bioplastics MAGAZINE 01/2013

01 | 2013

ISSN 1862-5258

January / February

Cover-Story

bioplastics

magazine

Vol. 8

Bioconcept Car | 10

Highlights Automotive | 10 Foam | 26

Basics PTT | 44

1 countries

... is read in 9

Pick and choose – We have the solution you need!

Pick and choose from the huge product-portfolio

Bio-Flex®

– Biodegradable Compounds for blown films

of biodegradable, compostable and biobased

Biograde®

– Biodegradable plastics for injection moulding

plastics. We provide you with the perfect solution

Fibrolon®

– Natural fibre reinforced plastics

for your flexible or durable application. Join in our

Terralene®

– Biobased Compounds based on Green PE

commitment for sustainable solutions, by using plastics made by nature!

Green PE

Polyethylene made from renewable resources

For more information, visit www.fkur.com • www.fkur-biobased.com

Editorial

dear readers The automotive industry and foam, usually the highlights of our first issue each year, are again the main topics in this issue, rounded off by industry news, applications news, and a ’basics’ article on PTT polytrimethylene terephthalate, an interesting polyester material...

Once in a while … we find information about developments that are not exactly ‘bioplastics’ products or processes. However, sometimes we find them interesting enough to publish in our magazine.

In this issue for example, there is the article about the Alginate Foams … but see yourself.

Once in a while … we also stumble over products, ideas or developments that do not exactly represent industrially relevant bioplastics products (or do they?). However, some seem very interesting or represent food for further thought, and so we do not want to hold them back. One example is the edible lamp on page 43.

Once in a while … I’m asked about our cover girls, and whether we want to continue this. Some readers suggested sometimes having men on the cover, others suggested bioplastics products. Well, after a product (albeit a ‘girl’) on our last issue’s cover page, we now have a man. By the way it is the third man since the beginning of bioplastics MAGAZINE in 2006. I think we’ll continue this way. Please share your opinion with me, if you wish …

And last but not least: Once in a while we organize conferences.

And this year it will again be a series of three Bioplastics Business Breakfasts B³ during the ‘K-Show’ in Düsseldorf. On October 17th, 18th, and 19th we will again be hosting our mini-symposiums, succinct and to the point, from 8am to 12 noon on the fairgrounds. See page 9 for some first info. ‘Call for Papers’ is open, and we are looking forward to your proposals.

Follow us on twitter! www.twitter.com/bioplasticsmag

Until then, we hope you enjoy reading bioplastics MAGAZINE Be our friend on Facebook! www.facebook.com/bioplasticsmagazine

Sincerely yours Michael Thielen

bioplastics MAGAZINE [01/13] Vol. 8

3

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

Photo: Michael Thielen

Cover

A part of this print run is mailed to the readers wrapped in bioplastic envelopes sponsored by Minima Technology (Taiwan)

Envelopes

Editorial contributions are always welcome.

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

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

The fact that product names may not be identified in our editorial as trade marks is not an indication that such names are not registered trade marks.

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

January/February

bioplastics MAGAZINE is read in 91 countries.

01|2013

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

ISSN 1862-5258 bM is published 6 times a year.

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

bioplastics magazine

Tรถlkes Druck + Medien GmbH 47807 Krefeld, Germany Print run:4,400 copies

Print

Elke Hoffmann, Caroline Motyka phone: +49(0)2161-6884467 fax: +49(0)2161 6884468 eh@bioplasticsmagazine.com

Media Adviser

Polymedia Publisher GmbH Dammer Str. 112 41066 Mรถnchengladbach, Germany phone: +49 (0)2161 6884469 fax: +49 (0)2161 6884468 info@bioplasticsmagazine.com www.bioplasticsmagazine.com

Head Office

Julia Hunold, Christos Stavrou Mark Speckenbach

Layout/Production

Dr. Michael Thielen (MT) Samuel Brangenberg (SB) contributing editor: Dr. Thomas Isenburg (TI)

Publisher / Editorial

Imprint Content

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

News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 - 09

Application News. . . . . . . . . . . . . . . . . . . . . . . . 42 - 44

Event Calendar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Suppliers Guide. . . . . . . . . . . . . . . . . . . . . . . . . 54 - 56 Companies in this issue . . . . . . . . . . . . . . . . . . . . . 58

Events 07 InnoBioPlast

Cover Story 10 Mobility of the future

Automotive 14 Biobased polymers for automotive safety components

18 Natural fibre composites

22 Ford Motor Company

24 Bio-PET fibres for Nissan electric vehicle

Foam

26 Durable and eco-friendly foams

28 High temperature resistant PLA foams

30 Cellulose-based polymer foams

32 Alginsulate foam

34 Bioplastic substrates in horticulture and agriculture 40 ReBioFoam Project

Materials

38 Biocomposite uses Green PE

38 Copolyester for consumer electronics

From Science and Research

45 Efficient drug release by an absorbable foam

Basics

46 PTT

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

News

100% renewable polyols Piedmont Chemical, headquartered in High Point, North Carolina, USA recently announced a new offering of renewable, sustainable polyester polyols – building-block chemical intermediates used in the production of urethane foams, coatings, adhesives and sealants. Piedmont combines Susterra® propanediol (Bio-PDO) from DuPont Tate & Lyle Bio Products (DTL, a 50/50 JV of DuPont and Tate & Lyle, headquartered in Loudon, Tennessee, USA) with Bio-Succinic Acid from Myriant Corporation (Quincy, Massachusetts, USA) to produce highpurity, 100% bio-based polyols that are functionally equal and cost-competitive with petroleum-derived polyols without requiring green-price premiums. The technical specification and polyol samples were announced to be available by the end of 2012 for urethane producers looking to utilize green polyols for their end-market applications.

The novel polyol formulations combining Susterra BioPDO and Bio-Succinic will specifically address the growing global demand for renewable urethanes (and thus renewable polyols) in industrial applications. Industrial applications, including paints and coatings, adhesives and sealants, and

microcellular elastomers, represent the single largest enduse sector for polyols.

