5258

March/April

Highlights Rigid Packaging | 18 Additives | 35 Basics

bioplastics

magazine

Vol. 7

Thermoforming | 54

Cover Story BioWareTM PLA cups | 16

... is read in 91 countries

FKuR plastics – made by nature!® TerraleneTM-excelling Green PE

FKuR distributes Braskem‘s Green PE and produces Terralene™ compounds based on Green PE. Bottles are made by Sauer Polymertechnik.

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

www.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

Editorial

dear readers bioplastics MAGAZINE

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Michael Thielen

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bioplastics MAGAZINE [02/12] Vol. 7

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Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Companies in this issue . . . . . . . . . . . . . . . . . . . . . 66

02|2012

January/February

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Application News

News

Expertise in PLA closedcycle waste management Closed-cycle waste management for PLA from all stages of the value chain: this is the aim of RE|PLA Cycle GmbH (Cologne, Germany), a new subsidiary in the Reclay Group.

RE|PLA Cycle is the first provider to set up PLA closedcycle waste management for reusable materials in the area of post-industrial waste. This concerns production waste from manufacturers, processors and fillers, for example.

Various pilot projects were carried out in sorting and recycling plants alongside process optimisation and establishment of the necessary logistics structures. “It was obvious that corresponding innovative recycling arrangements had to be created in parallel with the introduction and growing usage of PLA. The special characteristics of this bioplastic had hampered developments in the past. RE|PLA Cycle brought together all those involved – from manufacturers to the recycling industry – and did their homework with the help of this joint expertise. We have therefore laid the foundations for the further development of the market,” stated Raffael A. Fruscio, management member of RE|PLA Cyclne and shareholder of the Reclay Group.

RE|PLA Cycle is also working on solutions to enable PLA products from the area of post-consumer waste, after collection in (e.g. German yellow) recycling bags, to be processed in closed-cycle waste management in future. This should eliminate criticism in this respect relating to the use of PLA products in the packaging industry. “We already achieve high-quality recycling results in the area of post-industrial waste and would like to do the same for post-consumer waste as well,” remarked Dr. Edmund Stassen, director of the waste disposal business at the Reclay Group. “Although the current volume is still too low, the issue of finite fossil resources means that it is only a matter of time before bioplastics, made either wholly or partly of renewable resources, will be used to a significant extent. RE|PLA Cycle is already preparing the necessary structures for recycling,” added Dr. Stassen.

In addition to the development of complete systems for PLA, the product spectrum of RE|PLA Cycle also comprises the realisation of individual projects and support for all aspects relating to PLA as a key issue for the future. For example, RE|PLA Cycle provides companies with advice on the use of PLA right from the initial idea, and provides the necessary technical knowledge and engineering expertise to ensure successful implementation. As the volume of PLA used increases, RE|PLA Cycle will develop further innovative services and products – tailored entirely to the needs of market participants. MT

Danone and RE|PLA Cycle cooperate Danone GmbH (Munich,Germany) and RE|PLA Cycle GmbH (Cologne, Germany) have agreed to cooperate in the area of resource recycling. The aim of the new RE|PLA Cycle GmbH, a subsidiary of the Reclay Group is to achieve a closed recycling loop for PLA throughout the stages of the value chain (see left). In 2011, Danone introduced a yoghurt pot made from PLA, which is collected via the German ‘Yellow Bin’ (or yellow bags) system for lightweight packaging waste.

“It is our aim to reduce the use of fossilbased raw materials as much as possible”, said Pierre-Alexandre Tupinon, Sourcing & Supplier Development Director Central Western Europe at Danone. The collaboration with RE|PLA Cycle is an important step for us to advance recycling. RE|PLA Cycle with the many years of experience of the Reclay Group is ideally positioned to tackle these challenges.

RE|PLA Cycle is the first supplier to develop a closed PLA recycling loop in the post-industrial sector, we can build on this. “However, recycling PLA, given its special characteristics, is particularly complicated”, says Raffael A. Fruscio, partner of the Reclay Group. “We trust that we will be able to solve the issues surrounding PLA recycling in collaboration with further partners and our joint know-how. We believe that we are able to make a positive contribution to the development of the market this way”, Raffael Fruscio continues. MT www.danone.com

www.reclay-group.com

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News

Fraunhofer and Univ. Hannover bundle resources

Bio-based plasticizers from LANXESS

The Hochschule Hannover – University of Applied Sciences and Arts is one of the first universities of applied sciences in Germany to have a Fraunhofer Application Center starting in 2012. So far, Fraunhofer Application Centers usually exist at major universities only.

LANXESS (Leverkusen, Germany) is strengthening its commitment to renewable raw materials. The German specialty chemicals company aims to produce phthalate-free plasticizers from bio-based succinic acid from 2012 onwards. Its strategic partner is the U.S. company BioAmber, Inc., based in Minneapolis, Minnesota.

BioAmber is a global leader in succinic acid generated on the basis of renewable resources.

Together, the two companies are developing plasticizers, whose cost-effectiveness and safety profile make them sustainable alternatives to phthalate-containing formulations.

In close cooperation between the Fraunhofer Institute for Wood Research, Wilhelm-Klauditz-Institute WKI, directed by Prof. Dr.Ing. Bohumil Kasal, and the Hochschule Hannover, the Fraunhofer Application Center for Wood Fiber Research (HOFZET) is expected to bridge the gap between industry and science.

Head of the new Fraunhofer Application Center and at the same time WKI staff member will be Prof. Dr.-Ing. Hans-Josef Endres, who also directs the Institute for Bioplastics and Biocomposites (IfBB) at Faculty II – Mechanical Engineering and Bioprocess Engineering of the Hochschule Hannover.

“The creation of HOFZET will lead to a marked increase in bio-based materials research performed in close cooperation between the Hochschule Hannover and the Fraunhofer Institute”, Prof. Endres says. “Also, this is an important step forward to link up university-based research and the industry in the Braunschweig / Hanover region and beyond.”

Over the first 3 to 5 years HOFZET will receive a grant of approximately Euros 3 million in public funds from the German federal state of Lower Saxony. The Center is expected to be self-sustaining when the grant funding expires after five years.

Research at HOFZET will focus on all aspects of higher-value use of wood fiber materials for technical applications. WKI’s extensive experience in the development of wood fibers and wood-based materials as well as in the chemistry of wood, cellulose and renewable resources, combined with the very successful research on biocomposites conducted at the Hochschule Hannover in collaboration with industry partners for about 15 years, will form a solid basis for future joint activities. By pooling their resources, the two institutions will be able to expand their research potential for the benefit of all partners concerned.

“Sustainability cannot be achieved without natural fibers“, says Prof. Kasal, director of the Fraunhofer WKI. “Wood fibers have the highest potential and offer great possibilities for application ranging from the building and construction industry to high-performance composites.” In the future, new applications will be investigated, new products and technologies developed and issues raised that are growth-enhancing for the economy. The new Application Center will play a leading role in this process. MT www.fh-hannover.de

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www.wki.fraunhofer.de

BioAmber produces succinic acid through the fermentation of renewable raw materials.

The process developed by BioAmber consumes considerably less energy than the production of succinic acid using fossil fuels, is significantly more cost-effective and has a better carbon footprint. In the future, the company plans to use waste from the agriculture industry and sugarcane processing as starting materials.

“Our cooperation with BioAmber is a unique opportunity to launch a new generation of plasticizers on the market that meet all legal regulations and can also score in terms of environmental aspects and sustainability,” said Jorge Nogueira, head of Lanxess‘ Functional Chemicals business unit that manufactures phthalate-free plasticizers.

As a result of legal initiatives, demand for phthalate-free plasticizers is growing in markets such as North America, Western Europe and Japan.

An increase in demand is also being observed in global growth markets such as Latin America.

Authorities are increasingly restricting the use of phthalate-containing plasticizers for consumer goods such as toys, food packaging and cables. MT www.lanxess.com

News

Ajinomoto and Toray jointly research bio-PA

iStock

Ajinomoto Co., Inc. and Toray Industries, Inc. (both Tokyo, Japan) have entered into an agreement to begin joint research for manufacturing the nylon raw material 1,5-pentanediamine (1,5PD) from the amino acid lysine produced from plant materials by Ajinomoto using fermentation technology, and commercializing a biobased nylon made from this substance.

Obama calls for increased use of biobased products On February 21, 2012 the White House released a memorandum signed by US President Barack Obama detailing part of the Administration’s plan to increase the use of biobased products including such made from biobased plastics. The announcement makes provisions to increase the number of products designated in the program for Federal procurement by 50% in the next year, as well as increasing federal procurement of certified biobased products. The increased access to the federal procurement market is a major boost to biobased products producers, providing a consistent market for their products. In addition to the Presidential Memorandum, the newspaper USA Today carried a story in their February 21 issue featuring an interview with Secretary of Agriculture Tom Vilsack. Secretary Vilsack said, „We want to get to the point where we‘re using everything we grow and everything we raise,” to reduce dependence on foreign oil and increase rural jobs. The article included a picture of the USDA Certified Biobased label that consumers will see more and more of on their store shelves in the future. The online version also includes a video of the USA Today interview with Secretary Vilsack. MT The full text of the Presidential Memo, The article in USA Today and Secretary Vilsack’s announcement can be downloaded from www.bioplasticsmagazine.de/201202

www.biopreferred.gov

Biobased nylon is a type of nylon manufactured by polymerizing chemicals produced from plant materials. The biobased nylon that Ajinomoto and Toray will research and develop is produced from plant materials by decarbonating the amino acid lysine through an enzyme reaction to make 1,5-PD, which Toray then polymerizes with dicarboxylic acid. The amino acid lysine is a core product of the Ajinomoto Group produced using fermentation technology. This biobased nylon fiber made from 1,5-PD is not only sustainable because it is plant-based, but also shows promise for development into highly comfortable clothing. For example, nylon 56 fiber manufactured using 1,5-PD is pleasing to the touch, yet has the same strength and heat resistance as conventional nylon 66 fiber made from the petrochemical derivative hexamethylenediamine. It also absorbs and desorbs moisture nearly as well as cotton. MT www.ajinomoto.com www.toray.com

Foils for Thermoforming • special foils • OFO-Naturale

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OFO-Natylene Go pro nature and notice the difference!

Reduce GHG emissions!

Use OFO-Natylene which has taken 2,5 kg CO2 to create 1 kg Bio-PE. Available in natural or requested color.

Take advantage of the possibility to use OFO-Natylene several times. We will take back regrinded punch scrap out of the thermoforming process – but carefully sorted according to the type.

Use OFO-Natylene for the packaging of your BIO-products.

Suitable for deep freezing and cooking vegetables in the micro wave.

Please contact OFoTec-Folien GmbH for OFO-Natylene: Phone: +49 (0)74 73 9 14 34 Fax: +49 (0)74 73 2 59 89 Mobile: +49 (0)170 2 9767 03 e-Mail: vertrieb@ofotec.de D-72147 Nehren (Germany) bioplastics MAGAZINE [02/12] Vol. 7

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News

NatureWorks and BioAmber form JV NatureWorks and BioAmber (both Minnesota, USA) have announced the creation of AmberWorks, a joint venture to bring new performance bio-based polymer compositions to market.

Gaïalene plant fully operational.

The Roquette Group, one of the world leaders in the processing of raw vegetable materials, is now becoming a major plant-based plastics player. It has successfully launched its first industrial production unit (25,000 tonnes) for GAIALENE® plant-based plastics end of 2011 at its main site in Lestrem (Pas-de-Calais, France).

After several years of investment in research & development, the Roquette Group has developed a range of plant-based plastics that are now available in industrial quantities under the Gaïalene brand.

These unique Gaïalene plant-based plastics are produced with a patented technology from locally grown cereals. They have a particularly low carbon footprint and are veritable carbon traps thanks to their vegetable origin and what is more they are totally recyclable at the end of their service lives in the existing sectors.

The resins are used in the conventional processes to be found in the plastics technology such as the production of films, injection moulded parts and small bottles.

In order to serve the European market, where there is a big demand for products with a low carbon footprint, the Roquette Group chose to set up its first industrial production unit for GAÏALENE on its main site at Lestrem in northern France. The reason for this location is also to have the benefit of the upstream integration of plant-based resources within the biggest biorefinery in Europe. www.gaialene.com

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The joint venture builds on the natural synergy between the two.

Beyond its Ingeo™ PLA technology platform, NatureWorks brings to the joint venture a global commercial presence, established customer relationships, developed applications across a breadth of industries and deep experience in commercializing new-tothe-world polymers. BioAmber owns PLA/PBS compounding intellectual property and applies award-winning biotechnology and chemical processing to produce renewable chemicals. These renewable chemicals deliver high-performance, low-carbonfootprint building blocks that are cost competitive with their petrochemical equivalents. The joint venture combines the best of both companies into an entity tasked with developing a new family of bio-based compounded polymer solutions.

With the formation of the joint venture, NatureWorks plans to commercialize a new family of compounded Ingeo resin grades.

This new family of developmental Ingeo compounded resins is designed for food service ware applications, expanding the Ingeo property range in terms of flexibility, toughness, heat resistance, and drop-in processability on existing manufacturing equipment.

Based on market interest, further formulated solutions optimized for a number of different applications beyond food service will be assessed over the coming 12 to 24 months.

Compounded PLA/PBS resin grades, developed and manufactured

by AmberWorks, will be marketed exclusively through the NatureWorks global commercial organization as new and distinct solutions within the company’s Ingeo portfolio of products.

“The new product range being developed by the joint venture enables NatureWorks to broaden its existing product portfolio, allowing for bio-based product solutions in applications that were previously difficult to address,” said Marc Verbruggen, president and CEO, NatureWorks. “The properties of PLA and PBS are complementary and making compounds using both materials will result in a broad and attractive property profile...”

“The AmberWorks JV builds on BioAmber’s core business: the production of cost competitive, renewable chemicals that include succinic acid and 1,4-butanediol,” said Jean-Francois Huc, president and chief executive officer, BioAmber. “Our novel PBS compounding technology has enabled us to forward integrate into polymers and our partnership with NatureWorks, the global market leader in biopolymers, will strengthen and accelerate market access for our growing portfolio of renewable solutions.” MT www.natureworksllc.com www.bio-amber.com

News

Metabolix Provides Business Update Metabolix (Cambridge, Massachusetts, USA) plans to launch its business in PHA biopolymers under a new commercial model. Richard Eno, CEO of Metabolix: “(Since January) we are in discussions with about 15 potential offtake partners, and considering about 10 different manufacturing options. (In response to) questions including the timing of a partnership, possible structures, and the resulting financial implications (…) we need some time while we work through the option set so that we can provide solid information on our commercial model as we go forward.

Metabolix has retained a core team in biopolymers to provide continuity with the technology, manufacturing process and markets during this period of transition. In addition, the Company is working closely with customers to understand their product needs. With more than 5 million pounds of product inventory available, Metabolix expects it will have adequate product inventory to supply core customers with PHA biopolymer until new inventory becomes available and to continue product development in high value-added applications.

Eno: “We remain enthusiastic and committed to successfully commercializing the Mirel family of PHA biopolymers,” and in a conference call he continues: “from the customer and market perspective, the previous approach was very broad-based. This was due to the large scale of the ADM plant and widespread market interest in PHAs. What we now plan to do is focus on the high valued opportunities, which we have identified through our time in the market. The initial design of the ADM plant was about 50,000 tons per year. We are developing a market-entry opportunity in the 10,000 ton per year range. The technology base that was deployed at Clinton was a 2006-era technology-base, which performed well at a world-class industrial scale. However, since 2006 the technology has continued to advance rapidly, and there are numerous elements that were not yet installed at Clinton.

Going forward, we would see elements of this 2012 technology-base being deployed. What does that mean?

We expect lower capital, improved yields, and experience we bring from across the entire value chain, from fermentation right down through final product fabrication. With the combination of high valued segments, a smaller scale plant and new process technology, we expect to approach cash break-even much sooner than under the previous model. (…) As a leader in the development of bio-based polymer technology, Metabolix has assembled a broad intellectual property portfolio covering key elements of making and using advanced biomaterials, including biopolymer blends.

For areas outside of our technical and commercial focus, we are amenable to licensing arrangements that provide Metabolix the opportunity to receive licensing income, and pave the way for the introduction of new materials to the marketplace. With that interest, we recently issued a sub-license under a University of Massachusetts patent we control for biopolymer blends to NatureWorks, a global leader in the PLA biopolymers industry. This intellectual property helps NatureWorks expand the market for bioplastics, through blending its PLA product with other bioplastics.- MT

CAN YOU GUARANTEE THE ORIGIN OF RENEWABLE PRODUCTS ?

Vinçotte, leader in bioplastics certification

www.okbiobased.be

YOUR REPUTATION IS MINE. bioplastics MAGAZINE [02/12] Vol. 7

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Review

Handbook of Bioplastics and Biocomposites Engineering Applications

T

he intention of the new (2011) Handbook of Bioplastics and Biocomposites Engineering Applications, written by 40 scientists from industry and academia, is to explore the extensive applications made with bioplastics & biocomposites for the packaging, automotive, biomedical, and construction industries. Edited

by Srikanth Pilla (Research Staff in the BIONATES theme at the Wisconsin Institute for Discovery, University of Wisconsin-Madison) reports on current research and applications in the bioplastics and biocomposites arena. This interdisciplinary science integrates pure and applied sciences such as chemistry, engineering and materials science. The Handbook focuses on five main categories of applications packaging; civil engineering; biomedical; automotive; general engineering.

Srikanth Pilla (ed.), John Wiley & Sons, Inc., Hoboken, and Scrivener Publishing LLC, Salem, 2011, 594 p., hardcover, EUR 169.00, ISBN 978-0-470-62607-8

By Michael Thielen

The majority of the chapters review the properties, processing, characterization, synthesis and applications of the bio-based and biodegradable polymers and composites. This includes polylactic acid (PLA), polyhydroxybutyrate (PHB), guar gum based plastics, cellulose polyesters, starch based bioplastics, vegetable oil derived bioplastics, biopolyethylene, chitosan, etc. as well as thermosetting bioplastics and biocomposites with a focus on the automobile industry In addition the book shows ways how to improve the properties of bioplastics, polymer blends, and biocomposites by combining them with both synthetic and natural fillers and reinforcements such as nanoclays, nanotubes (CNTs), and natural fibers (both wood and plant fibers).

The Handbook is a good choice for engineers, scientists and researchers who are working in the fields of bioplastics, biocomposites, biomaterials for biomedical engineering, biochemistry, and materials science. The book will also be of great importance to engineers in many industries including automotive, biomedical, construction, and food packaging.