DTL commercially produces Susterra in Loudon, with a capacity of 63,500 tonnes per year. The plant has been operational since November 2006. Myriant will begin commercial production of Bio-Succinic Acid in first quarter 2013 in Lake Providence, Louisiana, USA, with a capacity of 13,600 tonnes per year.

Under a strategic collaboration between Piedmont, DTL and Myriant, the three companies have agreed to an open innovation concept by which the polyol formulations will be made available to polyol producers and the urethane industry at large. This means that polyol customers will be able to purchase polyols produced from DTL’s Susterra Bio-PDOand Myriant’s Bio-Succinic Acid from Piedmont as well as from other polyol producers. Piedmont will manufacture the initial polyol product samples and will offer commercial supply of the polyol products to the market. MT www.myriant.com www.duponttateandlyle.com

BioAmber collaborating with Faurecia and Mitsubishi Chemical for automotive bioplastics BioAmber, Minneapolis, Minnesota, USA will be the supplier of biobased succinic acid to a Faurecia-Mitsubishi Chemical partnership for the production of automotive plastics. Faurecia (headquartered in Nanterre, France) has been conducting research into bioplastics derived from 100% natural materials since 2006 (BioMat project) and has now signed an exclusive industrial partnership agreement with Mitsubishi Chemical Corporation (head office: Chiyoda-ku, Tokyo, Japan) to co-develop bioplastics designed for mass-production for use in automotive interiors. Faurecia plans to develop a full range of bioplastics, which are set to see a boom in the 2015 to 2020 period.

The objective of the joint Faurecia-Mitsubishi Chemical program is to develop a polymer that can be used in mass-production for automotive interior parts (door panel trim strip, structural instrument panel and console inserts, air ducts, door panel inserts, etc.). The joint development will start by modifying Mitsubishi Chemical’s patented biomass-derived

poly-butylene succinate (PBS) and ultimately target to be produced from 100% bio sources. BioAmber will be the supplier of bio-based succinic acid to the partnership. Under the terms of the agreement, Faurecia will hold exclusive rights to automotive applications of the specific polymers jointly developed under this project. This project builds on several years of development work carried out jointly with BioAmber, the leading specialist in bio-based succinic acid technology.

The agreement will enable three market leaders to pool their respective strengths: Faurecia, no. 1 worldwide in automotive interiors, Mitsubishi Chemical Corporation, one of the world’s largest chemical companies and BioAmber, a pioneer in the production of bio-based succinic acid. MT

www.mitsubishichem-hd.co.jp/english www.faurecia.com www.bio-amber.com

bioplastics MAGAZINE [01/13] Vol. 8

5

News

New strategic partnership Bio Base Europe Pilot Plant, based in Ghent and nova-Institute from Hürth, Germany announced in mid-January their strategic partnership in the biobased economy. The unique offer for development and scale-up of biobased products and processes by the Bio Base Europe Pilot Plant is now complemented with the economic and environmental analysis of novel processes by nova-Institute.

Plant for the choice of feedstock, the life cycle analysis of the novel product, a marketing strategy, the development of a scalable process, the production of the first sample material for application testing and the custom manufacturing of the first tonnes of product to enter the market.

The development of products from sustainable resources and processes too often fails to step out of the research laboratories.

nova-Institute’s managing director Michael Carus: “Together we can support biobased innovation from the lab scale to commercial scale and markets. Techno-economic and environmental evaluations are an invaluable tool to steer pilot plant processing and optimizations.“ MT

Now companies and research institutes can rely on the expertise of the nova- Institute and the Bio Base Europe Pilot

www.nova-institute.eu www.bbeu.org

Altuglas and NatureWorks launch marketing collaboration Altuglas International, a subsidiary of Arkema group, with its Plexiglas® and Altuglas® acrylic resins (Americas and Rest of World, respectively) and NatureWorks, a leader in the bioplastics market with its Ingeo™ PLA biopolymers, have signed a global co-marketing agreement. The agreement is designed to deliver a range of newly formulated bio-based, high performance alloys based on polymethylmethacrylate (PMMA) and polylactic acid (PLA).

The new materials will be marketed by Altuglas International as Plexiglas/Altuglas Rnew biopolymer alloys. Primary co-marketing efforts for these materials will be for durable goods applications.

The agreement grew out of the response the two companies experienced during the NPE trade fair in Orlando, Florida, USA last April, during which they jointly displayed examples of molded and thermoformed products made with their collaborative technologies for the durable goods market.

This unique range of resins affords customizable formulating latitude providing exceptional impact- and chemical-resistance properties. In addition, the resins offer a significantly reduced carbon footprint due to the Ingeo PLA biopolymer content. These biopolymer alloys also feature lower processing temperatures and greater melt flow properties without compromising the optics, scratch resistance, color acceptance or surface aesthetics for which the Plexiglas and Altuglas brands are known.

The collaboration offers a combination of properties especially for durable applications such as signage, lighting, consumer products, transportation, cosmetic packaging and large and small appliances.

6

bioplastics MAGAZINE [01/13] Vol. 8

“What makes this agreement so exciting is that two renowned, pioneering organizations are joining forces to combine some of the best in technology and market knowledge to foster new, high performing, yet sustainable, bio-based products,” said Christophe Villain, Altuglas International president. “The agreement between these two leading companies will provide transparent, sustainable materials that meet durable application performance requirements. Altuglas International will compound and sell the Rnew portfolio, incorporating Ingeo, directly into the market.”

Marc Verbruggen, NatureWorks president and CEO said, “By combining our respective reputations and strengths in biopolymers and acrylics, NatureWorks and Altuglas International will co-market clear materials that offer a complete package of innovative product performance. This is exactly what Ingeo was designed to offer.”

Through the collaboration, Altuglas International and NatureWorks will pool resources to accelerate the introduction of these new high performance biopolymer alloys into the market. MT

www.altuglasint.com www.natureworksllc.com

Events

InnoBioPlast 2013

T

he National Innovation Agency (NIA), Thai Ministry of Science and Technology in collaboration with Thai Bioplastics Industry Association (TBIA) and the PTT Group held their fourth international conference and exhibition InnoBioPlast 2013 on January 24-26 at Queen Sirikit National Convention Center, Bangkok, Thailand. More than 300 delegates from different Asian countries as well as a number of guests from other countries all over the world participated in this unique forum of sharing technological knowledge-base and progress under a statement: “Think Bioplastics Think Thailand”.