The book is available via the bioplastics MAGAZINE bookstore www.bioplasticsmagazine.com

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bioplastics MAGAZINE [02/12] Vol. 7

The book is the first application oriented book in the field of bioplastics and biocomposites. It is well written with plenty of illustrations and useful literature references. Studies that expand the boundaries of bioplastics that will allow for the new materials to be applied to most generic engineering applications. It is structured in six parts and a total of 19 chapters. A comprehensive index allows the quick location of information the reader is looking for.

Event (f.l.t.r.)

Michael Carus (nova-Institut Cord Grashorn (Linotech) Martin Vollet (Livemold) Nina Kehler (Resopal) Tanja Schaefer (Resopal) Frank Mack (Coperion) Robert Schwemmer (NAPORO)

2012 Biomaterials Innovation

W

ith 110 participants from 15 countries, the ‘5th International Congress 2012 on Bio-based Plastics and Composites & Industrial Biotechnology’ (14-15 March, Cologne, Germany) focused on Scandinavia, Italy and Germany. Organiser nova-Institute and sponsors Proganic and Coperion expressed their satisfaction with both the latest developments and the lively discussions at the congress. Innovation prizes were awarded to the companies Naporo, Martin Fuchs Spielwaren and Resopal.

www.coperion.com www.naporo.com www.martin-fuchs-spielwaren.de www.resopal.de www.biowerkstoff-kongress.de

Biomaterials, i.e. bio-based plastics and composites, are becoming increasingly visible on the market and playing an important role in establishing a bio-based economy that will one day completely replace petrochemistry. Companies such as Novozymes (Denmark), Borregard (Norway), Novamont (Italy), Bayer Material Science (Germany), Evonik (Germany) and Henkel (Germany) presented their concepts for biorefineries, new bio-polymers and natural-fibre-reinforced composites.

The congress sponsor Proganic, based in Bavaria, exhibited a wide range of new products – especially kitchen articles – made from its Proganic® material, which is composed of PLA, PHA, minerals and natural waxes, making it 100% bio-based. This material is now used to make fibres and yarns, opening up a whole world of potential new uses.

The 2012 ‘Biomaterial of the Year’ innovation prize, now in its fifth year and this time sponsored by Coperion GmbH (Stuttgart/Germany), attracted a great deal of interest. The congress’s advisory committee drew up a shortlist of five innovative products out of some 20 proposals- The relevant firms presented their innovations in a short talk and with some exhibits.

The audience then voted for their favourites.

Bulrush plants (iStockphoto)

1st prize: NAPORO GmbH – Fibre mouldings made from bulrush NAPORO GmbH from Austria manufactures low-density fibre mouldings for various uses from the little-used bulrush. The binding process works through the NAPORO ‘NATglue’ technology, whereby waxes and oils derived from the marsh plant are activated as binding agent. Bulrush is a wild plant that grows to heights of up to 4 metres, forms large, highly resistant clumps in wetlands and can be managed sustainably.

2nd prize: Martin Fuchs Spielwaren GmbH & Co. KG – ‘spielstabil bioline’ toy range made from modified PLA (see p. 24) 3rd prize: Resopal GmbH – RE-Y-Stone made from recycled paper with bagasse resin. MT

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Event Application News

T

he third biennial Innovation Takes Root Ingeo™ user’s forum (Feb. 20-22) in Orlando, Florida welcomed 314 attendees representing 171 companies from the USA and almost 50% from 20 different Asian, South American, and European countries. 27 exhibiting companies rounded the event off. Some of the many highlights are reported about below.

© liz linder photography, inc.

Review: Innovation Takes Root www.innovationtakesroot.com

Keynote addresses from Tom Clynes, acclaimed journalist, photographer, and author of Wild Planet, Gary Hirshberg (see photograph), co-founder and chairman of Stonyfield Farm, Steven Peterson, director of Sourcing Sustainability at General Mills, and Paul Conway, vice chair of Cargill discussed the macro issues facing society today and helped put into context the need for alternative solutions as opposed to business as usual.

Hirshberg of Stonyfield Farm said that over dependence on fossil fuels, environmental health risks, weakened ecosystems, species loss, and pollinator decline are extremely troubling trend lines. He showed how Stonyfield Farm by focusing on key issues can make a difference. Stonyfield Farm, which in 2011 had sales of $356 million U.S., has over the past six years achieved a 46 % reduction in greenhouse gas emissions, an 11 % reduction in facility energy consumption, a 57 % reduction in waste, and lessoned its use of petroleum-based plastic as demonstrated through a reduction of 18 tractor trailer loads of plastic per year.

Hirshberg passionately laid out the rationale for improvements to health, the environment, and the other trend lines he discussed earlier in his talk through heavier reliance on organic methodologies. Stonyfield Farm was the first company to move to bioplastic yogurt containers when it adopted an Ingeo blend in 2010.

Session highlights from conference technical tracks

Semi durables

Gary Hirshberg, Stonyfield Farm (© liz linder photography, inc.)

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Arkema’s Plexiglas® rNew technology has produced synergies in compounding PMMA with Ingeo that increase impact and chemical resistance that exceed conventional modified acrylics, allowing its products to compete with polymers such as PETG and PC while delivering excellent clarity and flow. IBM worked with a major compounder to establish a clear path to qualify Ingeo blends as potential replacements for polycarbonate. Polycarbonate represents 95 % of the materials consumed by IBM. This development opens the door for Ingeo expansion in IT applications.

Event

Packaging and food service

Fibers

“Sustainability in Sports Entertainment” showcased the journey the Portland Trail Blazers organization undertook to secure a Gold Leadership in Energy and Environmental Design (LEED) Certification for its arena (the Rose Garden), marking the first time that significant cost savings have been attributed to compostable products. Many contributing elements were noted in the area of compostable food packaging. Waste diversion rates now exceed 80 %, an increase of more than 40 % since 2007. The sports organization’s sustainability journey to attain LEED Gold Certification incurred costs of $560,000, while total savings to date from waste diversion equaled $836,000. Specific to food and packaging wastes, the introduction of new solutions, including the use of Stalk Market branded food service ware, many derived from Ingeo, increased both the diversion of waste from landfills and the composting of food and packaging waste.

NatureWorks reviewed data that showed new production capabilities are expanding the Ingeo resin product portfolio. In nonwoven fabrics, these new Ingeo resin grades provide lower shrinkage, increased dimensional stability, and opportunities for broader asset utilization.

Films and flexible packaging ConAgra Foods showcased various film applications. From tamper bands to shrink sleeves, the adoption of rPLA has allowed packagers to down gauge film because of Ingeo’s higher stiffness, achieve higher yield because of the lower density, and reduce energy costs due to cooler shrink tunnel temperatures and ease of storage. In addition to all these advantages, consumer acceptance has risen because of the higher visual appeal and ease of removal for the Ingeo bands. FKuR announced several new grades of Ingeo-based films. These films are clear, flexible, and, depending upon the grade, have a range of barrier properties that can be used for packaging fresh produce and other prepared foods.

Mestre-Venice, Italy, 23-24 April

Enter the promotional code: MAGAZINE to receive 10% off the current listed rate!

The Biopolymer World Congress 2012 is one of the not-tobe-missed biopolymer events of the year that is delivering engaging, thought-provoking speakers and world-renowned leaders. The Congress provides top quality education and artfully designed opportunities to network and interact with other industry professionals and biopolymer industry leaders.

There are many reasons to attend the Biopolymer World Congress this 23-24 April in Mestre-Venice, Italy.

Here are Just the Top 5 reasons You Should Attend the Congress:

Recent Developments & Latest Challenges More Than Just Sit and Listen. We Are Truly Interactive Meet Industry Leaders from Across the Entire Value Chain Unsurpassed Networking Opportunities Cost Effective & High ROI

as a Congress attendee, you have access to 21 educational talks, 10 interactive presentations, CONFERENCE.

and

11

networking

opportunities

over

the

duration

of

the

That’s 17+ hours worth of education and networking!

bioplastics MAGAZINE [02/12] Vol. 7

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News

bioplastics MAGAZINE presents: The 2nd PLA World Congress in Munich/Germany is the must-attend conference for everyone interested in PLA, its benefits, and challenges. The conference offers high class presentations from top individuals in the industry and also offers excellent networkung opportunities along with a table top exhibition.

Please find below the preliminary programme. Find more details and register at the conference website

2nd PLA World

C o n g r e s s

15 + 16 MAY 2012 * Munich * Germany

www.pla-world-congress.com

2nd PLA World Congress, Preliminary Program Tuesday, May 15, 2012 08:00 - 08:30 08.30 - 08.45 08:45 - 09:15 09:15 - 09:40 09:40 - 10:05 10:05 - 10:30 10:30 - 10:55 10:55 - 11:20 11:20 - 11:45

Registration, Welcome-Coffee Michael Thielen, Polymedia Publisher Harald Kaeb, narocon Udo Mühlbauer, Uhde Inventa-Fischer Roland Essel, nova-Institut Patrick Farquet, Sulzer Chemtech Q&A Coffeebreak Erwin Vink, NatureWorks

11:45 - 12:10

Francois de Bie, Purac

12:10 - 12:35 12:35 - 12:50 12:50 - 14:00 14:00 - 14:35 14:35 - 14:50

Kevin Yang, Shenzhen Esun Industrial Co Q&A Lunch Patrick Zimmermann, FkUR Karin Molenveld, Wageningen (WUR)

14:50 - 15:15 15.15 - 15:40 15:40 - 15:55 15:55 - 16:30 16:35 - 17:00 17:00 - 17:25 17:25 - 17:50

Daniel Ganz, Sukano Marcel Dartee, Polyone Q&A Coffeebreak Jan Noordegraaf, Synbra Makoto Kobayashi, Toray International Ramani Narayan, Michigan State University

(subject to changes, visit www.pla-world-congress for updates)

Welcome Keynote Speech: Bioplastics - Future or Hype ?

Uhde Inventa-Fischer’s pilot plant facilities for LA and PLA Meta LCA for PLA Sulzer plants for PLA production: efficient, compact and reliable sponsored by EREMA Ingeo Biopolymers: An update of the latest developments in Products, Sustainable Feedstock and Product Certification and End of Life High Heat PLA for use in high performance fibers and other durable applications PLA Alloy and Application

Modifying PLA to the next level Strain induced crystallisation as a method to optimize PLA properties in practical applications PLA Masterbatch Technology – State of the art and latest trends Additives / Masterbatches for PLA

Latest developments in E-PLA foam Toray‘s modified PLA materials Positioning and branding PLA products from carbon footprint and end-of-life

Wednesday, May 16, 2012 09:00 - 09:25 09:25 - 09:50 09:50 - 10:15 10:15 - 10:40 10:40 - 10:55 10.55 - 11:20 11:20 - 11:45 11:45 - 12:10 12:10 - 12:35 12:35 - 12:50 12:50 - 14:00 14:00 - 14:35 14:35 - 14:50 14:50 - 15:15 15.15 - 15:40 15:40 - 15:55 16:00 - 16:30

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Mr. Shim, SK Chemicals Karl Zimmermann, Brückner Frank Ernst, Taghleef Larissa Zirkel, Huhtamaki Q&A Coffeebreak Mathias Hahn, Fraunhofer IAP Shankara Prasad, SPC Biotech Johann Zimmermann Q&A Lunch Steve Dejonghe, Galactic Gerold Breuer, Erema Sebastian Schippers, Institut für Kunststoffverarbeitung (IKV) Harald Klöden, RE|PLA Cycle Q&A Panel discussion: End of life options

bioplastics MAGAZINE [02/12] Vol. 7

SK Chemicals’ New PLA Latest Technology in Film Stretching NATIVIA – The BoPLA film for packaging and labelling applications Innovative Concepts of Functional PLA Films

Modification of PLA with view to enhanced barrier and thermal properties Bio conversion of agriwaste to polylactic acid Experiences in Processing PLA

Building the recycling scheme for PLA Closing the loop on bioplastics by mechanical recycling Recycling of polylactic acid and utilization of recycled polylactic acid for packaging applications PLA closed cycle waste management

Bookstore Order now! www.bioplasticsmagazine.de/books phone +49 2161 6884463 e-mail books@bioplasticsmagazine.com * plus VAT (where applicable), plus cost for shipping/handling details see www.bioplasticsmagazine.de/books

NEW

Dr.-Ing. Michael Thielen

Bioplastics - Basics, Applications, Markets

General conditions, market situation, production, structure and properties New ‘basics‘ book on bioplastics: The book is intended to offer a rapid and uncomplicated introduction into the subject of bioplastics, and is aimed at all interested readers, in particular those who have not yet had the opportunity to dig deeply into the subject, such as students, those just joining this industry, and lay readers. r 5o * 0 8.6 € 1 $ 25.0 US

Author: Jan Th. J. Ravenstijn, MSc

The state of the art on Bioplastics

NEW

(Special prices for research and non-profit organisations upon request)

00*

69.

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red

Hans-Josef Endres, Andrea Siebert-Raths

Engineering Biopolymers

Markets, Manufacturing, Properties and Applications Hans-Josef Endres, Andrea Siebert-Raths

Technische Biopolymere

Rahmenbedingungen, Marktsituation, Herstellung, Aufbau und Eigenschaften

44*

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Rainer Höfer (Editor)

Sustainable Solutions for Modern Economies Apocalypse now? Was the financial crisis which erupted in 2008 the ‘writing on the wall’, the Menetekel for the Industrial Age? Is mankind approaching the impasse of Easter Island, Anasazi and Maya societies shortly before collapse – ‘‘which followed swiftly upon the society’s reaching its peak of population, monument construction and environmental impact’’? Or will mankind be capable of a new global common sense?

0*

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Handbook of Bioplastics and Biocomposites Engineering Applications Engineering Applications

‚The state-of-the-art on Bioplastics 2010‘ describes the revolutionary growth of bio-based monomers, polymers, and plastics and changes in performance and variety for the entire global plastics m arket in the first decades of this century...

0* 0.0 ,50 rice € 1 uced p

Edited by Srikanth Pilla

The intention of this new book (2011), written by 40 scientists from industry and academia, is to explore the extensive applications made with bioplastics & biocomposites. The Handbook focuses on five main categories of applications packaging; civil engineering; biomedical; automotive; general engineering. It is structured in six parts and a total of 19 chapters. A comprehensive index allows the quick location of information the reader is looking for.

This book is unique in its focus on market-relevant bio/renewable materials. It is based on comprehensive research projects, during which these materials were systematically analyzed and characterized. For the first time the interested reader will find comparable data not only for biogenic polymers and biological macromolecules such as proteins, but also for engineering materials. The reader will also find valuable information regarding micro-structure, manufacturing, and processing-, application-, and recycling properties of biopolymers

Cover Application Story News

Fair play Commitment to Environment Huhtamaki’s PLA beer cup assortment emerges as a clear winner in stadiums and arenas

S

ustainable packaging is quite a new addition to the environmental considerations for packaging. With eco-friendly PLA cold drink cups for the catering market, Huhtamaki has since several years been promoting this aspect. Recently, more and more organizers of big events and football games in stadiums decided to join the ranks.

In 2009, the first Premier League arenas in Germany together with several Second League stadiums pioneered the concept of using biodegradable NatureWorks® PLA beer cups for their big events. These were the early birds in recognising not only the positively practical benefits of these products, but also their sustainable aspects: PLA is made from annually renewable resources, is compostable and thus can be disposed of completely naturally. Other stadiums as well as various breweries were quick to follow, and soon both operators and visitors appreciated the evident advantages of this environmental-friendly solution for cups. Single use cups offer guaranteed hygiene, as each guest gets a new cup. There is no need for dishwashing as for reusable cups.

This saves labour time, water, heating energy and detergents. The lightweight PLA cups are safe, as they do not break nor splinter.

The cups are light to carry and easy to handle and in addition allow a faster and more focused customer service. Last but not least, the possibility for customised printing offers additional promotional opportunities.

In terms of sustainability, the concept offers far more. Belonging to Huhtamaki’s future friendly BioWare™ packaging portfolio, PLA beer cups together with molded fibre strongholders stand out as

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Cover Story

Our cover photo protagonists and their friends enjoy beer from PLA cups

the stadium’s visible demonstration of environmental awareness as promoter of new and fair-play solutions: The PLA cups offer a simple way of contributing to more sustainable environmental performance. Their PR appeal can rise an increased media interest. For sponsoring or advertising companies the cups can be used to improve the corporate and brand image and can help to differ from competition. And finally cups made from PLA offer a possibility for single waste stream.

Moreover, the PLA beer cups are compostable and certified in accordance with EN 13432, European norm for compostability of packaging, meaning that they degrade completely in industrial composting facilities. The options for disposal are plentiful: incineration with energy recovery, composting and recycling. Apart from that, Huhtamaki and stadium operators are jointly working on a promising ‘from cradle to cradle’ project, planning to build a closed recycled PLA material loop for stadiums and arenas.

Huhtamaki was the first to launch a complete range of compostable tableware. The BioWare family was launched in 2004 and is continuously developed with new products. BioWare products are available in Europe and Oceania.

Huhtamaki has maintained the Pass status in the Kempen SNS Socially Responsible Investing (SRI) Universe since 2002. Only those European companies that meet or exceed the strict business ethical, social and environmental performance standards set by Kempen Capital Management and SNS Asset Management qualify for inclusion. www.huhtamaki.de/foodservice

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Rigid Packaging

PLA for thermoforming More functionality by sustainable thermoforming films By Larissa Zirkel Huhtamaki Films Forchheim, Germany

U

nder the brand-name BioWare Huhtamaki offers a sustainable material concept, where all products are biodegradable, compostable and preferably bio-based, i.e. derived from renewable resources. Since 2004 Huhtamaki Films has been developing innovative PLA films for thermoforming purposes showing outstanding performance during processing and application. In general, the films have coextruded structures consisting of up to nine layers and are available in thicknesses between 180 and 800 Âľm.

Rigid packaging Standard PLA thick films for thermoforming are highly transparent and glossy. They exhibit a high tear strength, which is comparable to that of PS. Due to its intrinsic high value of surface tension of 36 to 38 mN/m, PLA is easily printable. Moreover, trays from PLA show an excellent sealability at temperatures much lower than required to process common polymer materials. Besides, special combinations of different biodegradable polymers offer the opportunity to create packings with easy opening properties by introducing a peel layer to either the lid film or the tray.

The very high oxygen and water vapour transmission rates often make an additional perforation step redundant as spare humidity from the product can easily evaporate through the PLA trays or lid films, thus, protecting e.g. food from moulding. As PLA has a very good flavour and aroma barrier, it is very qualified for packing food with a distinctive smell as e.g. cheese or goods, that require a protection of their specific aroma, like e.g. herbs. Furthermore, it could be shown, that the climatic conditions inside a PLA packaging due to the gas exchange from inside the package to the environment, related to its pronounced permeation ability, is beneficial for the maturing of cheese without influencing its unique taste.

Another advantage of PLA trays for packing food is its high resistance to grease and oil.

Flexibilised films Fig. 1: Die-cutting test with Huhtamaki standard (right side, Q. 4007) and flexibilised (left side, Q. 4010) PLA grades

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Although the application of pure PLA is preferred in many cases due to its 100% origin from renewable resources, these standard grades exhibit some disadvantages in terms of their mechanical properties. Thus, pure PLA has a high rigidity, which causes e.g. splintering when the films are die-cut (cf. fig. 1, right side, grade 4007). Additionally, trays and blisters especially for packing food but also other goods in general have to withstand drop tests. When dropping a package from a shelf at the point of sale, it should neither break nor splinter for giving a good protection to the products inside. This kind of damage is usually observed when using a standard pure PLA. Therefore, the material has to be modified to obtain a certain

Rigid Packaging

flexibility as it is known e.g. from the PET widely spread in this market. Adding special modifiers to PLA, which are also completely biodegradable, its mechanical properties can be improved to values close to the ones of PET (cf. fig. 2). Compared to standard PLA, the flexibilised version shows a significantly reduced elastic modulus in the range of PET and a relatively high impact strength, which could be increased to the 100-fold of the poor original value. These improved mechanical properties allow the PLA film to be diecut without splintering (cf. fig. 1, left side, grade 4010) and enable the trays and blisters produced thereof to withstand the required drop tests. As the flexibiliser is biodegradable, too, these modified films are certified according to the DIN EN 13432 for biodegradability.

Apart from the mechanical properties, the modifier does not affect the unique characteristics of PLA like transparency, gloss, printability, sealability, and aroma barrier. As there is no migration of the flexibiliser used, Huhtamaki PLA films comply with the FDA and, therefore, are appropriate for packing all kind of food.

By introducing different amounts of modifier to the PLA, the flexibilisation can be adjusted to the degree required by the specific application, enabling custommade solutions, which are offered by Huhtamaki in form of a wide variety of films.

PLA standard | PLA flexibilised | PET

3500

350

3000

300

2500

250

2000

200

1500

150

1000

100

500

50

0

md

td

E-Modulus in MPa

md

td

0

Impact Strength in kJ/m ≤

Fig. 2: Comparison of mechanical properties of Huhtamaki standard and flexibilised PLA films with PET

Golden PLA A very new product in the range of Huhtamaki BioWare films for thermoforming is a golden PLA developed for e.g. luxury packaging or the confectionary industry.

First results of production trials were presented already at the Interpack 2011 and the ProSweets 2012, where they attracted a broad interest (cf. fig. 3). The golden trays from coloured and metalized PLA are also fully biodegradable and comply with the DIN EN 13432.

Just like the transparent versions, Huhtamaki offers them with different degrees of flexibilisation to meet the specific application requirements.

Fig. 3: Golden trays for confectionary from Huhtamaki flexibilised PLA films; thermoformed by Falomo Termoplastici S.r.l., Italy

Barrier For some applications, mainly in the food packaging market, the high oxygen and water vapour transmission rates of PLA are of disadvantage.

Especially the infiltration of oxygen into the package significantly reduces the shelf life of fresh products.

The coextruded structure of Huhtamaki PLA films allows the introduction of additional functionalities as e.g. barrier properties. Figure 4 shows the oxygen

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Rigid Packaging

Oxygen and Water Vapour Transmission rate

OTR (cm≥/m≤d) | WVTR (g/m≤d)

10 8 6 4 2 0 Q. 1050 350 µm

Q. 1051 350 µm

Q. 1051 500 µm

Q. 1052 350 µm

Fig. 4: Comparison of oxygen and water vapour transmission rates for different Huhtamaki PLA based barrier films

Up to now, there is no appropriate bio barrier material available in the market, which is either biodegradable or derived from renewable resources. To be able to offer a sustainable solution, the Huhtamaki BioWare range was extended by developing films that are mainly biobased. Actually, a conventional barrier material was used, which is not biodegradable. However, due to the PLA basis of the films, they have a very high content of materials with an origin of renewable resources and could be certified “OK biobased” by Vinçotte with up to three stars for a content of bio-based material between 60% and 80%. Of course, the selection of an appropriate bio barrier material is an ongoing research process for Huhtamaki Films.

O2 | CO2 | N2

100

N2 CO2

Composition of Gas in %

80

60

40

O2

20

0

1

7

15

32

Time in d

Fig. 5: Temporal stability of a modified gas atmosphere inside a packaging of a Huhtamaki PLA barrier tray and lid film

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and water vapour transmission rates of the different Huhtamaki PLA barrier film qualities 1050, 1051, and 1052. With increasing film grade number, the thickness of the barrier layer is increased, which explains the strong decrease of the transmission rate values.

Besides the thickness of the barrier layer, an increase of the overall film thickness also reduces the permeation values to a certain extent. However, this decrease is not as pronounced as the one related to the thickness of the barrier layer. As the thickness of the film applied is mostly determined by the application specification, the required barrier level of the PLA film is normally adjusted by choosing an appropriate barrier layer thickness, which is represented by the three different grades shown in figure 4. The ability of a Huhtamaki PLA barrier tray combined with a PLA barrier lid film to keep a modified gas atmosphere inside the packaging over a long period of time is presented in figure 5. The results show an excellent stability of the gas composition during the 32 days tested.

All Huhtamaki PLA films for thermoforming can be easily processed on conventional production lines using standard machines, tools and moulds. This was confirmed by performing numerous trials with different machine manufacturers, converters and end users.

Compared to common materials for thermoforming, they are processed at significantly lower temperatures, saving energy for the production and, therefore, giving an additional benefit to the environment. www.huhtamaki-films.com

A sustainable alternative to traditional plastics

Cereplast® offers a wide range of bioplastic resin grades that are suitable for a variety of applications Cereplast Compostables® resins for certied compostable, single-use applications Cereplast Sustainables® resins for biobased, durable applications

Cereplast® resins work with all major converting processes Injection Molding Thermoforming Blown Film Blow Molding Extrusions

www.cereplast.com

Material Application News News

Food colouring meets bioplastics The GRAFE-Group (Blankenhain,Germany) is an innovative partner to the plastics processing industry. A joint venture between SENSIENT Imaging Technologies GmbH and specialist masterbatch manufacturer Grafe has managed to combine food colouring and bio-based plastics.

Environmental awareness and health protection have played an exemplary role within the Grafe-Group for several years. The company markets masterbatches for colouring bioplastics under the brand name “Biocolen”.

Combining plastics derived from renewable raw materials with food colourings opens new ways of achieving closed loop recycling.

The silica encapsulated colourants (SEC) by Sensient Imaging Technologies provide a technical solution for encapsulating natural food colourings which greatly restricts migration in formulations. Silica was chosen deliberately as this material is present in foods and is approved for food use.

The silicate matrix - the protective layer encapsulating the colourings - limits the oxidising effect of oxygen on the dye molecules and improve the colourings’ resistance to solvents, water, pH and environmental influences and minimise migration of the dyes out of the matrix. A wide range of natural and synthetic food colorants is used.

The Grafe Group has tested the colourings in different polymers, which has resulted in several colour combinations such as brown, green, orange, yellow, red and violet.

“It is not the strongest who survive, but the ones most adaptable to change.” (Charles Darwin) www.grafe.com

Bioplastic for plastic wrapping film Api Spa (Mussolente, Italy) has over half a century of success in the production of TPE (thermo plastic elastomers) and TPU (thermoplastic polyurethane). For the last 5 years they have used this experience to embark on an important project studying and developing bioplastics. In particular, API have concentrated on research into biodegradability, a property which is shared by all materials in the Apinat range.

After perfecting the formulation of Apinat (TPE) for use in injection moulding, extrusion of tubes and profiles, both soft and rigid grades, today new Apinat formulations are being developed which are ideal for plastic wrapping film. The new products may be converted using either blown or cast extrusion. With the new formulation of Apinat it is possible to obtain a film suitable for producing biodegradable plastic shopping bags which can be composted in compliance with both European Standard EN13432 as well as the requirements of Italian law.

The advantages which are most immediately derived from these innovative Apinat formulations are: It is very tough, which makes the bags very durable, even when carrying objects with sharp edges; The complete absence of unpleasant odours: all ingredients which may cause bad smells have been eliminated from the Apinat formulation; The mechanical properties of Apinat enable the film thickness to be reduced, resulting in numerous advantages including not only a reduction in the cost of raw materials, but also a reduction in the environmental impact because reduced material thickness means faster biodegradation times.

Apinat is the answer to the criticisms raised against biodegradable products: “…for the mechanical (extreme fragility) and organoleptic (the unpleasant smell produced) properties, it is very difficult for some industries to use these materials, especially small shops; imagine, for instance, a clothing and fabrics market, ironmongers or a shop selling household goods.” (Mr. Delio Dadola, president of Italian chemical association Unionchimica). www.apiplastic.com

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Material News

New mulch film material New machine for additives Laurel BioComposite LLC (Laurel, Nebraska, USA) has purchased an ENTEK E-Max 53mm twin screw extruder as the next step in its multi-tiered strategy to provide injection molders with its new patent-pending Bio-Res™.

The production-size extruder (~225 kW, 1200 rpm) joins a 25 mm unit in the advanced materials manufacturer’s Minnesota-based pilot plant and offers the capability to produce ~450 kg (1000 lbs) of Bio-Res per hour. The machine’s higher production rate supports ~3,600 tonnes (8,000,000 lbs) annually, 1/6 the projected full-scale (~22,000 tonnes or 48,000,000 lbs.) plant capacity. BioRes is a high-performance, cost effective replacement for traditional petroleum-based resins in a variety of manufacturing processes for plastics. Bio-Res is made from distillers grains (i.e. residues of the bio-ethanol production).

“Customers want to know that Laurel BioComposite has substantial production capacity available,” says Tim Bearnes, president of the board for Laurel BioComposite.

“The addition of the new extruder will allow us to make test articles for customers before the master batch plant is completed.” The extruder enables Bio-Res to cost-effectively raise the renewable or ‘green’ content of plastic products by as much as 40 %. The new biomaterial is available in a pellet form which blends easily with polyethylene, polypropylene, polylactic acid and PHA matrices.

With the addition of Ecovio® F Mulch, BASF (headquartered in Ludwigshafen,Germany) is expanding its line of biodegradable plastic compounds in the form of a grade for use in the manufacture of agricultural films. In contrast to agricultural film made from conventional polyethylene (PE), this film biodegrades. It is no longer necessary for farmers to retrieve the film from the field for disposal or recycling after the harvest. They can simply plow it under along with what remains from the plants. This saves time and reduces costs. Production of the film is also economical, since it can be manufactured at a lighter gauge than conventional PE film without any loss in performance. Moreover, Ecovio F Mulch represents a drop-in solution for the film producer: This resin can be processed on conventional PE extrusion machines without the need to further compound with other components and without extensive modification. Thus the processor can convert his equipment quickly and without great effort. The material is now available in commercial quantities around the world.

To test the performance of its resin, BASF conducted comparative investigations with recognized agricultural institutes in Spain and France. These involved growing vegetables in different locations without mulch film, with conventional PE film as well as with Ecovio F Mulch film.

The institutes investigated growth and yield in addition to the tear strength of the film. While for this purpose melons and lettuce were planted in France, the institutes in Spain grew tomatoes and peppers. All tests demonstrated that growth and yield do not depend on the type of plastic film.

Compared to growing without film, use of film always increased yields by 10 to 20%. www.basf.com www.ecovio.de

Bio-Res pellets are made of 80 % bio-material and sold in master batches. Injection molders can insert the pellets directly into injection molded parts. The material can also be blended with various resins. Superior flow characteristics make the material unique in the bio additives market for thermoplastics. Bio-Res is especially suited for use in a range of industries including shipping, lawn and garden, agriculture and automotive applications.

In addition to the material’s green advantages, customertested Bio-Res-based injection molded parts have already demonstrated a 10 % increase in stiffness and tensile modulus over the base resin. www.laurelbiocomposite.com

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Application Application News News

Bioplastic Connector (Photo: nova-Institute)

Scuffproof toys Martin Fuchs Spielwaren, is a German toy manufacturer from Zirndorf since almost a centrury….

After starting with plastic toys in the 1960s the company launched its ‘Spielstabil’ (rigid toys) line of products and is consequently relying on ‘Made in Germany’. The high quality products are only sold via specialised stores with competent customer consulting. In 2009 Fuchs started to use ecologically sustainably materials.

The latest product line ‘bioline’ comprises among other items, a series of ‘indestructible’ sandbox toys. The material used is a (>70% biobased) blend from PLA, PHA and other components (made by Linotech, Waldenburg, Germany and Livemold, Breitungen, Germany), which makes the products 100% biodegradable. “Not exactly compostable,” as Martin Vollet, Technical Manager of Martin Fuchs points out.” But composting is not the targeted end of life… . At least, these toys will never be found by archaeologists.”

For the end of life, this toy manufacturer has a very special solution. They ask consumers to send back their old toys, rather than dispose them. Fuchs promise to recycle even the oldest and dirtiest toys. This is possible by applying a special 2-component injection moulding technology. Here the post consumer scrap is injected as a core material in a 2-layer structure. The outer layer is beautifully coloured virgin material. www.spielstabil.de www.linotech.de www.livemold.de

Molex Incorporated, LisleISLE, Illinois, USA, announced the Stac64™-e connector for automotive applications has received third party Environmental Claims Validation (ECV). The UL Environment ECV certification confirms that the Stac64-e connector contains 71 % bio-based content in accordance with ASTM D6866-11. Constructed of resin derived from renewable plant-based castor oil, the Stac64-e harness connector provides an alternative to traditional petroleum-based connectors while offering equivalent performance and quality characteristics.

Designed to withstand harsh environments, the 20-circuit, dual-row harness Stac64-e connector has also successfully completed USCAR-2 Standard Class II validation testing for mechanical, environmental and electrical performance characteristics for unsealed connector automotive applications.

The bioplastic resin Stac64-e connector joins an existing portfolio of Molex Stac64 PCB connectors featuring a stackable, modular housing which can be ganged together into larger header assemblies, significantly reducing timeto-market by eliminating the need for custom tooling.

Stac64 connectors support the needs of navigation, instrumentation, and other automotive applications.

“Driving demand for innovative automotive electronics, we see a global proliferation of factories manufacturing vehicles with an array of sustainable components. Durable bioplastic based resins offer an excellent alternative to traditional resins,” states Mark Rettig, global marketing director, Molex. “For customers interested in reducing the use of petroleum- based resins without sacrificing quality, Molex connectors constructed of bioplastic resins are a natural fit.”

Recognizing the role of responsible automotive component manufacturers in advancing sustainable automotive design, Molex will continue to develop and build on its bioplastic based resin connector portfolio as a supplement to current product offerings www.molex.com

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bioplastics MAGAZINE [02/12] Vol. 7

Application News

High Performance PA for connectors Edgetek AMX is a high performance polyamide compound by PolyOne, using PA10T as the base resin, which offers high heat resistance, high flowability, high weld line strength and ultra low moisture uptake.

Compared with other high temperature polyamide, the low moisture uptake can dramatically avoid the blistering issue during IR reflow process.

The base resin of Edgetek AMX is PA10T, a bioderived material (50% derived from castor bean), which can address the sustainability concerns through the reduction of CO2 emission and energy consumption at the beginning of the product life cycle, which reduces the carbon footprint of the final products.

Edgetek AMX compounds offer the lowest moisture uptake in all high temperature polyamides. This important feature is critical for connectors, and there will be no blistering risk during IR reflow process. Edgetek AMX inherits all the other properties of high temperature polyamide (toughness, high weld line strength, etc.). In addition, it is easy to achieve UL V-0 with halogen-free flame retardant.

Edgetek AMX balanced the performance and cost for connector applications. The typical connector includes Signal/Backplane, Power, Memory card, FFC/FPC, Modular Jack, and BtB and I/O. www.polyone.com

Fairytale ending for premium sweets Miss Muffet & Co (London, UK) decided to use Innovia Films’ compostable cellulose-based material, NatureFlex™ to wrap its range of fairytale and nursery rhyme inspired premium confectionery.

Miss Muffet & Co is company, set up by Sarah Cadman, who has a philosophy of using natural ingredients wherever possible.

Outlining why she chose NatureFlex to wrap her range of quality sweets, Sarah stated, “It was really important for Miss Muffet & Co that our packaging had the lowest possible impact on the world around us and it had to clearly show the contents. We chose Innovia Films’ transparent NatureFlex, primarily due to its environmental credentials. At the same time it keeps our sweets tasting and looking good.”

NatureFlex offers significant advantages for packing and converting such as inherent deadfold and anti-static properties, high gloss and transparency, resistance to grease and oil, good barrier to gases and aromas, print receptive surface and a wide heat-seal range.

Transparent NatureFlex NE is used to flow wrap the sweets, which are then packed in beautifully designed, story book-shaped ‘keepsake’ boxes, with drawings by children’s illustrator, Rosie Brooks. The titles (stories) of sweets in the range include: Three Blind Sugar Mice, Oranges and Lemon Drops, Jack and the Jelly Bean Stalk, Goldilocks and the Jelly Bears and Tom Thumb Drops. www.innoviafilms.com www.missmuffetsweets.com

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Application News

Stand up pouches for easter eggs

Happy Candy

Innovia Films’ renewable, compostable cellulose-based material, NatureFlex™, won Ganong Bros Limited’s (New Brunswick, Canada) approval, to pack its range of Easter confectionery in stand up pouches.

Handy Candy LLC (Birmingham Alabama, USA) has developed a versatile and frankly fun new fresh food package made from plant based Ingeo™ (PLA) biopolymer. The ‘Handy Candy’ package was a finalist at the 2011 Produce Marketing Association Fresh Summit for innovative packaging, and Flavor Pic Tomato Co. was the first licensee to distribute. The unique package manufactured by Fabri-Kal (headquartered in Kalamazoo, Michigan USA) consists of their Greenware® 7 oz. cup and matching dome lid with hole for easy on-the-go snacking, and lends itself to a variety of uses for grape tomatoes – individual servings, pre-packed salads, and grab-and-go snacks. The Happy Candy package is child friendly and features a re-sealable label. The innovative graphics are friendly and eyecatching making the new package a delight any way one looks at it.