In his opening statement, Woravat Auapinyakul, Minister of Science and Technology of Thailand said that “The Ministry of Science and Technology (…) hopes that this meeting would partly encourage the development and investment of the bioplastic industry in Thailand in order to further enhance cooperation, transfer of technologies, and investment in the bioplastic business. The Government places explicit policies of developing the friendly-environmental industries.” The Minister emphasized that “Thailand is a good source of bioplastic production as we have a large amount of biomass for the production of bioplastic. The policies placed by the state sector of Thailand also help encourage the development of bioplastic industry.”

Supachai Lohlohakarn, Director-General of NIA stated that “Thailand ranks the bioplastic industry as a new wave industry and aims at being the bioplastic center of ASIA. By this regard, the National Map for the Development of Bioplastic Industry under a budget amounting to Baht 1,800 million (EUR 45 million) allocated in 2008 was approved. The expansion of Stage-2 project implementation (2010-2015) (… includes) the establishment of model plant for the production of resin plastic using local agricultural raw materials, e.g. cassava and sugarcane, receive tax privileges for investment and research and development, establish the bioplastic standards like the marketing and other environmental policies”.

Dr. Pipat Weerathaworn, President of Thai Bioplastics Industry Association or TBIA, stated that “The Association is derived from the formation of many entrepreneurs in the plastic industry, both

Derek Atkinson, Purac Asia Pacific

top-stream and down-stream, who realize the importance of environmental preservation. They set up a vision to be the bioplastic leader in this region. At present, the Association’s members comprise 47 companies.

Over the three days, the delegates heard presentations from speakers of companies like (among others) PTT, NatureWorks, nova-Institute, Samsung Fine Chemicals, Sulzer Chemtech, BioBag International, Showa Denko, Mitsubishi Chemical, Purac, Teijin, Toray, Unitika, Novamont, BASF, Sapporo Breweries, DIN Certco and JBPA, The conference was concluded by a panel discussion of representatives of international associations. Among these were (right to left in the photo below) TBIA, European Bioplastics, KBPA Korean Bioplastics Association, ABA Australasian Bioplastics Association, JBPA Japan Bioplastics Association, EBPA Environmentally Biodegradable Polymer Association (Taiwan) as well as a Professor from University Tunken Abdul Rahman (Malaysia). MT www.nia.or.th/innobioplast2013 www.tbia.or.th www.pttplc.com

Photos: M. Thielen

bioplastics MAGAZINE [01/13] Vol. 8

7

News/People

Good prospects for Metabolix

A

bout a year ago, we reported that ADM terminated Telles, its joint venture with Metabolix. Now, one year later, Metabolix seems to be on a promising track to success again. bioplastics MAGAZINE recently spoke with Rick Eno, Metabolix’s president and CEO. In early 2012, Metabolix decided to continue its activities in bioplastics, as it’s a fantastic market with a lot of growth opportunities, Eno pointed out.

He noted that Metabolix has a unique technology and a very high-quality product – Mirel, a PHA biopolymer that’s biobased and biodegradable. The Company bought the remaining Mirel inventory from ADM and started looking for an alternative manufacturing option for the biopolymer. In late July, Metabolix announced a relationship with Antibióticos in Leon, Spain.

“Currently, we are in the midst of a technology transfer. We have educated Antibioticos and they are in the construction process preparing for start-up,” Eno said. Antibióticos will start production of demonstration quantities of Mirel early this year. Commercial-scale production, with a capacity of up to 10,000 tonnes per year, is scheduled to commence later in 2013.

Mirel PHA made from EU sugar Until production of Mirel ramps back up at Antibióticos, Metabolix is selling from an existing inventory of over five million pounds (more than 2,000 tonnes), of various grades and qualities of PHA that was produced in the Telles plant in Clinton, Iowa. Customers have regained confidence and sales figures grew by 85 percent in Q3 over Q2/2012. However, in order to extend the range of inventory supply, Metabolix has started to compound or blend the PHA with other resins to create new products. The compounding is done

by European partner companies, and the products will be shipped and exported to customers around the world. The fermentation, however, will be done by Antibióticos as the initial commercial production partner of Metabolix. While the feedstock for the Telles plant in Iowa was corn sugar from the ADM corn mill, the raw material for PHA production in Spain will come from various corn or sugar beet distributors in the EU. “Antibióticos has more than 50 years of experience in purchasing and converting sugars,” Eno said.

New grade of Mvera film resin Within the Mirel™ family of PHA-based products, Mvera™ is specifically developed for the compostable bag market. It consists of Mirel PHA and other

8

bioplastics MAGAZINE [01/13] Vol. 8

News/People biodegradable polymers “in a proprietary formulation that meets the requirements of the compostable bag market,” according to Eno. Just recently, Metabolix introduced the next generation of Mvera, B5008. The new product leverages the existing inventory of Mirel in an effective way, and it offers better performance compared to the B5002 grade that it is replacing. “It will certainly strengthen our reputation as a supplier of a high-quality product that meets the needs of the market,” said Eno.

Additives for PVC Asked why Metabolix is now developing additives for PVC, Eno explained, “In the post-Telles phase, we carefully looked at why customers were buying our Mirel PHA. And certainly, one reason was the biodegradability. But we also noticed that customers were buying Mirel because of its use as a performance enhancer, once blended with other polymers. Some customers didn’t necessarily consider the biodegradation characteristics when selecting Mirel.” Metabolix subsequently developed a series of products that are very easily miscible with PVC. Some new PHA formulations have been developed to improve plasticization, impact and process modification of rigid and flexible PVC, “with reduced migration concerns,” as Eno pointed out. One of these new products is I6001, and is 85 percent biobased. It was launched this past December.