Bruce Rafuse, Vice President of Marketing at Ganong explained “We had two primary objectives in selecting the package: first and foremost was to improve sales and distribution and second to differentiate us from the competition.

We considered several alternatives, but based upon feedback from consumers and retailers decided upon NatureFlex due to it being compostable and the distinct competitive advantage this gives us. Our ultimate goal is to move all our products into compostable pouches.”

The stand up pouch pack is converted by Canadian based - Genpak - using compostable NatureFlex NKR laminated to a biopolymer sealant layer. “NatureFlex provides excellent barriers to oxygen and moisture, which ensure the product maintains its quality. The film also printed and performed well on our machines,” said Bill Reilly, Development Manager, Genpak.

The range of Ganong’s Easter confectionery which is packed in the NatureFlex stand up pouches includes: Chocolate Covered Cherry Eggs, Easter Eggs, Chocolate Covered Marshmallow Eggs and Easter Animal Jellies. These products will be available nationally in Canada in the run up to Easter.

The pack design has already the caught the eye of the industry and won a PAC (The Packaging Association) Silver Award for ‘Branded Package Made in Canada’.

NatureFlex was an obvious solution for use in this application as the film begins life as a natural product – wood - and breaks down at the end of its lifecycle in a home compost bin (or industrial compost environment) within a matter of weeks. www.innoviafilms.com www.ganong.com www.genpak.com

The stand up pouches for Ganong’s Easter confectionery range are made using Innovia Films’ compostable NatureFlex material.

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www.natureworksllc.com www.myhandycandy.com www.fabri-kal.com

Show Preview

Chinaplas 2012

T

he 26th International Exhibition on Plastics and Rubber Industries, CHINAPLAS 2012, which is dedicated to showcasing the worldclass cutting-edge plastics and rubber technologies, will be held at Shanghai New International Expo Centre on April 18-21, 2012. This year again, there will be a special themed zone dedicated to bioplastics but which will be 40% bigger than last year.

With the growing global concern with regard to green manufacturing, bioplastics is inevitably the focus in the plastics industry, with enormous potential in the market. As the international platform for advanced technology in the plastics and rubber industries, CHINAPLAS 2012 will introduce the world’s leading bioplastics suppliers and their products, such as PLA, PHA, PBS, PPC, PCL, PVA, TPS, PA and PTT. The renowned exhibitors include Cardia, Danisco, Ecomann, Esun, Hisun, Kingfa, NatureWorks, etc. Highlighting advanced technology and the latest development in bioplastics, the 4th International Conference on Bioplastics and their Applications will be held at the same time as CHINAPLAS 2012. As in 2011, speakers from the leading bioplastics suppliers will share their expertise with the audience. The conference is supported by overseas and Chinese plastics associations.

This article contains details of a number of companies exhibiting at Chinaplas 2012. In addition please see the detailed floor map in the centre of the magazine. This detachable ‘Show Guide’ will help you find most of the exhibitors who are showcasing bioplastics-related products and services. Those not mentioned here will be covered in the show review in the next issue. If you visit Chinaplas make sure to visit the booth of bioplastics MAGAZINE in Hall N3 (booth N3L37).

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bioplastics MAGAZINE [02/12] Vol. 7

Toray Toray Industries, Inc./Toray Plastics (China) Co. Ltd., are becoming ‘a leading global company of advanced materials’ by pursuing technological innovation based on chemistry under the corporate slogan ‘Innovation by Chemistry’. Toray is focusing on ‘Green Innovation Business’ as the future growth opportunity. The company aims to contribute to a ‘Sustainable Low-Carbon Society’ all over the world. At Chinaplas Toray is exhibiting ‘Green Innovation Products’ and advanced materials for applications such as photovoltaic, lithium ion batteries, LED, electric vehicles / hybrid electric vehicles etc. for smart community and automobile industry use. They display bio-based polymers, and will propose a solution to the global environmental issues. For example floor mats made from PLA can be found in a production model car. These unique fibres are made from PLA/ Nylon polymer-alloy improving abrasion quality. In addition Toray has been developing new polymer particles and succeeded in fabricating such a micro-particulate PLA. www.toray.com N3H41

Shenzhen Ecomann Shenzhen Ecomann Biotechnology Co. LTD., is a high-tech enterprise that is engaged in R&D, manufacturing, and sales of PHA and PHA based bio-resins with a current annual capacity of 5,000 tonnes and new capacity of 75,000 tonnes in 2 years.

Ecomann’s PHA is EN13432 and OK Compost Home certified and its PHA based bio-resins are available for various applications such as film, sheet, injection moulding and thermoforming.

At Chinaplas 2012, Ecomann will not only display PHA based bio-resins and finished products, but also present its development in employing PHA to improve physical and chemical properties of other bio-based polymers. www.ecomann.com N3L17

Show Preview Fukutomi FUKUTOMI CO. LTD., has developed a wide range of eco-friendly PLA products. These include PLA cutlery and food packaging which greatly reduce landfill waste. They are 100% non-toxic and certified to international food safety standards. Custom designs are available.

PLA golf tees do not need to be picked up when broken. PLA golf tees are more durable than traditional wooden ones. Fukutomi offers tees with customised logo printing. Flower pots made of PLA can be buried with plant seedlings, it is not necessary to remove them from the ground. They offer excellent ventilation with smooth finishing.

Fukutomi furthermore offers PLA Pellets made from PLA production scrap. These are suitable for various manufacturing industries and are available in different levels of toughness, transparency and heat resistance www.fukutomi.com N3P01

Wuhan Huali Wuhan Huali Environment Technology Co. LTD., will present ‘ECO-KEEP’ products at the 2012 Chinaplas Exhibition. Eco-keep is the Wuhan Huali brand of disposable housewares and these items are made from PSM® bioplastics, which use plant starch and other renewable sources as their main components, manufactured by polymer modification and plasticization.

At the end of 2010 the first generation of ‘Eco-Keep’ products arrived on the supermarket shelves of the Hubei Province in China. Shortly after their launch these eco-friendly household goods gained a high level of praise from consumers. In June of 2011 ‘Eco-keep’ successfully enter into the procurement system of more than 400 Wal-Mart supermarket stores in China and by 2012, ‘Eco-keep’ will be successfully launched in 2000+ stores in China, including Wal-mart and Carrefour, upgrading the product lines to 16 categories and nearly 100 SKU’s. www.psm.com.cn N3M31

Kingfa Kingfa Sci. & Tech. Co. Ltd., the largest modified plastics manufacturer in China, owns five manufacturing facilities in that country (Guangzhou, Shanghai, Mianyang, Tianjin and Zhuhai) with an annual production capacity over 1,000,000 tonnes of modified plastics.

ECOPOND® biodegradable plastics has become a world leader with independent intellectual property rights. Based on a strong technical background, perfect quality control and a global sales network, Kingfa is expanding the Ecopond biodegradable plastics product range and applications.

For strategic development Kingfa built a new manufacturing plant for Ecopond products with an annual capacity of 30,000 tonnes. Ecopond fully biodegradable plastics (FLEX162, FLEX-262 and FLEX-64D) comply with all the biodegradability standards including EN 13432, ASTM D6400 and AS 4736 (Australia). Products are ideal for 100% biodegradable shopping bags, trash bags, mulching films, food containers, office supplies and toys, etc. www.kingfa.com.cn N3L31

bioplastics MAGAZINE [02/12] Vol. 7

29

Show Preview Xinfu Zhejiang Hangzhou Xinfu Pharmaceutical Co., Ltd. is, among other things, a global leading manufacturer of vitamin B5. In addition XINFU specializes in the field of biochemicals, fine chemicals and Eco-Materials.

Biocosafe™ is a type of biodegradable macromolecular polymer synthesized from diacid and diols by a direct process of condensation polymerization catalyzed by a highly effective non-toxic catalyzer that is developed by XINFU. It is certified compostable as to EN13432 and ASTM D6400.

The Biocosafe resin series includes Biocosafe 1803 (PBSA), Biocosafe 1903 (PBS) and Biocosafe 2003 (PBAT), which can satisfy the different processing requirements of injection moulding, extrusion, blown film, fibre, bristle, straw and tube. Xinfu also have a research team to develop resin modification and product applications.

XINFU is seeking opportunities to cooperate with different partner in order to develop biodegradable plastic market. www.xinfupharm.com N3K03

Fukan Plastics*

WinGram

Shanghai Fukun New Material Science & Technology Co. Ltd., presents AddiFlex oxo-biodegradable plastic additive as a viable, practical and easy to use solution for the present plastic littering situation in China. It was developed in Europe and the USA over the last 15 years.

WinGram Industrial, a Hong Kong based company specialized in cellulose acetate (CA) material, started with traditional CA 15 years ago. WinGram is a major CA material supplier to most of the spectacle frame makers in China who produce European and US high quality branded frames. Two years ago they started developing biodegradable CA and successfully formulated their own 100% biodegradable polymer material which was recently certified to ISO14855.

The picture demonstrates a real life test indicating oxidative degradation of an HDPE polymer carrier bag within 6 weeks in outdoor weather conditions similar to those in China, i.e. general weather conditions between 18°C and max 40°C, sunlight and rain.

The results have been backed by a parallel test in Germany under weather conditions between 5°C and max 28°C, sunlight and rain.

The first stage of the degradation process leads to macromolecular chain breakdown due to the decomposition of peroxides which drives the auto-accelerating oxidation of the polymer, and it is this decomposition which is accelerated by the transition metal catalysis. Oxidation, technically known as degradation, as per ASTM D6954 The second stage, known as the biodegradation stage, is when the material from stage one is metabolized by microorganisms resulting in biomass, water and carbon dioxide. www.fukan-cn.com N3S51

After the biodegradable material launch not only do the spectacle frame makers now ask for the material to build up their own Eco line, but also toy manufacturers started to test the material. An important advantage of working with WinGram CA material is that there is no need to modify or alter existing tooling or injection machines. The material passed comprehensive testing, such as impact, drop and hardening tests. Three grades are available: S70 is a 100% biodegradable CA. It is specially formulated for spectacle frame production and it is highly transparent if needed. It is suitable for both injection moulding and sheet extrusion.

S72 is a 100% compostable CA. It is slightly yellowish but it is good for semi-transparent injection moulding and sheet extrusion processes for toys or other plastic products.

S73W: This grade is a hybrid of CA and traditional plastic, or formulated as 100% compostable upon-request. Ready for coloring is an injection moulding grade material for toys or household products.

The results exceeded the performance seen in controlled laboratory tests

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www.ecoplant.hk N3S39

Show Preview NatureWorks

Hisun In 2012 Zhejiang Hisun Biomaterials Co. Ltd., heatresistant PLA resin received more and more attention from manufacturers of branded cutlery. Therefore, Hisun improved the existing type REVODE213 and developed a new heat-resistant modified PLA resin, Revode213S, which is perfectly suitable for durable heat-resistant tableware. Revode213S has excellent heat-resistance, higher safety, easier colour matching and brighter gloss, as well as better processing and mechanical properties. In terms of the cost, properties, food contact safety and many other characteristics, Revode213S performs better than high-end melamine products in the current market.

In 2009, Hisun launched a cost-effective modified PLA resin, Revode213, with a heat-resistance of 90°C, which overcomes the low heat-resistance problems of traditional PLA and is better than starch-based products in processing and mechanical properties. All of these characteristics were quickly growing in popularity with the majority of tableware manufacturers. For better marketing, Hisun established a close cooperation with some professional green product manufacturers to focus on 100% biodegradable products such as disposable knives, forks and spoons. The product quickly won the international market’s recognition, a large number of orders from Europe and the United States pushed the manufacturers’ production capacity which was expanded several times in one year. At the same time Hisun also gained additional status through its heat-resistant PLA in the industrial field. www.plaweb.com N3L39

* As this preview is based upon an open invitation for editorial contributions from all exhibitors, it also contains information about companies presenting oxo-degradable products. However, we are still not convinced that these products will completely biodegrade. Until now, no independent scientific evidence has been presented to the editor.

NatureWorks LLC is a company dedicated to meeting the world’s needs today without compromising the earth’s ability to meet the needs of tomorrow. NatureWorks LLC is the first commercial scale manufacturer and global supplier of polylactide biopolymer, which markets under the Ingeo™ brand name.

Ingeo biopolymers are derived from 100% annually renewable resources with performance and economics that compete with oil-based plastics and fibres. By replacing petroleum with a renewable plant-based feedstock, NatureWorks production of Ingeo uses significantly less non-renewable energy, and generates significantly lower CO2 emissions than all traditional petroleum-based polymers. The environmental credentials are backed by a rigorous, peer reviewed, published eco-profile.

NatureWorks booth at Chinaplas 2012 will present a series of low-carbon-footprint products, including packaging, electronics, clothing, housewares, health and personal care, semi-durable, and the foodservice industry products which are made from Ingeo biopolymers. www.natureworksllc.com N3K31

Shenzhen Esun Founded in 2002, Shenzhen Esun Industrial Co.,Ltd not only inventively synthesize PLA in China, but also consider PLA modification as its overriding goal and obtain satisfactory achievement in PLA alloy.

PLA alloy has excellent biocompatibility, good mechanical strength, elastic modulus, and thermoforming.

Esun has launched two new PLA alloys: PLA/PBS alloy Esun 1323A and PLA/POM alloy Esun1604A. These two alloys contain a high amount of PLA. In line with pure PLA it can be processed easily on standard injection lines and converting equipment.

Esun 1323A and Esun 1604A offer good toughness and impact resistance, shining surface and pigment ability, high mechanical strength, low shrinkage, can be used many applications.

Esun PLA meets the requirements of EN13432 and ASTM D6400. www.brightcn.net N3M21

bioplastics MAGAZINE [02/12] Vol. 7

31

Show Guide Chinaplas 2012

Booth

Company

N3K17

ACUMEN ENGINEERING PTE LTD

N3P09

ADSALE

7

N3K21

BIOGRADE (NANJING) PTY LTD.

29

N3L37

bioplastics MAGAZINE

26

N3L27

CHINA PLASTIC & RUBBER JOURNAL

21

N3M11

FEIXIANG CHEMICAL BINHAI CO., LTD

11

N3S51

FUKAN PLASTICS GMBH

3

N3P01

FUKUTOMI COMPANY LTD.

6

N3M01

JIANGSU CAIHUA PACKAGING GROUP COMPANY

9

N3L31

KINGFA SCIENCE AND TECHNOLOGY CO., LTD.2

28

N3K31

NATUREWORKS LLC

N1M21

NGAI HING HONG COMPANY LTD.

17

1

2

3

8

6

9

30 (N1)

N3M07

NING XIA LIVAN BIODEGRADABLE PRODUCT CO., LTD.

8

N3M19

NUVIA TECHNOLOGIES INC.

10

N1F41

POLYONE

(N1)

N1E01

RHEINCHEMIE

(N1)

N3S57

SHANDONG FUWIN NEW MATERIAL CO. LTD.

1

N3L07

SHANDONG TAIKANG BIODEGR. PACKAGING MATERIALS CO.LTD.

12

N3L21

SHANGHAI SANCHENG POLYMER SCIENCE & TECHNOLOGY CO.LTD

25

N3L17

SHENZHEN ECOMANN BIOTECHNOLOGY CO.,LTD

14

N3M21

SHENZHEN ESUN INDUSTRIAL CO., LTD.

20

N3M27

SHENZHEN PLASTIC & RUBBER ASSOCIATION

19

N3S41

SHONAN TRADING CO.LTD.

4

N2 B01

SK CHEMICALS

(N2)

N2B01

SK INNOVATION

(N2)

N3K11

SUZHOU HANFENG NEW MATERIALS CO.,LTD.

N1H41

TEIJIN CHEMICALS LTD.

N3L01

TIANJIN GREENBIO MATERIALS CO. LTD

13

N3H41

TORAY

24

N3S55

VICTORY PLASTICS PTY LTD.

2

N3L11

WELLS PLASTIC LIMITED

15

N3S39

WINGRAM INDUSTRY CO., LTD

5

N3M31

WUHAN HUALI ENVIRONMENT TECHNOLOGY CO., LTD.

23

N3M41

YAT SHUN HONG COMPANY LTD

22

N3K03

ZHEJIANG HANGZHOU XINFU PHARMACEUTICAL CO., LTD.

16

N3L39

ZHEJIANG HISUN BIOMATERIALS CO.,LTD.

27

18 (N1)

11

7 10

19

22

20

23

On this floor plan you find the majority of companies offering bioplastics related products or services, such as resins, compounds, additives, semi-finished products and much more.

BIOADIMIDETM IN BIOPLASTICS. EXPANDING THE PERFORMANCE OF BIO-POLYESTER.

For your convenience, you can take the centerfold out of the magazine and use it as your personal ‘Show-Guide’ .

4

12

13

5

16

14 15

18

17

Focusing on performance for the plastics industries.

Whatever requirements move your world: We will move them with you. www.rheinchemie.com

21

25

29

bioplastics

MAGAZINE

26 28 27

30

24

Booth E1G41 High Quality Film Production: Efficiency, Productivity, Flexibility 

High uptime, throughput and raw material efficiency



Fast product changes



Easy operation and low maintenance



Reduced manpower and energy consumption



Excellent film quality



Processing of bio-based and bio-degradable film

www.brueckner.com

Register now! www.pla-world-congress.com

2nd PLA World

C o n g r e s s

15 + 16 MAY 2012 * Munich * Germany

Show Preview PolyOne

Tianjin

reSound™ Biopolymer Compounds: Bio-based Compounds for Durable Applications.

PolyOne’s reSound compounds combine high performance engineering thermoplastic resins with bio-derived polymers such as polylactic acid (PLA) for a unique balance of temperature, impact and cost performance, making them ideal candidates for durable applications across a variety of industries. Previously, manufacturers of durable goods had little opportunity to enhance sustainability by integrating biopolymers into their product design, due to the limited performance properties of unmodified biopolymers. Customers now have the freedom to design using reSound biopolymer compounds, a solution that provides improved performance and significant bio-based content to address marketplace demand for sustainable solutions.