Bio-BDO and acrylic acid In addition to its biopolymers business, Metabolix is also further pursuing the development of other biobased chemicals. C4 chemicals such as bio-BDO (butanediol), for example, as well as the lesser-known bio-GBL (gamma butrylactone) are chemical intermediates used in the production of plastics (such as PBT), resins, solvents, auto parts, spandex, fabrics, fibers and personal care products. Eno noted that Metabolix has also “been successful in making ultra-pure biobased C4 chemical products.”

And finally, Metabolix is also active in the field of C3 chemicals, including biobased acrylic acid. “We have biobased acrylic acid product samples in the market,” said Eno, “and we are continuing to innovate around that as well, for example, with butyl acrylate, which is being used in applications like paint and coatings.”

Concluding the talk with bioplastics MAGAZINE, Eno said, “it wasn’t easy, but we are quite satisfied with where we stand today. We are now very much focused on getting the product launched, and are focused on the quality of the product. We have great technical resources and an outstanding team focused on advancing the product’s quality. We are truly looking forward to and continuing the progress we are making in 2013.” MT

Other polymers, such as PLA, can be improved with the addition of Mirel PHAs.

www.metabolix.com

organized by

17. - 19.10.2013

Bioplastics in Packaging

Messe Düsseldorf, Germany

Bioplastics Business Breakfast

B

3

Call for Papers now open www.bioplastics-breakfast.com Contact: Dr. Michael Thielen (info@bioplastics-magazine.com)

PLA, an Innovative Bioplastic Injection Moulding of Bioplastics Subject to changes

At the World’s biggest trade show on plastics and rubber: K’2013 in Düsseldorf bioplastics will certainly play an important role again.

On three days during the show from Oct 17 - 19, 2013 (!) biopolastics MAGAZINE will host a Bioplastics Business Breakfast: From 8 am to 12 noon the delegates get the chance to listen and discuss highclass presentations and benefit from a unique networking opportunity.

The trade fair opens at 10 am.

bioplastics MAGAZINE [01/13] Vol. 8

9

Cover Story

Mobility of the future by Christoph Habermann Project leader IfBB – Institut für Biokunststoffe und Bioverbundwerkstoffe University Hanover Hanover, Germany

T

he future of mobility goes green – the IfBB (Institute for Bioplastics and Biocomposites, University of Hanover, Germany) as well as the race driver Smudo (our front cover hero, who is a well-known celebrity in Germany as a singer of the German hip-hop group Die Fantastischen Vier) and the Four Motors Racing Team are convinced of this trend.

The co-operation is funded by the Agency for Renewable Resources (FNR Fachagentur Nachwachsende Rohstoffe e.V.) on behalf of the German Federal Ministry of Food, Agriculture and Consumer Protection. The joint operation is focused on the development of biobased materials and sustainable parts for the automotive industry as well as the change towards a ready-for-the-future mobility.

Being constructed with more and more biobased parts, the Bioconcept Car (bM has reported on the development on a regular basis since 2007) can even take part in longdistance races such as the VLN Endurance Championship or the ADAC 24 hour races on the famous Nürburgring circuit.

The aim of this project is, therefore, to develop parts for the automotive industry and racing by using bioplastic materials and biocomposites. Thus, the Bioconcept-Car sets out a path for a change to a ready-for-the-future mobility not only in racing but also in normal traffic. It gives evidence that biobased materials can be used in modern, technical and heavily used automobile constructions.

Materials An increasing number of components for the Bioconcept Car are made of resource-saving biobased materials which are extremely lightweight in order to minimize the vehicle’s petrol consumption i.e. energy consumption. To reach this target different materials are used and material combinations are being evaluated (Compare the illustration Materials, cf Fig. 3). On the one hand thermoplastics which are biobased or petrochemical-based (in this case they are used in combination with natural fibres in order to obtain a bio composite) are used reinforced with different fibres or modified without fibre reinforcement; on the other hand biobased or petrochemical-based thermosetting materials are combined with various fibres. At least the developed materials are fully or partly biobased – either the fibre and/ or the resin. For the lightweight car body resins reinforced with natural fibres are used: lighter than fibre-glass, cheaper than carbon fibre and made from renewable raw materials.

Table 1: Examples for biobased components of the Bioconcept Car: Natural Fibre reinforced resins (thermosetting materials):

Natural Fibre reinforced plastics (thermoplastic materials) or bioplastics:

Doors

Fuel filler flap

Tailgate

Covering of steering column

Hood

Various technical boxes

Front

Mirror bodies

Underbody (Diffusor)

10

bioplastics MAGAZINE [01/13] Vol. 8

Automotive

Fig.1: The current Bioconcept Car is a specially modified Volkswagen Scirocco 2.0 TDI (photo: Four Motors)

Using natural fibres as a reinforcement for thermoset resins is a sustainable alternative for lightweight car bodies and is even successful under the extreme stresses applied during racing. This will give those composites the chance to be the key material for the future in automobile construction.

Weight saving is a magic word in the automotive industry – not only with regard to minimizing fuel consumption and thus reducing CO2 emissions, but also to achieving longer distances for electrically driven cars.

Furthermore, other more complex shaped parts - for example components under the hood and the interior part of a car - are designed with injection-moulded biobased plastics or biocomposites.

The IfBB preselect the materials i.e. material components and their configuration according to the requirements of the application and the part that has to be realized. The next step is a laboratory-confirmed specific development and optimization of different material concepts and biobased materials. Actually the range of biobased plastic, biobased additives and biobased reinforcements is so abundant that the new fuel filler flap of the Bioconcept Car was produced in a comparable quality on a large-scale production injectionmoulding machine with the standard mould. Especially for this application a commercially available biobased Polyamid 6.10 from DuPont was modified with talc and different additives.

The proportion of renewable raw materials in the vehicle is thereby successively increased. Other thermoplastics to be

investigated include polytrimethylene terephthalate (PTT, (see also page 46).

Before and after a race season, the construction parts are examined and analysed by material testing. The results are compared in order to analyse possible changes of the materials caused by the stresses applied during a race.