Tianjin Greenbio Material Co., Ltd. produce Sogreen™ PHA products through fermentation from non-GMO natural sugars and starch and can supply a wide range of products – PHA powder and different grades of PHA blended pellets for blown film, extrusion foaming, injection molding and fiber drawing. They can be degraded into carbon dioxide and water by microorganisms in a variety of environments including soil, sewage, fresh and marine waters within 3-6 months. Compared to functionally equivalent plastic products, they do not cause any harm to the environment. As derived from plants rather than from oil, our PHA products have very low greenhouse gas emissions throughout their life cycle. Thus, it is truly “from nature and back to nature”.

www.polyone.com N1F41

www.tjgreenbio.com N3L01

Wells Plastics * Wells Plastics Limited is the developer, owner and manufacturer of the Reverte oxobiodegradable technology and trademarks.

Rhein Chemie Rhein Chemie’s innovative product line BioAdimide™ has been specifically formulated for bioplastics and is poised to widen the applications of bio-based plastic. It enables the production of renewable, bio-based polymers for durable applications with a lower environmental impact.

BioAdimide additives are specially suited to improve the hydrolysis resistance of bio-based polyester, and to expand its range of applications. Currently, there are two BioAdimide grades available.

The BioAdimide 100 grade improves the hydrolytic stability up to seven times that of an unstabilized grade, thereby helping to increase the service life of the polymer. In addition to providing hydrolytic stability, BioAdimide 500 XT acts as a chain extender that can increase the melt viscosity by 20 – 30% compared to an unstabilized grade, allowing for consistent and easier processing. The two grades can also be combined, providing both hydrolysis stabilization and improved processing, for an even broader reach of applications. www.bioadimide.com N1E01

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Wells supports Reverte with an unrivalled laboratory facility at which Reverte laboratory staff conduct a raft of tests on customer specific finished products ensuring correct addition levels of Reverte and performance of the product. Reports are issued for each individual customer.

Many brand owners have seen the benefits in using Reverte in a wide range of applications, from check-out bags through to complex laminate structures for food packaging. Reverte has also been used in technical applications where the degradation profile is critical to provide a functioning product, such applications include netting and agricultural films.

In addition to the standard grades of Reverte Wells will be unveiling a new check-out bag grade of Reverte, which contains the same additive package which has achieved ASTM 6954-04 in polyethylene applications but with a more cost effective method of delivery, making Reverte even more competitive and the best all-round solution for oxo-biodegradability on the marketplace. www.reverteplastics.com N3L11

Additives

New products for

bio-based polyesters

R

hein Chemie (Mannhein, Germany) was honored by Frost & Sullivan with the Global New Product Innovation Award 2011 in the Bioplastic Additives Market for its new product line BioAdimide™. This additive has been specifically developed for bioplastics and is poised to widen the applications of bio-based polyesters.

Additive solutions to expand the applications of bio-based polyesters

The new product line under the trade name BioAdimide of Rhein Chemie’s Engineering Plastics Division enables renewable, bio-based polymers for durable applications like E&E, automotive interior, etc.

Currently, there are two BioAdimide grades available. The BioAdimide 100 grade improves the hydrolytic stability up to seven times of an unstabilized grade, thereby helping to increase the service life of the polymer. In addition to providing hydrolytic stability, BioAdimide 500 XT acts as a chain extender that can increase the melt viscosity 20 to 30 % compared to an unstabilized grade,making it more stable and easier to process in extrusion, blow-molding or filament applications.

The two grades can also be combined, providing both hydrolysis stabilization and improved processing, for an even broader reach of applications. The new product line opens up the possibility for bioplastics to expand into previously out of reach durable markets .

Moreover, the addition of BioAdimide offers the ability to incorporate higher levels of regrind into customer formulations.

The amount of regrind can be increased to a level as high as 40%.

MT

Retained tensile strength [%]

„We are very pleased that Frost & Sullivan selected us for this award from many strong competitors. They recognized the innovation of our new BioAdimide product line which enables the industry to use bio-based polymers for durable applications with a lower environmental impact. The increasing use of renewable bioplastics leads to significant reduction in the carbon footprint, boosting overall sustainability” emphasized Fei Tan, Head of Global Business Development, Engineering Plastics Division.

Hydrolysis stabilization

Testing conditions: 65°C in water

100 80 60 40 20 0

5

10

15

20

25

30

35

Time [days] Unstabilized

0.5% BioAdimide 100 + 1.0% BioAdimide 500 XT

1 x extruded 0.75% BioAdimide 100 + 0.75% BioAdimide 500 XT

1.0% BioAdimide 100 + 0.5% BioAdimide 500 XT

Melt volume rate modification Melt volume rate [cm3/10 min]

“The inherent deficiencies of bioplastics, such as poor processing characteristics and insufficient physical and mechanical properties, have limited the opportunities for their expansion into advanced application arenas,“ notes Frost & Sullivan Industry Analyst Deepan Kannan. “However, with the incorporation of BioAdimide as an additive in the bioplastic formulation, these challenges can be avoided, facilitating their use in high end applications.“

Testing conditions: 200°C / 2.16 kg

6 5 4

4,2

4,5

4,6

1.0% BioAdimide 100

1.5% BioAdimide 100

3,4

3 2 1 0

Unstabilized

1x extruded

The BioAdimide product line enables the production of renewable, bio-based polymers for durable applications with a lower environmental impact

www.bioadimide.com

bioplastics MAGAZINE [02/12] Vol. 7

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Additives Application News

Make PLA better Improving Processing and Properties

By Connie Lo and Zuzanna Donnelly Arkema Inc. King of Prussia, Pennsylvania, USA

I

t took over a decade to get to the present day, and scientists are continually working to improve the processing and properties of PLA. Two areas of interest include impact modification to improve toughness of PLA to overcome the extremely brittle nature of the polymer; and increasing the melt strength of the molten polymer in order to access applications such as blown film and foaming which require a high degree of melt strength and melt elasticity.

Toughening of PLA PLA is a brittle polymer compared to many traditional petroleum-based plastics. However, with the addition of core shell impact modifiers, these modifiers can dramatically increase the impact toughness of PLA by as much as several orders of magnitude. Core shell impact modifiers have been observed to impart the highest degree of toughening in PLA. These modifiers mitigate cracking and chipping problems during processes such as thermoforming as well as improving the performance of the finished article. Impact toughening becomes increasingly critical for durable goods applications that require higher impact strength and good low temperature impact. The decrease in tensile and flexural modulus is proportional to the amount of modifier added and can decrease the stiffness of PLA in applications such as blown film.

Modulus [MPa]

4000

Flexural Modulus

3000 2000 1000 0

0 2 4 6 8 10 12 wt % Impact Modifier

12

Gardner Impact (1mm (40 mil) molded disk)

Figure 2: 1 mm (40 mil) thick injection molded PLA disk without impact modifier (right) and with 5% rubber based core shell impact modifier (left).

Impact [J]

10 8 6 4 2 0

0 2 4 6 8 10 12 wt % Impact Modifier

Figure 1. Mechanical properties of PLA core-shell impact modifier

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bioplastics MAGAZINE [02/12] Vol. 7

Additives

Improving Melt Processing

The melt strength of PLA decreases with decreasing PLA molecular weight. As with other condensation polymers, PLA is subject to degradation through hydrolysis when melt processed in the presence of moisture. Thus drying of PLA pellets as well as PLA regrind scrap is required prior to processing. When drying equipment is not available, the use of melt strengthening additives has been shown to compensate for losses in melt strength due to hydrolysis as illustrated in Figure 3 below. Thus the addition of 4% of an acrylic melt strengthener can improve the melt strength of PLA that has been processed without drying to levels above the virgin resin.

0.18 0.16 0.14 Force [N]

Another area of interest for PLA modification is increasing the melt strength of the polymer. PLA has very low melt strength resulting in difficulties in processing the polymer with techniques such as blown film, deep draw thermoforming or foaming which rely on large draw down ratios or rapid controlled expansion of the melt. Melt strength of PLA can be improved by the addition of small amounts of linear high molecular weight acrylic copolymers. These copolymers are highly miscible with PLA resulting in a blend that is optically transparent. In this manner the melt strength of the blend can be increased by 50-100% over the neat PLA. Figure 2B qualitatively illustrates the effect of addition of acrylic melt strengthener on the PLA melt. The melt containing additive is noticeably stiffer and holds its shape better than the neat PLA.

neat PLA PLA with 2% additive PLA with 4% additive

0.12 0.10 0.08 0.06 0.04 0.02 0.00

0 100 200 300 400 Pull-Off speed [mm/s]

Figure 2 A) PLA strands analyzed on a Rheotens apparatus with and without acrylic copolymer.

Figure 2 B) PLA without additive (left) and with 4% melt strengthener (right)

Future Trends

0.20 0.18 0.16

undried PLA processed with 4% additive Unprocessed PLA PLA processed without drying

0.14 Force [N]

Bioplastics only contribute to 1% of the plastics used in the world today. However, its range of applications is rapidly growing and developing as processors look towards using bioplastic in areas traditionally dominated by petroleum based resins. In addition to the additives presented here, much work is being devoted to addressing the issues of the low heat distortion temperature of PLA and increasing the rate of crystallization of PLA from the melt. There are also trends towards making blends of PLA with starch and other degradable bioplastics for completely biodegradable articles.

On the other end of the spectrum, manufacturers are looking to blend PLA with thermoplastics such as polycarbonate or PMMA for making durable goods with an increased biobased content. With the current push towards sustainability coupled with the steadily increasing global PLA production capacity the applications and innovations around PLA will undoubtedly grow in the coming years.

Rheotens Analysis of PLA

0.12 0.10 0.08 0.06 0.04 0.02 0.00

0 100 200 300 Pull-Off speed [mm/s]

Figure 3. Rheotens data showing effect of acrylic melt strengthening additive on PLA processed without drying

www.arkema-inc.com

bioplastics MAGAZINE [02/12] Vol. 7

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Additives

T

he prototype Biocoustic Module originated within the scope of a joint research project covering “clear lightweight construction panels from renewable raw materials as space divider elements with acoustic function” being run by the company Nimbus Group, Stuttgart, Germany together with the Institute of Building Structures and Structural Design of the University of Stuttgart. The translucent module should be able to be used as a room divider in office blocks or public buildings. To allow the use of polylactic acid (PLA) in interiors, it was modified to give the desired behaviour in case of fire, and improved thermal stability.

Background Fig.1: Biocoustic Module (Photo: nimbus group)

Biocoustic room divider Flame retardant PLA for interior use By: Carmen Köhler Institute of Building Structures and Structural Design University of Stuttgart

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bioplastics MAGAZINE [02/12] Vol. 7

As part of an increasingly intense debate about sustainable construction and resource scarcity, there is a growing demand for materials that are resource-efficient, aesthetic and versatile.

In new buildings an increasingly large amount of acoustically hard materials such as concrete walls, smooth floors and large windows is used. Hence sound cannot be sufficiently absorbed.

The reverberation time increases dramatically. From practical experience comes the desire for an easily movable or convertible room divider, which maintains the visual open appearance and transparency, but which is also in a position to enable an acoustically pleasant environment.

The aim of the project, which was funded by DBU (Deutsche Bundesstiftung Umwelt – a German government environmental agency ), was to develop a transparent or translucent acoustic board which has a high ratio of renewable resources in its construction and which can be used as a flexible space divider, either as a movable wall or as a component of space-in-space systems. An injection moulded module was developed, which is based on two half-shells that can be joined together.

The perforated surface layers, the edges of the module and connector systems are manufactured using the injection moulding process. The micro-perforation is required for realizing an acoustically effective space planning while maintaining the visual transparency.

Material requirement The translucent acoustic module should be offered at a competitive price for the market. With a view to resource protection a very high proportion of components made from renewable resources is important. Therefore, the decision was made to use the biobased plastic PLA. In terms of fire behaviour the classification UL94-V0 was desired. A heat distortion temperature of 70 degree centigrade should be able to be achieved. After modification, the PLA must still have a low viscosity, because the melted polymer must flow around the numerous steel pins in the tool. In addition to the performance improvement, a certain translucency of the PLA compound should be achieved.

Additives

Modifications and results The flame retardant triphenyl phosphate (TPP) was chosen, because it does not affect light transmission (Fig. 6 upper right).

TPP is a fish toxin. It is also used as a plasticizer for cellulose acetate polymers. The experiments have shown that addition of only 7-8 % by weight is sufficient.

In fire tests in line with the U.S. standard UL 94-V, the modified material always extinguished by itself within 1-3 seconds after removing the flame. Non-burning droplets emerged during the second flaming. Cotton, at a standardised distance to the specimen, did not ignite (Fig. 4).

Fig.2: An example of the application of the Biocoustic Module ©Nimbus Group

The softening effect of TPP lowers the softening point and thus the heat distortion temperature (Fig. 5+6) at 45-46°C. To enhance this, a nucleating agent in form of a masterbatch was added to the compound. During injection moulding the cavity temperature was increased and the cooling times were varied. The cooling time begins with the volumetric filling of the mould, and ends with the opening of the mould. The heat deflection temperature (HDT-B) increases with increasing cooling time. In experiments at a mould temperature of 100°C and a cooling time of 3 minutes a PLA compound of 7 % by wt. TPP and 3 % by wt. nucleating agents the HDT-B values were obtained that indicated an average increase of 59.7°C. If the cooling time is extended by one minute, the HDT-B improves again by 20°C (average). The individual values fluctuate strongly, since the crystallization is not completed. A subsequent tempering to minimize these fluctuations increases the HDT-B additionally (Fig. 5 t3)

Fig. 3: Samples of different materials after flammability test

A variant would be the production of the mouldings with the usual mould temperature for PLA of 25°C and a conventional cooling time. Five minutes of tempering at 100°C led to an average HDT-B of 73.5 degrees. To control any tendency to warp, expensive clamping tools must be built. The shrinkage

Fig. 4: results of the flammability test (UL 94-V)

burning time after each flame impingement

t1

t2

t3

Cellulose acetate + 15wt% TPP + other

PLA

PLA PLA + 3wt% + 7wt% TPP potassium-diphenyl+ other sulfone-sulfonate + 3wt% Nanoclay + other

> 40s, fire was extinguished

> 35s, fire was extinguished 1 to 3s

total flaming/combustion time (10 experiments)

t4

t5

> 35s, fire was extinguished

11 to 25s

burn-off until burning clamp

fire was extinguished before reaching the burning clamp

fire was extinguished before reaching the burning clamp

after flame - and annealing time after the 2nd flame impingement

> 30s, fire was extinguished

> 30s, fire was extinguished 1 to 3s

no

PLA + 7wt% TPP + 2wt% Nanoclay + other > 30s > 300-320s

yes. In other experiments fire was extinguished before reaching the burning clamp

no

> 35s, fire was extinguished

> 40s yes

combustion of the cotton

yes

yes

no

yes

Flammability class UL94

V2

V2

V0

V2

V2

transparency before burning

yes

yes

yes

no

no

~ 100

~ 92,5

~ 93

~ 90

proportion of renewable resources [%] ~ 60

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Fig. 6. Various degrees of transparency of the panels and their thermal stability (HDT-B), depending on the formulation and production parameters

of the material during the post-mould treatment should be considered during the mould design. The aim was to get a good HDT-B and a high degree of transparency. The yellowness index of the PLA was neutralized with an optical brightener for polylactide. Depending on the dosage of additives, the bioplastic compound consists of 92.5 % by wt. of renewable raw materials

Outlook The necessary longer cycle time of 180 to 240 seconds, instead of about 20-30 seconds, reduces production capacity per day. This leads to a high cost per piece. This aspect leads to the conclusion that this PLA compound could be mainly used in the higher priced design sector.

The further goal is to minimize the cycle time for each halfshell and to improve the transparency. www.itke.uni-stuttgart.de www.nimbus-group.com

test compound

processing and curing

t1

PLA (without additives)

CT 25°C; cooling time regular

51,7

t2

PLA + nucleating agent

CT 25°C; cooling time regular

51,9

CT 25°C; cooling time regular

45,6

CT 100°C; cooling time 3min

64,9

CT 100°C; cooling time 4min

65,3

t3

t4

PLA + TPP (8wt%) CT 25°C; cooling time regular; + nucleating agent (4wt%) temper 5min at 100°C + brightener CT 25°C; cooling time regular; temper 180min at 100°C

97,3 112,5

PLA + TPP (7wt%) CT 100°C; cooling time 3min + nucleating agent (3wt%) CT 100°C; cooling time 4min + brightener

59,7

cavitiy temperature (CT) start temperature: 26°C workload: 0.450 MPa

Fig.5. HDT-B subject to processing method and curing

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73,5

CT 100°C; cooling time 4min; temper 480min at 100°C

parameter HDT-B: ramp: 120.00 °C/h preheat time: 300s

40

HDT-B [°C]

79,9

Additives By Michael Wagner Deifel Buntfarbenfabrik Schweinfurt, Germany

Colour-differences of conventional HDPE to PLA, PLA blend and PBS, that were each pigmented with the same yellow, red, green and blue masterbatch, with the first column showing the natural colour of each plastic.

In this colouring test the maximum pigment level allowed (regarding the heavy-metal content as per EN 13432), was used in order to show the optimum colouring effect.

Colorants for bioplastics

T

HDPE

PLA

PLA-Blend

PBS

oday many biobased and/or biodegradable/compostable plastics are required to be coloured. In order to fulfil, for instance, the compostability standards (such as EN 13432 or ASTM D6400), some specific technical know-how is essential with regard to pigment composition and the quantity required for a specific task.

Considering this, the company Deifel GmbH & Co. KG in Schweinfurt, Germany, has tested various bio-plastics and cooperated with appropriate test laboratories. Even faced with the stringent requirements in the standards, good prospects for colorants suitable for bio-compostable plastics have been developed.

Whereas dispersing agents or other processing aids could be chosen on a natural basis (e.g. wax, oil, etc.), for pigments and other dyestuffs it is quite different: bio-based and biodegradable colorants of herbal origin (e.g. indigo) do not withstand the high processing temperature of thermo(bio-) plastics, hence no ecological alternatives for conventional colorants are available. Therefore a certain percentage of non-biodegradable components has to be tolerated: for instance according to EN 13432 a maximum of five different alien (i.e. non-biodegradable) components is allowed, with each not exceeding one percent in the end-product.

With the product line DeiÂŽBio, the colorant producer Deifel designed colour batches, which are matched exactly to this special purpose.

Of course, besides quantity, the quality of colorants is also of decisive importance. Only pigments and other dyes, which are recommended for the colouring of bioplastics, should be used. A decisive restriction is, for instance, the heavy-metal content, which excludes a large number of colorants and limits both the possibilities of combination among themselves (affecting various colour-shades, created by pigment mixtures), and their percentage as an addition to the desired bioplastic (affecting the intensity of a colour).

A potential negative influence on compostability, which may be caused by an unpredictable reaction between single components, will not be seen before the certification tests.