The main innovation of 2012 was a combination of natural (flax) fibres with a biobased (epoxy) matrix which is being used for the tailgate, and, in the next stages, for hood and spoiler of the Bioconcept-Car. Different natural fabrics with variable weight and variable weave were produced and tested in order to achieve the necessary quality/character in terms of stability or processing properties and to ensure the desired results in combination with the biobased resin. After the initial trials with fabrics made of different natural fibres the engineers from Hanover decided on a pure flax twill weave.

The result of this investigation is a flax fibre which offers a high tenacity, and is readily available. It is a particularly fine, homogeneous, flexible and drapable material. i.e. it can be put into the shape of the part to be moulded without significant problems in terms of folds etc.

The raw materials for a biobased epoxy resin can be different vegetable oils in order to achieve the necessary properties, e.g. hardness, viscosity or a quick curing time, as well as the ability to be combined with natural fibres.

bioplastics MAGAZINE [01/13] Vol. 8

11

Automotive

“Within this project we not only try to optimize the material components themselves. We also determine for example the optimum fibre/matrix ratio using test panels in order to achieve the targeted stability in combination with minimized weight”, explained Prof. Endres. The test panels are then subjected to tensile tests, impact tests or crash behaviour before real parts for use in the race car are produced.

The biobased resin actually used in the tailgate of the Bioconcept Car is made from an epoxy resin based on oil from pinewood and by-products of biodiesel. This process is steadily being optimized and will be also be adopted for the design of further parts for the car.

Fig. 2: Fuel filler flap

short fibres (< 4mm) biobased fibres (CF)

Award winning project

Adaption

glass fibres (GF)

thermoplastics

petrobased biobased

Adaption

Bioconcept Car

Adaption

petrobased biobased

Thermoset-resins

Adaption

long fibres (fabric) glass fibres (GF)

carbon fibres (CF)

natural fibres (NF)

Biobased polymer fibres (BF)

Fig. 3: Materials

Composite Density vs. E-Modulus

E-Modulus of composite [MPa]

25000 20000 glass fibre carbon fibre viskose fibre flax fibre

15000 10000 5000 0

0,4 0,5 0,6 0,7, 0,8 0,9 1 Composite Density [g/cm3]

Fig 4.: Modulus of elasticity of the composites for various fibre types

Tensile strength of composites [MPa]

Composite Density vs. Tensile Strength 800 700 600 500 400

glass fibre carbon fibre viskose fibre flax fibre

300 200 100 0 0,4 0,5 0,6 0,7, 0,8 0,9 1 Composite Density [g/cm3]

Fig 5.: Tensile strength of the composites for various fibre types

12

bioplastics MAGAZINE [01/13] Vol. 8

With the tailgate the Bioconcept-Car was a winner of the 7th Global Bioplastics Award 2012 (see bM 06/2012)

60% Weight savings With a tailgate, bonnet and doors made from a thermoset resin reinforced with natural fibres the Bioconcept-Car weighs now 67 kilograms less. In comparison with the same components made from steel the weight saving is 60 %. The standard door weighed in at 38.5 kilograms, and the door made from the material reinforced with plant fibres weighed only 14 kilograms. “When we think that 100 kilograms could be saved in the weight of a standard car, which means a fuel saving of about half a litre per 100 kilometres, the importance of our project for the automobile industry is clear”, said Prof.

Endres.

Technically it is possible to use thermoset resins in serial car production. At the end of this project a catalogue will be prepared that contains full details of the materials used for each component, and the production processes involved, together with recommended applications for biomaterials. The tool will help the automotive designer to check the application and potential of the biobased materials. It will however be a long road.

A comparison of potential lightweight materials shows the advantages and disadvantages of the different fibres (see Figs. 4 and 5, and table 2). The advantage of carbon fibres lies in their construction performance, but which come at a price – both economical and environmental. The glass fibres are certainly cheaper but are heavier and have similar ecological disadvantages to carbon fibres. Both types of fibre have negative acoustic qualities to be considered. Viscose fibres have advantages in their light weight and better ecological and acoustic properties, but do not have the higher mechanical performance of carbon or glass fibres. Even flax fibres cannot reach these levels but have their advantages in terms of weight, cost, ecology and acoustics. Thanks to their very low weight (and price) an increase in their use for those parts where the required mechanical performance is in fact achieved, is still a very attractive cost saving proposition.

Cover Story Table 2 Carbon fibre design-relevant properties

Glass fibre

Flax fibre

Viscose fibre

Density

+

-

+

+

Tensile strength

+

+

-

-

E-Modulus

+

+

-

-

Economic factors

Costs

-

+

+

+

Additional properties

Acoustics

-

-

+

+

Ecology

Sustainability

-

-

+

0

Within the next stages further parts of the Bioconcept Car will be produced using biobased polymers.

Hereby the Bioconcept Car paves the way for future sustainable mobility. It brings the ideas generated in the laboratories to the street and makes them applicable for future series production in the automobile industry. Not only alternative parts for motor sport are being developed, but these parts can also be included in the series production of standard cars.

The Institute for Bioplastics and Biocomposites (IfBB) In the Bioconcept Car project the recently established Institute for Bioplastics and Biocomposites (IfBB) at the University of Applied Sciences and Arts Hanover will hold the primary responsibility for materials engineering concerning the car.

Sponsored by the German Federal Ministry of Food, Agriculture and Consumer Protection, and supported by the Agency for Renewable Resources (Fachagentur Nachwachsende Rohstoffe e.V.), Prof. Hans-Josef Endres and his team are in charge of material development and the selection of raw materials, as well as the production of the various biobased parts, for example, hood, doors, or tailgate.

www.ifbb-hannover.de www.fourmotors.com http://mediathek.fnr.de/broschuren/nachwachsende-rohstoffe/ biowerkstoffe/bioconcept-car.html

C I

B

D

E

A

A

Tailgate:

H

F

G

Now:

Before:

Bio-based plastic (epoxy resin) with flax fabric

Sheet steel

B

Rear spoiler:

Bio-based plastic (epoxy resin) with flax fabric

Petroleum-based plastic (epoxy resin) with carbon fiber

C

Roof spoiler:

Bio-based plastic (epoxy resin) with flax fabric

Petroleum-based plastic

D

Fuel filler flap:

Bio-based plastic (polyamide) filled with talc

Petroleum-based plastic

E

Door:

Petroleum-based plastic (epoxy resin) with flax fabric

Sheet steel

F

Closed underbody:

Bio-based plastic (epoxy resin) with flax fabric

Petroleum-based plastic (epoxy resin) with carbon fiber

G

Diffuser:

Bio-based plastic (epoxy resin) with flax fabric

Petroleum-based plastic (epoxy resin) with carbon fiber

H

Front splitter:

Bio-based plastic (epoxy resin) with flax fabric

Petroleum-based plastics

I

Bonnet:

Bio-based plastic (epoxy resin) with flax fabric.

Sheet steel

bioplastics MAGAZINE [01/13] Vol. 8

13

Automotive

Biobased polymers for automotive safety components By Udo Gaumann Plastic Competency Management Global Engineering Airbag Takata AG, Aschaffenburg, Germany

Fig. 1: exploded view of airbag and steering wheel

Emblem Cover Cushion

Retainer

Bezel

Steering wheel

F

or a lot of people biobased polymers are sufficient for packaging or plastic parts with low technical requirements.

For them it will be astonishing that biobased polymers (that are either partially or entirely based on renewably-sourced raw materials) are fully able to fulfill the high requirements of automotive safety components like airbags and steering wheels.

The increased pressure on fossil-oil based products motivated Takata, of Aschaffenburg, Germany, and a global leading supplier of airbags, steering wheels and vehicle safety systems, to look more closely into the use of bio-based polymers in automotive safety components as an alternative to traditional polymers.

Several years of development work ended in a complete and fully functional steering wheel including driver airbag.

To achieve this target the available biopolymers were benchmarked according to technical requirements and the most promising materials were chosen. Following this the components were tested in compliance with the specifications of the automotive industry to verify the material limits in steering wheels and airbags.

In November 2012 the fully functional airbag/steering-wheel prototype received the 7th Global Bioplastics Award.

Fig. 2: deployed airbag.

Component overview Emblem The emblem, which shows the carmakerâ&#x20AC;&#x2122;s logo, is important for brand consciousness. OEMs demand high technical performance and appearance for this part. It has to fulfill surface appearance tests, scratch resistance, resistance to certain substances (e.g. sweat, glass-cleaner, stain remover, sun cream, etc.).

Usually the emblem is located in the centre of the airbag cover.

During deployment of the airbag in case of an accident the emblem

14

bioplastics MAGAZINE [01/13] Vol. 8

Automotive

PROPERTY Melting point Melt flow rate Density Tensile properties @ 23 °C

Testing method

Unit

Hytrel DYM250S BK497

Hytrel RS renewably-sourced

ISO 11357

°C

219

220

g/10 min

15

16

kg/m3

1.16

1.16

ISO 1133 @ 2.15 kg/240 °C ISO 1183 ISO527 – 5A bar

Tensile strength Elongation at break Tensile modulus Tensile properties @ –40 °C

MPa

20

20

%

365

375

MPa

188

193

MPa

39

28

ISO527 – 5A bar

Tensile strength Elongation at break

%

244

247

MPa

440

406

N/mm²

49

47

@ 23 °C

kJ/m2

63

64

@ –40 °C

kJ/m

76

72

Tensile modulus Tear strength @ 23 °C Charpy impact strength

ISO 34A ISO 179 1eA

has to suffer high dynamic deformation within the complete working temperature range (-35°C to +85°C). Due to this the emblem needed an excellent ductility to pass deployment tests in the airbag system without damage. A biobased polyesterelastomer blend (Hytrel® RS by DuPont) was used as the basic material for the emblems. This material has a good elasticity to assure a good deployment performance on one hand, and on the other hand at +85°C the emblem must still be rigid enough. After injection moulding a metallic layer was applied

by PVD technology as a substitute for the chrome plating.

The combination of TPC-ET and PVD coating passed the OEM requirements. As an additional feature chrome was eliminated as critical substance.

Cover The airbag cover is a highly sensitive component. First of all it has to meet the safety requirements during its whole lifetime. And as a visible component, it has to fulfill the highest demands in terms of surface appearance. At deployment the airbag cover has to open within milliseconds, along the defined, integrally-moulded tear seam. During deployment there should be no fragments breaking off from the cover.

In the past Takata used, for serial applications, the standard TPEs Hytrel DYM 250 or DYM 350, which have been specially developed for this application to show a specifically optimized balance between stiffness and low temperature ductility.

For the biobased airbag cover, DuPont developed a grade of Hytrel RS that is more or less a biobased copy of the DYM 250 airbag cover grade in terms of its properties. Tests showed only a minimal difference between the conventional and the new, renewably-sourced grade of Hytrel RS, which is based on 35 % renewably-sourced content (cf. bM issue 01/2011).

2

Table 1. Comparison of basic material properties of Hytrel DYM 250 and its equivalent renewably-sourced grade of Hytrel RS (Source DuPont) According to the standard material testing procedure, Takata tested processability, paintability, outgassing, odour, ageing and airbag deployment reliability. During airbag deployment, the most critical test, carried out at 85 °C and at –35 °C, shows similar opening forces and inflation times within the OEM-specified requirement of 3 to 5 ms.

Even after ageing (UV radiation, high temperature ageing, humidity ageing, …) the covers passed the test programme without any abnormality.

Cushion The challenge for a cushion is to dissipate the high dynamic energy of the passenger during an accident, without harming the occupant. Here a defined elasticity and high strength from the cushion fabric is required. For current production PA66 and PET fabric are being used. After a market screening of potential materials Takata chose Sorona® EP

by DuPont. Sorona is a biobased PTT (polytrimethylene terephthalate see page 46) as the fabric raw material. But particularly the weaving of test fabric requires, due to the high throughput during production, a high expenditure of time and money. So it was decided to compare only the mechanical properties of Sorona EP yarns to PET fabric yarns. The tenacity of PTT fibers is approximately 10% lower compared to PET fibers. The elasticity however, is three times higher. Due to this excellent overall mechanical performance the engineers at Takata are confident that PTT is suitable as a cushion material.

bioplastics MAGAZINE [01/13] Vol. 8

15

Automotive Retainer The airbag retainer is the structural backbone of an airbag system. It connects the single airbag components to an assembly and during deployment the retainer keeps the whole airbag and its components in position and has to withstand a high dynamic load of approximately 1,500 kg. Due to its good ductility and strength mainly PA6 GF40 (impact modified) is used for airbag retainers. As a biobased substitute PA6.10 GF40 was chosen. This sebacine acid (bio-) based polyamide has comparable basic properties to standard PA 6 GF40 in terms of stiffness, impact resistance, strength, dimensional stability and warpage, and due to its lower moisture absorption, compared to PA6, it shows superior performance after high humidity storage.