This is one of the reasons why testing of the end-product is essential. However, a specific and safe previous choice of working materials (in this case the colorants) is reasonable and may be more likely ensure a successful certification to the norms mentioned above.

The pigment formulation and the masterbatch producer will competently and consultatively assist all customers in the plastics processing business, enabling them to realize their individual goals when it comes to product colour – whether bio-based or biodegradable/compostable.

Besides prescriptive limits regarding heavy metal content, the basic and natural colour of a certain bioplastic plays a major role that has to be considered. The same colorant may look quite different within various plastics (see photo).

Therefore, when choosing a suitable bioplastic, not only technical requirements, but also the limits of possible colours should be in focus.

The transparent appearance of natural PLA allows a high degree of freedom when considering colours. However, if there are any technical requirements (e.g. shock-resistance achieved by using a PLA blend) it is usually necessary to compromise on the coloration, because of the restrictions outlined above.

The colour applications laboratory at Deifel is engaged in this subject and can usually help with the choice of the appropriate type of bio-plastic. For most biodegradable/ compostable plastics (e.g. PLA, PBS, PHA, ‌) pigment powder or masterbatch pellets can be used for colouring. www.deifel-masterbatch.de

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Additives Application | Masterbatch News

Brighter hues and special effects New, bright green and gold pearlescents open new opportunities www.clariant.com

Natural

A

s part of a continuing effort to expand the color and appearance options available for compostable biopolymers, Clariant Masterbatches, Muttenz, Switzerland, is adding new brighter colors and eye-catching special effects to its RENOL®-compostable product line.

Typical of the new offerings are a brighter, clearer green concentrate and a gold-pearl special effect that can add sparkle to personal care packaging.

Until recently, companies developing products from biopolymers had to make a difficult decision. They could use all-natural masterbatches and accept that the range of colors and additives available was limited, expensive and not very stable. Or, they could use conventional pigments and functional ingredients and compromise on the environmental friendliness of their product. Clariant’s Renol-compostable range provides them with a third choice that could lead to increased acceptance of biopolymers in new markets. Application targets include packaging and single- or limited-use products like plastic utensils, drink cups and pens.

Renol-compostable colors and Cesa-compostable additive masterbatches incorporate conventional (non-natural) additives and pigments but they have been formulated and independently tested for compliance with EN 13432:2000 – the widely recognized European standard for compostable plastic packaing (including heavy-metal content and plant toxicity). In addition, Clariant has obtained the highly desirable ‘OK compost’ certification issued by AIB Vinçotte International (Vilvoorde, Belgium). The products made at Clariant facilities in Italy and Spain have obtained the Vinçotte approval stamp for the range of new eco-friendly masterbatches that they manufacture.

The Renol-compostable product line includes masterbatches based on over 80 different pigments, and new color choices are becoming available every day. Cesa-compostable additive masterbatches include UV-stabilizer and antioxidant packages, with more additives currently pending review.

Renolnature

Renol compostable Ecotex-tested pigments

Renol-BL and BA standard range of MB for biopolymers Price/ Performance

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bioplastics MAGAZINE [02/12] Vol. 7

Color Choice

Materials

Energy (Biogas) Fertilizer (Liquid) Anaerobic Digester

Good for AD Versatile bioplastic product enabling increased use of Anaerobic Digestion

Bio Fiber (Solid)

A

naerobic Digestion is a well known process by which organic wastes are decomposed in the absence of oxygen by anaerobic micro-organisms; often resulting in the production of significant amounts of methane gas. Anaerobic Digestion is most commonly used in wastewater and sewage treatment and in the treatment of animal manure waste. Over the past decade, there has been a strongly growing interest in Anaerobic Digestion as sustainable and environmentally friendly way to process biodegradable wastes and as a means to produce renewable energy. Anaerobic Digestion compatible waste bags will enable increased use of this technology.

Anaerobic Digestion Basics Anaerobic Digestion can be implemented in a wide variety of configurations. Key variables include: temperature (mesophilic ~20-45˚C, or thermophilic ~49-70˚C), number of chambers/ stages, batch or continuous process, solids content in process (high solids ‘dry’ at 25-40% solids, high solids ‘wet’ at ~15-25% solids, or low solids at less than 15% solids), biogas use (burned on site or purified for sale), feedstock(s), and output streams/ treatments. Like many technologies, Anaerobic Digestion benefits from economies of scale; but small or medium size installations can be economically feasible in specific situations.

Anaerobic Digestion systems can be designed for very efficient land use, for facilities in urban setting. If properly designed and operated, they produce no harmful emissions and minimal unpleasant odors.

The outputs of Anaerobic Digestion usually include biogas, fibrous solid/sludge, and process liquor. The latter two may be combined in a slurry. The biogas is typically 50-75% methane. It can be combusted as-is or scrubbed/purified for sale as natural gas. The biogas typically contains 25-50% carbon dioxide and small quantities of other gases; including hydrogen sulfide (up to about 3%, which can be removed by scrubbing). The solid/sludge can be used in the same way as compost as a soil improver, or it can be composted after Anaerobic Digestion to increase the breakdown of lignin and cellulose. The process liquor is typically nutrient rich and can be used as a fertilizer. However, if liquor volume is excessive (e.g. with a large low-solids installation), process liquor may be discharged or re-used following additional treatment (primarily to remove nutrients and dissolved solids).

By Robert Kean Biodegradable Technologies Manager Cortec Corporation St. Paul, Minnesota, USA

Anaerobic Digestion is an excellent technology for treatment of (and energy recovery from) animal manure and numerous facilities have been constructed exclusively for this purpose.

However, other biodegradable feedstocks produce significantly higher biogas yields. Favorable feedstocks include: food waste, paper, yard waste (grass/leaves), and crop residue. The biogas

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Materials

US Municipal Waste 2010

80000

Waste in thousand tons

70000

63%

60000 50000 40000 3%

30000

53%

20000 10000 0

Paper/ Food Waste Paperboard

Recovered |

Yard Waste

Landfill / Incineration

Data source: US EPA 2010 Municipal Solid Waste Report

Figure 1: Recent historic recovery of municipal organic waste via recycling or compost

yield can be highly variable based on feedstock and operating conditions. However, a typical yield for food scraps may be about 265 m3/t and almost 1000 m3/t for fat and grease. This compares with biogas yields in the range of about 25 (cow) to about 80 (chicken) m3/t for manure [1]. Grass clippings and yard waste would likely be in the range of 150-200. Except for materials high in lignin (e.g. wood waste), most natural organic materials are readily degraded with Anaerobic Digestion. Somewhat surprisingly, most compostable bioplastics do not degrade quickly in Anaerobic Digestion, especially at lower temperatures.

A study [2] using life cycle assessments (LCA) has shown that Anaerobic Digestion of municipal organic waste is clearly superior to both composting and incineration. A key contributor to the improved LCA is the energy recovered with Anaerobic Digestion (as biogas), compared with the energy input required for turning/aeration of compost. Incineration also recovers energy, but this benefit is offset by greater emissions (of CO2 and other gaseous combustion products) and the ash waste which may be concentrated in toxic heavy metals.

Most (non-recyclable) municipal organic waste now goes to land fill or incineration, with minor amounts diverted to home or industrial composting. Data from the US, for 2010 (Figure 1) show that only about 3% of food waste was recovered (through composting). Recovery of yard waste was considerably better (at about 57%). In comparison, about 63% of paper and paper board was recovered through recycling. Thus, municipal organic waste (especially food waste) is a large, favorable, and mostly untapped source of raw materials for Anaerobic Digestion. Implementation of Anaerobic Digestion would show numerous environmental benefits over current disposal methods and provide a clean source for renewable energy. Based on these benefits, many communities are now exploring Anaerobic Digestion as a preferable option. One concern in many countries is the collection infrastructure and logistics, including the availability, cost, and performance of waste bags.

PHA Advantages for Anaerobic Digestion

[1] Yeatman C.: Biogas Experiences and Ethanol Prospects, Oxford Farming Conference, 2007, pp. 1-12.

[2] Edelmann W, Baier U, Engeli H.: Environmental aspects of the anaerobic digestion of the organic fraction of municipal solid wastes and of solid agricultural wastes, Water Sci Technol. 2005;52(1-2):203-8.

[3] Darby, Debra: Innovation with a Marine Focus: New Film Products for Marine and Anaerobic Digestion, bioplastics MAGAZINE, 05/11, 2006 pp. 32-33

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bioplastics MAGAZINE [02/12] Vol. 7

EcoWorksŽ AD, by Cortec Corporation, St. Paul, Minnesota, USA, first described in a previous issue of this magazine , is ideally suited for expanding the use of Anaerobic Digestion for disposal of municipal organic waste. EcoWorks AD is made from Mirel™ P5001 PHA (polyhydroxyalkanoate), which degrades rapidly and completely in Anaerobic Digestion (demonstrated by ASTM D5511). This means that debagging of waste is not necessary for feeding of materials into the Anaerobic Digestion system, and it is compatible with a wide range of operating conditions (high or low solids, high or low temperature).

EcoWorks AD has good mechanical properties, including high tear and impact strength (table 1). Unlike some other compostable/ degradable bags (especially paper bags and some starch bioplastic blends), EcoWorks AD does not become weak or sticky when it gets wet. EcoWorks AD can be made in a range of sizes and thicknesses, to accommodate commercial (e.g. large bags for restaurant or food service waste collection) or residential (e.g. counter top food scrap bins, yard waste bags) applications.

Materials

Property

Test Method

Units

Typical Value

Caliper

ASTM D6988

µm

44.45

Breaking Factor

MD ASTM D882-02 TD

kN/m

0.70 0.63

Tensile Strength at Break

MD ASTM D882-02 TD

MPa

15.98 13.94

Elongation at Break

MD ASTM D882-02 TD

%

594.26 567.84

Yield Strength

MD ASTM D882-02 CD

MPa

8.85 11.43

Tear Strength

MD ASTM D1922-06a mN CD

4332.75 3044.37

Dart Drop Impact Resistance

ASTM D1709-04, Test Method A

grams 147.29

Puncture Resistance

MIL-STD-3010, TM 2065

N

6.65

* Typical properties represent average laboratory values and are not intended as specifications but as guides only.

is working with Metabolix to continue development and production of EcoWorks AD. The product expands Cortec’s portfolio of bioplastic products while growing the market for the Mirel brand bioplastic. Cortec is now manufacturing EcoWorks AD bags and film, along with the companion brand EcoOcean™, at its Advanced Films division in Cambridge Minnesota, USA. Plans are underway to also manufacture the product at the EcoCortec subsidiary in Beli Manaster, Croatia in the future. EcoWorks AD is targeted to be price competitive with other compostable bioplastics, yet provides the superior benefits described above. www.cortecvci.com www.mirel.com

Table 1: Typical Properties Eco Works AD

Further environmental benefits of EcoWorks AD include: Suitable for use in home compost. EcoWorks AD will degrade at the lower temperature (even ambient temperatures) of home compost bins compared to commercial compost facilities.

It will biodegrade in marine (ASTM D7081), soil, and fresh water environments; reducing long term effects of inappropriate disposal (litter). Its ability to biodegrade in marine environments provides coastal areas with a technological “safety net” for coastal and marine preservation.

It contains 77% biobased carbon content (ASTM D6866) and has been awarded USDA Biopreferred designation for Waste Bags Meets ASTM D6400 standard for compostable plastics.

In municipal composting facilities, EcoWorks AD breaks down faster than most other compostable bioplastics, allowing faster composting cycles and/or less ”plastic” residue visible in the compost product.

Shaping the future of biobased plastics

The combination of mechanical and degradation properties of EcoWorks AD create the opportunity for a more environmentally friendly plastic shopping bag. If provided by retailers, consumers would use the bag to transport their merchandise home. Then the bag could be used to collect home waste for disposal via Anaerobic Digestion, home composting, or collection for municipal composting.

EcoWorks AD represents a collaborative development between Cortec and Telles. With the recent termination of the Telles joint venture, the ownership of the Mirel brand and technology has reverted to Metabolix. Cortec

www.purac.com/bioplastics bioplastics MAGAZINE [02/12] Vol. 7

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Report Application News

Meta-analysis of 30 LCAs Bio-based plastics convince with high climate protection potential and low use of fossil resources By Roland Essel Environmental Scientist nova-Institut Hürth, Germany and Michael Carus Managing Director nova-Institut Hürth, Germany

A

meta-analysis of 30 life-cycle assessments by the nova-Institute for innovation and ecology on behalf of the Proganic company shows unambiguously positive results for the widespread biobased plastics PLA and PHA/PHB. Since bio-based plastics have increasingly established themselves and have been showing double-digit growth rates, there is a growing public discussion regarding whether these new plastics, that are based on biomass instead of mineral oil, really do, or do not, have ecological advantages. The Proganic GmbH & Co. KG company from Rain am Lech, Germany, which exclusively relies on bio-based plastics and has already managed to place different product lines such as garden and household goods on the market, wanted to figure it out exactly and entrusted the nova-Institut, Hürth, Germany, with conducting a comprehensive meta-analysis of PLA and PHA/PHB, thus answering the question of ecological assessment based on the latest state of scientific knowledge.

Oliver Schmid, managing director of Proganic commented: “More and more customers are interested in bio-based solutions, but only in those that have distinct ecological advantages. We owe it to our customers to generate reliable data and make these available to them.”

The Proganic® material used by Proganic mainly consists of the biobased polymers PLA and PHB, therefore in the Meta-LCA the novaInstitut looked at PLA and PHA materials.

The result of the meta-analysis of 30 life cycle assessments of PLA and PHA/PHB

The full study “Meta-analysis of life cycle assessments for bio-based polymers in the production of Proganic” (in German language only) can be downloaded free of charge at www.bioplasticsmagazine.de/201202

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The production of the bio-based polymers PLA and PHA/PHB provides ecological advantages compared with the production of petrochemical plastics. The emission of greenhouse gases and also the use of fossil raw materials are definitely diminished. Therefore the substitution of petrochemical plastics with bio-based plastics yields positive impacts in the categories of climate change and depletion of fossil resources – two criteria that are playing a major role in current political and public discussion. Michael Carus, co-author and managing director of the nova-Institut, did express his surprise. “After the excited public debates of recent months we hadn’t expected such a clear result, the more so as bio-based plastics are still at the beginning of their development. So the meta-analysis not only shows the advantages already existing today, but also the substantial ecological potential as a result of further process optimisations.”

Report

Figure 3 shows that the production of bio-based polymers in comparison with the production of petrochemical plastics in most cases also leads to greenhouse gas emission savings. The biggest greenhouse gas emission savings can be found again when comparing bio-based polymers to polycarbonate (PC). For PLA, the average savings potential in this case amounts to 4.7 ± 1.5 kilograms of CO2 equivalents per kilogram of plastics. For PHA, the average savings potential in this case amounts to 5.8 ± 2.7 kilograms of CO2 equivalents per kilogram of plastics. In comparison with PET and Polystyrene (PS), considerable savings potentials ranging between 2.5 and 4.2 kilograms of CO2 equivalents per kilogram of plastics are to be found in the production of bio-based polymers. The lowest savings potential are to be found when comparing biobased polymers with polypropylene (PP).

Greenhouse gas emissions in kg CO2 eq./kg

8 Petroleum based polymers

6

(PP, HDPE, LDPE, PET, PS, PC)

4 2

PLA

Proganic

0

20

40

60

80

100

120

PHA

-2 -4

Depletion of fossil resources in MJ/kg

Figure 1: Comparison of the environmental impacts of different polymers and Proganic in the impact categories of climate change and fossil resource depletion

Savings of fossil resources in MJ/kg

Figure 2 shows that the production of bio-based polymers, in comparison to all petrochemical plastics examined, leads to savings in fossil resources. The biggest savings potential can be found in comparison with polycarbonate (PC). The average savings potential in the production of PLA amounts to 56 ± 13 megajoules per kilogram of plastics here. The average savings potential in the production of PHA compared with PC amounts to 65 ± 25 megajoules per kilogram of plastics. But also in comparison with PP, HDPE, LDPE, PET and PS, average savings amounting to between 20 and 40 megajoules per kilogram of plastics are to be expected.

10

100 90 80

PLA PHA

70 60 50 40 30 20 10 0

Bio-based Bio-based Bio-based Bio-based Bio-based Bio-based vs. PP vs. HDPE vs. LDPE vs. PET vs. PS vs. PC

Figure 2: Savings of fossil resources by the production of bio-based polymers in comparison with the production of petrochemical polymers

Savings of greenhouse gas emissions in kg CO2 eq./kg

Figure 1 shows three ellipses, separated from each other, that represent the clusters of results. The ellipse on the upper right, which contains data based on using fossil resources of more than 70 megajoules per kilogram of plastics and greenhouse gas emissions of partly clearly more than three kilograms CO2 equivalent per kilogram of plastics, correlates with petrochemical plastics. The other two ellipses illustrate the results of the bio-based plastics PLA and PHA/PHB, the data of which for the use of fossil resources are lower than 70 megajoules per kilogram of plastics. At the same time the greenhouse gas emissions of bio-based plastics amount to clearly less than three kilograms of CO2 equivalents per kilogram of plastics. The ellipse of the PHA/PHB material exhibits a considerably wider spread of results than the ellipse of PLA.

9 8 7

PLA PHA

6 5 4 3 2 1 0 -1

Bio-based Bio-based Bio-based Bio-based Bio-based Bio-based vs. PP vs. HDPE vs. LDPE vs. PET vs. PS vs. PC

Figure 3: Reduction of greenhouse gas emissions due to the production of bio-based polymers in comparison with the production of petrochemical polymers

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Report Results for Proganic What do these results mean for the Proganic compound? For this, the novaInstitut has carried out a simple model calculation, to be able to estimate the environmental impact of Proganic in the different categories mentioned. The Proganic material consists of PLA, PHB, minerals and carnauba wax. The greenhouse gas emissions and the use of fossil resources in the production of Proganic are significantly determined by the components PLA and PHB. For the model calculation, in both impact categories the data of NatureWorks LLC and Metabolix Inc were used. For the minerals, a greenhouse potential of 75 kilograms CO2 equivalents per kilogram of mineral is assumed. From carnauba wax, having the lowest mass fraction, no relevant influence is to be expected.

Furthermore the compounding and transport processes were included in the calculation.

The result: Calculating the greenhouse potential of Proganic yielded an amount of 0.5 kilograms of CO2 equivalent per kilogram of that bio-based material. The use of fossil resources was calculated at 27 megajoules per kilogram of Proganic.