Bezel To enhance the car interior appeal OEMs use bezels and covers to set visual accents. The main requirements for this component are excellent appearance, good scratch resistance and an adequate impact behaviour, such as is required for dashboards. Different biobased materials were compared. PTT convinced the engineers with its excellent optical properties.

Due to its crystallinity Sorona shows a superior depth effect with a shiny lustre which is comparable to a multi-layer painting appearance. This material gives the ability to produce parts with a premium appearance only by injection molding. magnetic_148,5x105.ai 175.00 lpi 45.00° 15.00° 14.03.2009 75.00° 0.00° 14.03.2009 10:13:31 10:13:31 Prozess CyanProzess MagentaProzess GelbProzess Schwarz

c i t e n tics g s a a l P M for • International Trade in Raw Materials, Machinery & Products Free of Charge • Daily News from the Industrial Sector and the Plastics Markets • Current Market Prices for Plastics.

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

er.com lastick www.p

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

sional Profes Fast • • te a d Up-to-

16

bioplastics MAGAZINE [01/13] Vol. 8

The only weak point of Sorona is that it did not pass all scratch resistance tests of Takata’s customers. The tests results are so close to requirements that it is expected to be given a deviation approval where it is necessary.

Steering wheel (foam) Today the steering wheel basically consists of a frame that is mostly responsible for the power transfer from driver to steering column and the stability of the steering wheel. The frame is coated with foam. The foam is lacquered and forms the surface of the steering wheel, or leather is glued to the foam and sewn. This foam has to meet the customers’ lifetime, outgassing and hardness requirements. A biobased foamed, TPU, showed a good performance in resistance to critical substances, hydrolysis storage and heat ageing. For resilience, abrasion and hardness slight deviations to the specification were found. However, Takata is confident that a material modification will solve the abrasion issue. The foam hardness and the resilience deviation are mainly for tactile reasons.

So no negative impact in the steering wheel functionality are expected.

Conclusion The feasibility of a steering wheel, including an airbag, is proven through numerous tests with all components.

From the technical point of view there are some slight deviations according to current specifications which are not significant to the functionality. The showcase model consists up to 50 % of plant-based raw materials. The experts at Takata are sure that the weight increase of 7% compared to fossil-oil based raw materials can be compensated due to the better mechanical properties (e.g.

Polyamide 6.10).

The biggest handicap of biobased polymers in steering wheels and airbags is the much higher raw material price (100-250% additional costs). To enable the success of biobased polymers for the automotive industry it needs not only technical performance, but also external stimulation such as a high fossil oil price, tax privileges for CO2 reduction or a positive customer approach. The showcase development project introduced here will go ahead to represent always the newest capabilities in biobased polymers for Takata’s products. www.takata.com/en

Automotive

Natural fibre composites

Fig. 1: Components made from renewable resources by Daimler (GLK/X204) (Source: Daimler AG)

Environmental awareness as a key driver for lightweight solutions

I

n 2009 the European Union adopted new legislation that forces the automotive industry to reduce the CO2 emissions from new cars [1].

In fact the new car fleets are not allowed to emit more than 130 g CO2/km by 2015 and 95 g CO2/km by 2020. Since the automotive industry is making a big effort to meet these targets the average emissions are falling each year and by 2011 the average emissions were already reduced to about 137.7 g CO2/km.

In this context the application of natural fibre as a reinforcement in composite materials in the automotive industry plays a crucial role, since the use of renewable or bio-based materials can not only reduce the CO2 emissions by reducing the component weight, but can also build up the positive image of a company by promoting sustainability and environmental awareness, as well as preserving the limited resources on earth.

Natural fibres as a reinforcement in composite materials The use of natural fibres such as wood, flax, hemp, kenaf or sisal as a reinforcement in composite materials has been well established in the automotive industry for several years. Natural fibre reinforced composites are mainly used in semi-structural automotive interior parts such as door panels, instrument panels, package trays, trunk liners or seats [2]. For these applications the natural fibres (fractions between 50% and 90%) are processed to non-woven mats, where the fibres are distributed almost randomly within the mat, and used as reinforcement in both thermoplastic, mainly polypropylene, and thermoset resins such as acrylic, polyurethane or epoxy resin.

Fig. 3: Door panel of Mercedes S-Class (W221), made with Lignoflex (Source: Faurecia)

18

bioplastics MAGAZINE [01/13] Vol. 8

Here, the technological advantage of the natural fibres is, due to their low density (approx. 1.45-1.55 g/cmÂł), a large weight reduction potential at a high level of functionality in the composite. But also such benefits as good crash performance, good energy absorption, fracture resistance (splinter-free failure) or price stability of natural fibres (independent of oil price) play a very important role for the use of natural fibres in automotive applications.