This means that if the production of PLA and PHB, in comparison with the production of petrochemical plastics, leads to lower greenhouse gas emissions and a lower use of fossil resources, this is also to be expected for Proganic itself, according to our calculations. Figure 1 shows can see the respective values marked with the asterisk.

Further results of the Meta-analysis Compared with bio-based plastics, petrochemical plastics have already come a long way in their development. For this reason one can assume that the learning curve for an efficient production of bio-based polymers in the coming years will rise to the same degree as the bio-plastics market is expected to grow.

Along with that, the need for research increases, particularly the need for advanced methods for assessing the environmental impact of bio-based polymers. In addition to the development of standards for taking into account the temporary storage of carbon in bio-based products, there is a lack of knowledge with regard to the impact of indirect changes in land use as well as the carbon dynamics on agricultural land. Sensitivity analyses and dynamic models can make a positive contribution to advancing the existing methods.

The results of the meta-analysis show that the environmental impact of biobased polymers also depends on the relevant renewable resource basis. The question of which renewable resources cause the lowest environmental impact, however, cannot be conclusively answered due to the inadequate data base.

But in general one can say that the use of by-products does improve the area efficiency of renewable resources and thus the life cycle assessment of biobased polymers. Here the use of agricultural by-products (e.g. corn straw, sugar cane bagasse, etc.) for the generation of process energy (heat, power) improves the life cycle assessment as well as their utilisation as an additional source of raw material (2nd generation biopolymers).

www.bio-based.eu/ecology www.nova-institut.eu www.proganic.de

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Methodology for the ecological assessment of bio-based and petrochemical plastics The life cycle assessment (LCA) method is used to analyse the ecological impacts of a production system; it is internationally standardised (ISO 14040). A meta-analysis of different life cycle assessments for bio-based polymers such as PLA and PHA, in contrast to looking at only one single life cycle assessment, makes it possible to give an overall view of the ecological ‘pros’ and ‘cons’ of the use of PLA and PHA in comparison with the use of polypropylene and other petrochemical based plastics.

A meta-analysis is a statistical method to define similarities and differences in the results of different studies and to analyse the reasons for their respective nature and extent. Due to the particular importance of the topics on the use of fossil resources and climate protection in the public debate, the content focus of the meta-analysis is restricted to two categories of ecological impacts.

Here the use of fossil resources is understood to include all fossil resources that are materially or energetically used for the production of the plastics (in MJ/kg). The greenhouse potential, expressed as CO2 equivalents per kilogram of plastics, serves as an indicator for climate protection.

The studies looked at are so-called ‘cradle to gate’ analyses, i.e. the environmental impacts looked at are analysed from the cradle (i.e. the cultivation of renewable resources) to the factory gate (i.e. preparation of plastic resin). So all subsequent phases of the product life cycle, such as the utilisation phase or the disposal phase, remain unconsidered in most of the studies.

In the meta-analysis conducted, more than 30 studies on the ecological assessment of the production (material and energy flows, preliminary products) of polylactides (PLA) and polyhydroxy fatty acids (PHA/PHB) were examined, evaluated and their results compared with one another.

That makes it possible to generalise statements and to draw reliable conclusions with regard to the strengths and weaknesses of the production systems analysed.

The impact categories looked at in the metaanalysis are the use of fossil resources and climate change. When looking at further impact categories, ecological drawbacks may also be revealed in the production of bio-based polymers – as is inevitable with any kind of industrial use of biomass, and already seen in the agricultural cultivation of renewable resources.

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Basics

Basics of the 14C method How to use radiocarbon dating to determine the biobased carbon content By Ann-Sophie Kitzler Hans-Josef Endres Andreas Schettler all University of Applied Sciences and Arts Hanover (Institute for Bioplastics and Biocomposites) and Michael Nelles University of Rostock, Department of Waste Management and Material Flow

C

arbon exists in nature in the form of three isotopes – carbon 12 (12C), carbon 13 (13C) and carbon 14 (14C) – which are present in the atmosphere in various proportions. 12C, at just about 99%, represents the majority, whilst 13C at something in excess of 1% is the second largest proportion. A 14C atom, statistically speaking, occurs only in trace amounts as about 1 part per trillion of the carbon in the atmosphere, yet is the key to radiocarbon dating [1].

C occurs in the upper atmosphere (lower stratosphere and upper troposphere). Cosmic radiation impacts on the atoms in the atmosphere and via a splintering (spallation) reaction liberates neutrons. In a further process such neutrons react with nitrogen (14N) and lead to a nuclear reaction. Here a proton breaks away and a 14 C atom is produced. After it has been formed, this atom, like other carbon isotopes, combines with the oxygen in the air and forms carbon dioxide. This carbon dioxide is distributed in the atmosphere and by photosynthesis finds its way into the biosphere. It is absorbed by plants and forms part of the food chain [1].

14

C, unlike 12C and 13C, is very unstable and is subject to radioactive break-up which produces low level Beta radiation. This reaction is the origin of the name “radiocarbon dating” and there are various research procedures that depend on this process [1].

14

The half-life of 14C, according to Willard Frank Libby, is around 5568 years (± 30) [2]. By the constant exchange of carbons from the atmosphere and the biosphere (plants and animals on the earth) we can assume a constant balance between the three isotopes, which is in line with that natural balance described above. This means that even in the so-called renewable resources the maximum possible 14 C content from the atmosphere is to be found. This content level decreases at a precise rate when the exchange of carbons due to a breakdown in biological activity occurs, i.e. when the metabolic process can no longer be followed, and the organism dies. The reduction in 14C, always in line with the half-life given above, is no longer compensated by new 14C formed in the atmosphere. Thus there is a change in the natural ratio of 12C to 14C [1, 3], within the biomass integrated in a no longer living metabolism.

This article is an excerpt of a longer version which is available for download at www.bioplasticsmagazine.de/201202

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This means that in fossil materials such as coal, petroleum, or natural gas, 14C is no longer contained because the material has been dead for a very long period of time. Thus the changes that have taken place in their natural condition allow conclusions to be drawn regarding the age of materials.

Cosmic Ray

Basics

Proton

N + n → 146C + p

14 7 Spallation Products

14

Thermal Neutron

C

Oxidation CO2

14

Photosynthesis

Disolved CO2 Carbonates Bicarbonates

Fig. 1: Graphic representation of the formation, distribution and breakdown of natural 14C, modified [2]

Description of the method Before any analysis can take place the sample has to be prepared. In the case of radiocarbon dating the sample is oxidised to form carbon dioxide by heating to a very high temperature. The resultant CO2 can now be further converted to suit the appropriate analysis method (for example into benzol), and for a method using mass spectrometry it can be reduced to pure carbon or fed directly to the Counter for analysis [3, 4].

Depending on the carbon content and the size of the sample there are two different methods specified by the standard for radiocarbon dating. The 14C content can be determined by counting the decomposing 14C atoms in the Counter (Liquid Scintillation-Counter (LSC)) in line with Libby or (preferred) the still available 14C atoms (Accelerator Mass Spectrometry (AMS). In the following we briefly describe the mass spectroscopy method.

About 0.5 - 0.7 grams of the test material is heated in a quartz sample vessel at 900°C for at least 2 hours. After cleaning the pure CO2 gas this is liquefied under cryogenic conditions (i.e. by liquid nitrogen at very low temperature) and fed, in a liquid state, into an AMS sample vessel.

The isotope ratios of 14C/12C and 13C/12C are calculated relative to a standard substance [4]. Here a figure of 0 pmC 14 C (pmC = percent modern carbon), means that the sample is a fossil carbon source whilst the reading of 100 pmC 14C points to the sample being a modern carbon source [4].

All of the chemicals required to purify the combustion gas, as well as the precise method and interim steps, can be found under the applicable standard (ASTM-D6866)

Examples of the application of 14C analysis Even though radiocarbon dating has its origins in determining the age of archaeological specimens (radioactive age determination) and thus is used for dating organic articles, it has now found applications in some very different fields of research. It can be used to identify works of art and fakes, or in the testing of foodstuffs, for example to differentiate synthetic, chemically identical, but not natural foods (such as aromas and fragrances, alcohols or carbon dioxide in sparkling wines and mousses.

It is also used for research and determination of the unique fingerprint of biobased raw materials in industrial products such as lubricants, cosmetics and plastics [2, 3]. Whilst

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B IO

when investigating lubricants an exact definition of mineral (fossil) and biogenic lubricants can be achieved, with cosmetics the differentiation between mineral and biological ingredients is often difficult. In all cases, by analysing the 14C content, conclusions can be drawn about the actual level of renewable (i.e. biological) ingredients. The determination of the level of biogenic materials in bioplastics is also based on analysis of the biogenic carbon level.

D > 85 ASE %

%

D2 ASE 0 - 50

%

B

SED 50 - 85 BA

IO

B

B

Basics

B IO

A common method here is as in the ASTM-D6866 standard [4], which is based on the same principle as radiocarbon dating without attempting to identify the age of the specimen and using the method aimed at measuring the biobased content of the materials [4]. In addition to the redrafting of the German packaging ordinance, which since 2005 has exempted certified compostable biopolymers that contain at least 75% renewable resources from the obligation to be accepted for return by the suppliers, in the recent past special regulations covering bioplastic have been increasing. In the future therefore, there will be more attention paid to the percentage of renewable resources used [5], which currently can be most accurately checked using the above standard.

Fig. 3: The DIN CERTCO quality logo for biobased products [6]

A weak point in the procedure lies in the fact that it supplies only data on the biogenic carbons without considering other substances such as hydrogen, oxygen or nitrogen. Thus a bioplastic filled with glass fibres qualifies as 100% biobased, as only the biobased carbon content is identified. Anorganic fillers of natural origin on the other hand (e.g. calcium carbonate) are classified as non-biobased materials since calcium carbonate contains no 14C [5].

A further difficulty is found in the evaluation of bioplastic blends.

This is due these days to the often very different carbon content of the components of the blend, so that in most cases it is not possible to make statements about the mass or weight percentage of renewable resources in the material directly from the biobased carbon content.

Using correction factors that are obtained from the carbon content of the individual materials, and using the empirical formula, it is a simple task to carry out the calculations, and so with little expense the actual mass of biogenic materials can be easily calculated.

For a comparison of a fully or partially biobased biopolymer this correction factor should always be considered when evaluating the 14 C measurement in order to ensure a genuine analogy of the values.

Only in this way can, for example, a comparable value for CO2 neutrality levels be achieved, because – to stay with the example of starch and PP – when burning PP, because of its structure, more CO2 is produced than by starch.

Figure 2 shows the total carbon content and a comparison of biobased with non-biobased carbon of a few examples of biopolymers according to 14C analysis.

Certification of the biogenic material content Fig. 4: The Vinçotte certification logo for biobased products [10]

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In parallel to establishing the method of measurement the special regulations regarding biobased plastics are constantly growing. This means that the materials or products made from renewable resources

Vinçotte also gives permission to use its certification logo stating the level of biogenic carbon in the product.

The crucial figure is indicated by the number of stars on the left-hand side of the logo. The levels are: 20 – 40% (1 star), 40 – 60% (2 stars), 60 – 80% (3 stars) and > 80% (4 stars). Again the percentage figure used indicates the biobased carbon level of the material [7, 9].

With both of these programmes only a voluntary certification is offered which the manufacturer may or may not wish to request. A unified guideline for the testing and certification of biobased products, as well as a unified evaluation of the materials, is currently planned at a national and international level, but has not yet been presented [11].

Additionally, at the current time the option is being discussed of using not only the ratio of the carbon isotopes to determine the biobased content, but also to use the isotope ratio of other elements such as oxygen, nitrogen and hydrogen. However a new standard must first be developed [11].

70 60 50 40 30 20

Bio-PE

Celluloseester

CA-Blend

Copolyester

Starch - PP - Blend

biobased not biobased

PBS

0

PLA

10 PLA-Copolyester-Blend

DIN CERTCO applies a double minimum standard in the certification procedure of each product. This is, on the one hand, a minimum level of organic material which is determined by loss on ignition, and which must not be less than 50%, as well as a minimum content of biobased carbon that must be more than 20%. If this latter figure is not reached a statement is supplied confirming the biogenic carbon content, and a ‘registration of a biobased product’ with a biobased content of < 20% (without the certification logo, symbol, or label) is issued [6, 8].

80

PHB

DIN CERTCO supplies so-called ‘Quality logos for biobased products’, at various levels: 20-50%, 50-85%, > 85%, whereby the figure used relates to the biobased carbon content [6].

90

PVLA

So far, in Europe, this has been possible through only with two certification offices, namely DIN CERTCO (Germany) and Vinçotte (Belgium). With both companies the 14C analysis method presented here for checking the percentage of biogenic material is in line with ASTM 6866 and indicates on the certification logo the level of biobased carbon [6, 7].

100

Gesamt-Kohlenstoffanteil [%]

are being increasingly tested for their content of biogenetic material and are also being appropriately certified.

Fig. 2: Percentages of biobased and non-biobased carbon content within the total carbon content of various bioplastic molecules

References [1] S. Bowman, Radiocarbon dating, University of Carlifornia Press, 1990.

[2] L. A. Currie, The remarkable metrological history of radiocarbon dating (II), Bd. Journal of Research of the National Institute of Standards and Technology, Gaithersburg, U.S.A.: National Institute of Standards and Technology, 2004.

[3] TÜV Rheinland, 2011. [Online 2011] http://www.agroisolab.de/de/unterscheidung_biogen_fossil.html [4] ASTM-D6866-04, Standard Test Methods for determing the biobased Content of natural range Materials using radiocarbon and isotope radio mass spectrometry analysis, West Conshohocken, United States: ASTM International, 2004.

[5] Endres, Hans-Josef; Siebert-Raths, Andrea, Technische Biopolymere, München: Carl Hanser Verlag, 2009.

[6] DIN CERTCO, „Zertifizierungsprogramm biobasierter Produkte nach ASTM 6866,“ November 2010. [Online 2011] www.dincertco.de [7] Vincotte, „Certification - C14 Dating Method,“ 2011. [Online 2011] http://www.okcompost.be, Dokumentation [8] DIN CERTCO, [Online 2011] www.dincertco.de [9] Vincotte, „Zertifizierung - OK biobased und Gebrauch der Logos,“ 2011. [Online 2011] http://www.okcompost.be, Dokumentation [10] Vincotte, [Online 2011] http://www.okcompost.be [11] DIN CERTCO, „Zertifizierung von biobasierten Produkten,“ November 2010. [Online2011] http://www.dincertco.de [12] B. Kromer, „Bestimmung des fossilen Kohlenstoffanteils mit 14C,“ Heidelberger Akademie der Wissenschaften, Heidelberg, 2009.

[13] P. Becker-Heidmann, Die Tiefenfunktionen der natürlichen Kohlenstoff-Isotopengehalten von vollständige dünnschichtweise beprobten Parabraunerden und ihre Relation zur Dynamik der organschen Substanz in diesen Böden; Dissertation, Hamburg: Hamburger Budenkundliche Arbeiten, 1989.

[14] W. T. Hering, Angewandte Kernphysik: Einführung und Übersicht, Stuttgart, Leipzig: Teubner Verlag, 1999.

[15] Universität Erlangen, [Online 2011] http://www.14c.uni-erlangen.de [16] Beta Analytic Inc., „Explanation of results - biobased Analyses unsing ASTM-D6866-11,“ Miami, 2011.

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Basics

The thermoforming process By Martin Barth Illig GmbH & Co. KG Heilbronn, Germany

B

ased on several process steps, thermoforming allows the production of a dimensionally stable plastic part made from semi-finished products. At increased temperature, molded parts are created from semi-finished products, i.e., from thermoplastic plastic sheets or roll-fed material.

There are different heating-up methods for heating the semi-finished products in the thermoforming process [1].

Infrared radiation by means of ceramic, quartz or halogen heater elements is applied as the universal heating-up method in most cases.

The forming process of the semi-finished product takes place in the rubbery-elastic area, the so-called forming temperature [2]. The deformation of the semi-finished product is reached by pressure difference as well as partly by mechanical support [1]. Mechanical pre-forming is carried out by a pre-stretcher leading to a better material distribution in the cavity. The later shape of the molded part will then be reproduced by feeding compressed air or vacuum. The component geometry is given by a one-sided tool. Once the semi-finished product has taken on the contour of the cold tool, the oriented molecular chains freeze in their stretched position, thus under mold constraint, and the formed plastic retains its shape [3].

Demolding of the thermoforming product takes place by the holding forces on the clamping when opening the tool and/or by ejectors in the tool. If several molded parts like cups are formed from a larger semi-finished product, these will be punched out afterwards. The skeletal is what remains as production waste.

Compared to other plastics processing procedures like injection molding technique, the thermoforming process offers many advantages [1]. Due to the low process forces, even large components are relatively easy to produce. In consequence of the low forming pressures and the only onesided tools, the machine and tool costs are considerably lower for the thermoforming process. In particular for small quantities, wooden tools or plastics that can be easily processed are used. The series tools mostly consist of

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Basics (Source: CustomPartNet)

temperature-controlled aluminum. Through the use of multilayer semi-finished products, the properties of a thermoforming product can easily be influenced. This allows the realization of the best possible individual solution for each packaging.

The open process control shows the limits of the procedure.

This makes the molding production prone to external changes.

Through the use of only flat semi-finished products, no custom parts of mold can be produced and there will always be a wall thickness reduction.

In principle, all thermoplastic polymers can be processed with the thermoforming method. Amorphous thermoplastics have a higher softening temperature than semi-crystalline thermoplastics [4]. The processing of semi-crystalline thermoplastics requires precise process control. As a result, only a few semi-crystalline thermoplastics are applied in the thermoforming process, e. g., PP, PE, and PET [4], but also for example, PLA. Among the most frequently processed amorphous thermoplastics are PVC, PS, ABS, SAN, PMMA, PC and A-PET [5]. Furthermore, composite materials are used as multi-layer films as well as fiber-reinforced semi-finished products and foamed semi-finished products. The production of various packaging, e. g., yoghurt cups and trays in the food sector is a major field of application for the thermoforming process. Thin semi-finished products < 2 mm in the form of rolls are the material the packaging industry usually processes.

The material proportion of the product’s total costs may be 80 – 90 %, here [6].

There are many other applications exceeding the mere processing of semi-finished products into packaging. A closer look reveals that this forming technology is applied across almost all industries and areas of daily life, be it in the fridge, in the car, for furniture, in the building sector as facing or light dome, as surfboards, swimming pools or as a hull. In addition, the machine building industry produces cover parts or it packs its spare parts by using thermoforming – and flower pots for the hobby gardener or complete garden ponds are also created on thermoforming lines.

References: [1] Weinand, D.: Modellbildung zum Aufheizen und Verstrecken beim Thermoformen; Dissertation, IKV, RWTH Aachen (Aachen University), (1987).

9, (1993), p. 293-305.

[2] Brinken, F.: Untersuchung zum Wärmeübertrag beim Thermoformen von Thermoplasten; Dissertation, Faculty of Mechanical Engineering, RWTH Aachen (Aachen University), (1979).

[3] Hegemann, B.: Deformationsverhalten von Kunststoffen beim Thermoformen, experimentelle und virtuelle Bestimmung; Dissertation, IKP, Stuttgart University, (2004).

[4] Howery, M. F.: Material selection for thermoforming applications; Annual Technical Conference Proceedings (ANTEC), (1997).

[5] Beilharz, F.: Einfluss der Herstellungsbedingungen von PPHalbzeugen auf die Thermoformeigenschaften; Dissertation, IKT, Stuttgart University, (2010) [6] Albert, K. A., et al.: Acrylic modified polypropylene for thin-gauge thermoforming: Improved processing properties and economics; Journal of Plastic Film and Sheeting [7] Schwarzmann, P.: Thermoformen mit Universalmaschinen, Adolf Illig Maschinenbau GmbH & Co., (2000).

[8] Schwarzmann, P.: Thermoformen in der Praxis, Adolf Illig Maschinenbau GmbH & Co., (2008).

www.illig.de

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Basics

Thermoforming of bioplastics

B

efore the first bioplastics entered the market in significant quantities and qualities a few years ago, the industry no longer relied on the development of new plastic types over decades, but only on the production of polymer blends with the objective of maintaining the respective advantages and of eliminating the disadvantages. The ‘sustainability’ by reducing the thickness of mouldings was at the expense of the reduced recyclability of such multi-layer composite materials. Now, with the availability of new bioplastics, it is the task of the producers of extruded films and sheets, as well as of thermoformers, to ensure the processing methods, and this is where some, partly significant, differences arise compared to conventional plastics.

Up until now bioplastics have been used as a replacement for conventional packaging, which means that they have to meet the requirements of the packaging industry. This is achieved by multi-layer structures, the use of special additives, but also by admixing non-bio materials. The knowledge acquired over the years when blending plastics helps in obtaining good and fast results.

Today’s modern thermoforming machines offer a maximum possibility to meet the widely varying requirements of bioplastics.

During the processing of bioplastics it is essential to deal with issues which did not arise during the processing of conventional thermoforming materials.

In terms of quantity, the most commonly used bioplastic is PLA. Already in 1995, ILLIG GmbH & Co. KG (Heilbronn, Germany) conducted the first thermoforming tests with PLA films. In 1996, the first household containers with lids formed on an Illig-RDKP 72d were presented at Interpack in Düsseldorf, Germany. In both cases, the films came from OFoTec Folien GmbH (Nehren, Germany), the raw material from the first plant was provided by Cargill, USA. Processing in a thermoforming machine does not cause any problems for current raw material qualities. The producers have done their homework and the initial difficulties have been eliminated.

Large dairies like Danone rely on PLA for their bio-packaging

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plastics. Since these products are mostly sold via the cold chain, the low heat deflection temperature of standard PLA imposes no limitations.

Through the use of a silicone layer on the film, the low shrinkage of PLA film can be compensated for by better demouldability, as well as stack- and de-stackability. In addition, a reduction of the brittleness is possible with appropriate additives (see other articles in this issue).

Thus, impact modifiers have already been added to Ofotec’s first films.

It is generally possible to use the same tools that are used for commodities, also without preheating. Depending on the type of the moulded part, the mould temperatures can be lower than in case of polystyrene (PS).

The poor thermal properties of standard PLA limit the range of possible applications. However, at present, there are small test quantities being developed with the objective of producing stereocomplex versions created with defined parts of L- and D-lactic acid. The developments with regard to specialties do not yet allow a large-scale operation in the packaging arena. Illig will be there when such versions are considered for testing.

There are different scenarios for the waste issue. In principle, production waste such as punch scrap and rejects can be ground up and fed back to the production process (film extrusion). However, Ofotec has also processed punch scrap into foam sheets, even though there is still a significant lack of applications.

The highest rates of growth are attributed to bioplastic PHA (PHB). The properties are ideal for their use as packaging plastics. The high temperature stability, the FDA approval, detailed reproduction accuracy/forming sharpness all make the plastics an excellent choice for higher temperature-stable packaging. A special feature is the minimum demoulding temperature which has to be adhered to. While the well-known thermoplastics follow the rule that “the colder the conditions for demoulding of the moulded part, the more dimensionally

Basics

by Martin Barth Illig GmbH & Co. KG Heilbronn, Germany Ekkehard Adam OFoTec-Folien GmbH Nehren, Germany

stable it will be”, these plastics have to be removed from the tool with a minimum residual heat. The new plastics used require a high crystallinity which ensures sufficient stability when using it. If the crystallization stage is passed through too quickly during the cooling process in the thermoforming machine, too few crystals arise and the plastic becomes very soft. If the moulded part is demoulded at a temperature above 60° C, crystals can begin to form over a longer period which leads to the desired stability. During processing the film tends to stick. This does not cause a problem with regard to the processing on an automatic roll-fed thermoformer where the film, held at the side by pins, is fed through the plant in chains.

However, the processing on form-fill-seal lines is prevented.

This machinery uses contact heating and this would directly stick to the plastics. The final stability of the thermoformed article is only reached after a few days. This means that the products require “Do not process before …” information.

reviewed to what extent possible changes of the settings in the automatic thermoforming machines are necessary and/or to what extent cycle times or stacking methods have to differ.

Here, too, Ofotec was once again the partner and presented appropriate films. All-purpose tools have been applied as well as tray tools which are normally used to process PP films.

Many types of bioplastic, mainly the starch-based ones, can only be used if they include a defined water content. Due to the moisture, the thermoformed articles become ready to use and do not break on being subjected to the smallest load. But precisely this moisture level makes the processing with the well-known parameters of conventional plastics impossible.

The water immediately begins to evaporate, forming blisters on the surface. In such cases, the thermoforming machine must be equipped with a special heating control.

There will be no universal solution when it comes to processing, but rather a lot of possibilities and challenges.

Further development of thermoforming machines towards designing all-purpose machines for all thermoplastically processable plastics will ensure that it is possible to respond to any special aspects that may arise. Sophisticated machine technology, used here in some cases, is not only limited to the thermoforming machine and its tools regarding longitudinal and transverse stretching as well as temperature control of the transport chains, but it also covers additional components like regular and continuous unwinding from the roll, gentle stacking, a skeletal granulator adapted for smooth materials and a precisely adjustable punching technique. The central role is assigned to the heating. Unlike conventional thermoforming materials, an extremely accurate temperature control is necessary. In many cases, there are only a few degrees between ‘still too cold for processing’ and ‘decomposition is beginning’.

A very interesting plastic material for technical applications is manufactured by Tecnaro. Their plastics, based on lignin, offer ideal properties for thermoforming with highest precision on sheet processing machines.

Based on the company’s environmentally aware thinking, Illig is not limited solely to a possible reduction of film thicknesses for material and thus resource saving and to the applicability of PLA films. Together with Ofotec, Illig devotes itself to the use of green HDPE made from sugar cane based bioethanol. This material can be recycled according to the established and proven procedures.

Illig also takes care of these new materials. It should be

It became apparent that the direct change from one film type to another is possible. This applies to unreinforced films.

However, in the meantime, Ofotec is also working on highly filled versions. Here, the content of the plastics used – even though already renewable – is to be stretched with mineral filling for a further increase of the sustainability level. In this case the film can be heated more easily because the mineral filler has the task of transporting the heat inside the film and thus to distribute it more evenly. However, during the punching process, caution is advised and an optimization may be necessary. Promising tests are under way.

www.illig.de www.ofotec.de

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Suppliers Guide 1. Raw Materials 10

20

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

30

40

GRAFE-Group Waldecker Straße 21, 99444 Blankenhain, Germany Tel. +49 36459 45 0 www.grafe.com

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

50

Simply contact:

Tel.: +49 2161 6884467

60

suppguide@bioplasticsmagazine.com 70

Stay permanently listed in the Suppliers Guide with your company logo and contact information.

80

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

90

For Example: 100

120

130

39 mm

110

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

140

Sample Charge: 150

160

39mm x 6,00 € = 234,00 € per entry/per issue

DuPont de Nemours International S.A. 2 chemin du Pavillon 1218 - Le Grand Saconnex Switzerland Tel.: +41 22 171 51 11 Fax: +41 22 580 22 45 plastics@dupont.com www.renewable.dupont.com www.plastics.dupont.com

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!

1.1 bio based monomers

Grabio Greentech Corporation Tel: +886-3-598-6496 No. 91, Guangfu N. Rd., Hsinchu Industrial Park,Hukou Township, Hsinchu County 30351, Taiwan ® Natur-Tec - Northern Technologies sales@grabio.com.tw 4201 Woodland Road www.grabio.com.tw Circle Pines, MN 55014 USA Tel. +1 763.225.6600 1.5 PHA Fax +1 763.225.6645 info@natur-tec.com www.natur-tec.com

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

Sample Charge for one year: 6 issues x 234,00 EUR = 1,404.00 €

170

180

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.

190

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

200

www.cereplast.com US: Tel: +1 310.615.1900 Fax +1 310.615.9800 Sales@cereplast.com Europe: Tel: +49 1763 2131899 weckey@cereplast.com

210

220

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

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

240

www.facebook.com www.issuu.com

260

www.twitter.com 270

58

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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

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 sales@aandofilmpac.com www.bioresins.eu

1.3 PLA

230

250

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

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

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

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

Suppliers Guide 1.6 masterbatches

GRAFE-Group Waldecker Straße 21, 99444 Blankenhain, Germany Tel. +49 36459 45 0 www.grafe.com

4. Bioplastics products

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

WEI MON INDUSTRY CO., LTD. 2F, No.57, Singjhong Rd., Neihu District, Taipei City 114, Taiwan, R.O.C. alesco GmbH & Co. KG Tel. + 886 - 2 - 27953131 Schönthaler Str. 55-59 Fax + 886 - 2 - 27919966 D-52379 Langerwehe sales@weimon.com.tw Sales Germany: +49 2423 402 110 www.plandpaper.com Sales Belgium: +32 9 2260 165 Sales Netherlands: +31 20 5037 710 info@alesco.net | www.alesco.net

3.1 films

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

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

2. Additives/Secondary raw materials

Arkema Inc. Functional Additives-Biostrength 900 First Avenue King of Prussia, PA/USA 19406 Contact: Connie Lo, Commercial Development Mgr. Tel: 610.878.6931 connie.lo@arkema.com www.impactmodifiers.com

GRAFE-Group Waldecker Straße 21, 99444 Blankenhain, Germany Tel. +49 36459 45 0 www.grafe.com

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

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

Rhein Chemie Rheinau GmbH Duesseldorfer Strasse 23-27 68219 Mannheim, Germany Phone: +49 (0)621-8907-233 Fax: +49 (0)621-8907-8233 bioadimide.eu@rheinchemie.com www.bioadimide.com

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

Cortec® Corporation 4119 White Bear Parkway St. Paul, MN 55110 Tel. +1 800.426.7832 Fax 651-429-1122 info@cortecvci.com www.cortecvci.com

Eco Cortec® 31 300 Beli Manastir Bele Bartoka 29 Croatia, MB: 1891782 Tel. +385 31 705 011 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 esmy@minima-tech.com 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

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 6. Equipment 6.1 Machinery & Molds

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

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

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

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Suppliers Guide 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

9. Services

Osterfelder Str. 3 46047 Oberhausen Tel.: +49 (0)208 8598 1227 Fax: +49 (0)208 8598 1424 thomas.wodke@umsicht.fhg.de www.umsicht.fraunhofer.de

10.2 Universities

Bioplastics Consulting Tel. +49 2161 664864 info@polymediaconsult.com 10. Institutions 10.1 Associations

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

7. Plant engineering

Uhde Inventa-Fischer GmbH Holzhauser Strasse 157–159 D-13509 Berlin Tel. +49 30 43 567 5 Fax +49 30 43 567 699 sales.de@uhde-inventa-fischer.com Uhde Inventa-Fischer AG Via Innovativa 31 CH-7013 Domat/Ems Tel. +41 81 632 63 11 Fax +41 81 632 74 03 sales.ch@uhde-inventa-fischer.com www.uhde-inventa-fischer.com

Institut für Kunststofftechnik Universität Stuttgart Böblinger Straße 70 70199 Stuttgart Tel +49 711/685-62814 Linda.Goebel@ikt.uni-stuttgart.de www.ikt.uni-stuttgart.de

narocon Dr. Harald Kaeb Tel.: +49 30-28096930 kaeb@narocon.de www.narocon.de

8. Ancillary equipment

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

University of Applied Sciences Faculty II, Department of Bioprocess Engineering 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

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

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

New ‘basics‘ book on bioplastics This new book, created and published by Polymedia Publisher, maker of bioplastics MAGAZINE will be available from early April 2012 in English and German language.

The book is intended to offer a rapid and uncomplicated introduction into the subject of bioplastics, and is aimed at all interested readers, in particular those who have not yet had the opportunity to dig deeply into the subject, such as students, those just joining this industry, and lay readers. It gives an introduction to plastics and bioplastics, explains which renewable resources can be used to produce bioplastics, what types of bioplastic exist, and which ones are already on the market. Further aspects, such as market development, the agricultural land required, and waste disposal, are also examined.

An extensive index allows the reader to find specific aspects quickly, and is complemented by a comprehensive literature list and a guide to sources of additional information on the Internet.

The author Michael Thielen is editor and publisher bioplastics MAGAZINE. He is a qualified machinery design engineer with a degree in plastics technology from the RWTH University in Aachen. He has written several books on the subject of blow-moulding technology and disseminated his knowledge of plastics in numerous presentations, seminars, guest lectures and teaching assignments.

110 pages full color, paperback ISBN 978-3-9814981-1-0: Bioplastics ISBN 978-3-9814981-0-3: Biokunststoffe

Pre-order now for € 18.65 or US-$ 25.00 (+ VAT where applicable, plus shipping and handling, ask for details) order at www.bioplasticsmagazine.de/books, by phone +49 2161 6884463 or by e-mail books@bioplasticsmagazine.com

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bioplastics MAGAZINE [01/12] Vol. 7

Events

Event Calendar 19.06.2012 - 20.06.2012

18.04.2012 - 21.04.2012 www.chinaplasonline.com

Biobased materials WPC, Natural Fibre and other innovative Composites Congress

23.04.2012 - 24.04.2012

www.nfc-congress.com

Chinaplas 2012

Fellbach, near Stuttgart, Germany

Biopolymer World Congress

05.09.2012 - 06.09.2012

NH Laguna Palace Hotel, Mestre-Venice (Italy) www.biopolymerworld.com

naro.tech 9th International Symposium

25.04.2012 - 26.04.2012

www.narotech.eu

Erfurt, Germany

Durable Bioplastics

02.10.2012 - 04.10.2012

Minneapolis, MN, USA

BioPlastics – The Re-Invention of Plastics

www.infocastinc.com/bioplastics12

Las Vegas, USA Caesars Palace Hotel

08.05.2012 - 09.05.2012

Bioplastics Compounding & Processing

www.InnoPlastSolutions.com

The Hilton Downtown Miami, Miami, Florida, USA www.amiplastics-na.com

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

09.05.2012 - 10.05.2012

5. BioKunststoffe

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

Hannover, Germany

www.hanser-tagungen.de/biokunststoffe

10.05.2012 - 11.05.2012

2nd Congress on Biodegradable Poplymers Packaging Milano, Italy Centro Congressi Fiera di Milano – Rho www.biopolpack.unipr.it/preregistration.htm

• International Trade in Raw Materials, Machinery & Products Free of Charge

14.05.2012 - 18.05.2012

SPE Bioplastic Materials Conference Seattle, Washington USA Renaissance Seattle Hotel www.4spe.org

May 15-16, 2012

2nd PLA World Congress presented by bioplastics MAGAZINE

Holiday Inn City Center, Munich Germany www.pla-world-congress.com

23.05.2012 - 24.05.2012

6th Bioplastics Markets Bangkok, Thailand

www.cmtevents.com/register.aspx?ev=120523&

13.06.2012 - 15.06.2012

BioPlastics: The Re-Invention of Plastics

• Daily News from the Industrial Sector and the Plastics Markets

C

M

• Current Market Prices for Plastics.

Y

CM

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

MY

CY

CMY

K

er.com lastick www.p

San Francisco, USA Hilton - Downtown

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

l ssiona • Profe t s a F date • Up-to-

www.BioPlastix.com You can meet us!

Please contact us in advance by e-mail.

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Companies in this issue Company

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bioplastics MAGAZINE [02/12] Vol. 6

Editorial Advert

Company

Editorial Advert

Company

Editorial Advert

2nd PLA World

C o n g r e s s

15 + 16 MAY 2012 * Munich * Germany

The 2nd PLA WORLD CONGRESS... ... is this spring’s ‘must-attend’ event for all who are interested in or even already workig with PLA.

Register now:

bioplastics MAGAZINE is now organising this unique meeting for the second time now, after the ‘kick-off’ PLA World Congress in 2008.

Experts from all involved fields will share their knowledge and contribute to a comprehensive overview of today‘s opportunities and challenges and discuss the possibilities, limitations and future prospects of PLA for all kind of applications. Together with a table top exhibition the unique congress offers best opportunities to meet new contacts or refesh existing ones. Benefit from the various networking possibilities!

The 2 full-day-conference will be held on the 15th and 16th of May 2012 in the Holiday Inn Munich City Centre in the beautiful town of Munich, Germany.

The 2nd PLA World Congress is the must-attend conference for everyone interested in PLA, its benefits, and challenges.

Register now to reserve your seat for just € 899,00 + VAT

www.pla-world-congress.com

Tel.: +49 (2161) 6884469

The conference will comprise high class presentations on Latest developments Market overview High temperature behaviour Barrier issues Additives / Colorants Applications End of life options Online registration is open at www.pla-world-congress.com

A real sign of sustainable development.

There is such a thing as genuinely sustainable development.

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

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

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

Inventor of the year 2007

Within Mater-Bi® product range the following certifications are available

The “OK Compost” certificate guarantees conformity with the NF EN 13432 standard (biodegradable and compostable packaging) 3_2012