Automotive

material

by Luisa Medina

compression

LignoLight

Senior Research Manager Institut für Verbundwerkstoffe IVW

injection

Kaiserslautern, Germany

thickness

density

area weight

potential

[mm]

[g/cm3]

[g/m2]

[%]

1,6

0,90

1450

-44

LignoFlex

2,0

0,95

1900

-26

LignoProp

2,0

0,95

1900

-26

NF PP

2,0

0,95

1900

-26

NF PP

2,4

0,85

2000

-22

NAFI - PP NF20

2,0

0,95

1900

-26

PP LRF 25

2,2

1,00

2200

-15

PP LGF 20

2,2

1,04

2288

-11

ABS

2,2

1,05

2310

-10

ABS+PC

2,2

1,13

2486

-3

PP/PE TD14

2,5

1,03

2575

Reference

PP/EPDM T20

2,5

1,04

2600

1

PP T20

2,5

1,05

2625

2

SMA GF15

2,5

1,18

2950

15

Fig. 2: Material analysis showing the lightweight potential of NF materials, done by Faurecia Interior Systems

In this respect the company Faurecia Interior System shows, in a material study [3], the lightweight potential of natural fibre reinforced composites compared to standard plastics such as talc-filled polypropylene or PC-ABS (Fig. 2). This study shows a weight saving potential in a door panel of around 25 % compared to the conventional material, (14% filled polypropylene), by the use of commercially available NFPP mats. This potential can be increased up to about 40 % by using the newly-developed wood mat material LignoLight. These new wood-based mats, with an optimized area weight of around 1400 g/m², also show a weight saving of some 25 % compared to the conventional mats with an area weight of around 1900 g/m² (Fig. 3). Not only Faurecia but also all other suppliers are strongly working on material development to improve the material performance despite weight reduction, and to meet the continually increasing demands in the automotive industry.

But material development is not the only factor in the forefront of industrial investigations. Process development and optimization is also very much a key factor for increasing the application fields of bio-composites, since optimized processes, including for example functional integration or combining processes, also means cost reduction of the component, which is, another factor contributing to a spread of applications for these kinds of materials. In this context one can point to the new process of Johnson Controls Interior for using natural fibres with epoxy resin (EP) to produce semifinished materials [4].

The production-ready process is already being applied for the production of the door panel of the BMW 5 Series with 2 colour PVC foil (Fig. 4 and 5).

Ramstein, Germany) where a natural fibre pre-impregnated mat with about 70% natural fibre content and an acrylic matrix [5] is used. For the manufacturing of these semifinished materials the NF mats are impregnated with the acrylic resin using foulard rollers. After the impregnation the mats must be dried to a certain residual humidity level and can be processed in hot compression moulding (Fig. 6).

The BMW door panel with the newly-developed NF material in 2009 won the Automotive Innovation award from the Society of Plastics Engineers.

Research and development areas for biopolymers Since the market is asking for more eco-friendly materials with similar properties to the petrochemical-based ones, at competitive prices, science and industry are working together to develop new materials based on renewable resources. This is appreciated in some research projects such as “FENAFA” (founded by the Agency for Renewable Resources / FNR Fachagentur Nachwachsende Rohstoffe in Germany) where a total of 16 partners from agriculture, industry and research are cooperating to develop new products based on renewable materials [6]. FENAFA stands for ‘integrated handling, processing and manufacturing strategies of natural fibre materials’. Within the project small and medium companies in particular are supported in the development of equipment, production lines and systems for the processing of natural fibres in technical areas. Also the automotive industry is strongly involved in the project with JCI as Tier 1 and with Isowood, a natural fibre materials supplier for the automotive industry.

This process is not far removed from the manufacturing process of Nafacryl® (from Dittrich & Söhne Vliesstoffwerk in

bioplastics MAGAZINE [01/13] Vol. 8

19

Automotive

Fig. 4: Door panel BMW 5 Series (with 2 colour PVC foil) (Source: JCI)

In Europe, bio-composites are mainly available at an industrial level only for semi-structural automotive applications. To expand the application area of bio-composites to structural parts, also for non-automotive applications, it is important to improve their performance. Therefore, the main objective of two European projects (NATEX and Bio-Build) at IVW is to develop aligned textiles from natural fibres that are suitable for use as high-strength reinforcing fabrics (Fig. 7).

These fabrics are the basis for structural composite materials with improved mechanical properties. In both projects the scientific objective of IVW is to develop and adapt processing methods to manufacture the novel bio-based composites with natural fibres and bio-based and petroleum-based thermoset and thermoplastic matrices respectively [7, 8, 9].

Fig. 6: Door Panel from Natural-Fiber Prepreg Composite (copyright Dräxlmaier Group)

The NATEX project, which was successfully completed in 2012, is based on the use of hemp and flax natural fibres which are mainly cultivated in Europe. Within the work aligned natural fibre textiles were used as reinforcement with both bio-based thermoset and thermoplastics. In order to increase the bio-composite performance further the impregnation methods of natural fibre textiles with different matrices were optimized. Considering both improvements in the bio-composite manufacturing process (application of NF aligned textiles and optimized semi-finished material manufacturing process) it was possible to increase the partâ&#x20AC;&#x2122;s stiffness or rigidity by about 3 times in both NF reinforced thermoplastics and NF reinforced thermosets Whereas in the NATEX project the main research focus was the evaluation of appropriate materials, the knowledge gained can now be applied and deepened in the new BioBuild project. The aim of BioBuild (High Performance, Economical and Sustainable Bio-composite Building Materials) is to use bio-composites to reduce the embodied energy in building facades, supporting structures, and internal partition systems by at least 50% over current materials with no increase in cost. This means sustainable materials (natural fibres and bio-resins) will be used to replace aluminum, steel,

20

bioplastics MAGAZINE [01/13] Vol. 8

Automotive

Fig. 5: Natural fibre material (NF-EP) (Source: JCI)

FRP, bricks, and concrete in buildings, mainly in facades and internal partitions. The resins in this project are furan based and cashew nut oil based with reinforcing fibres of flax and jute. The bio-composites and construction products should have a life span of 40 years by protecting the fibres with novel treatments and coatings.

The know-how acquired in these projects regarding new renewable materials (both natural fibres and biopolymers), manufacturing methods for semi-finished materials and optimized processes for these new compounds, can also be transferred within a reasonable period time to new application areas in the automotive industry. www.ivw.uni-kl.de [1] http://ec.europa.eu/clima/policies [2] Andreas Beckmann, Einsatz von Naturfasern im KfzInnenbereich, Landtechnik 2/2001, p. 229-230 [3] Günther, P.; Reichhold, J. (Faurecia Interior Systems): Innovative material concepts - natural based - for automotive interior applications, AVK – Arbeitskreissitzung “Naturfaserverstärkte Kunststoffe“, Frankfurt am Main, 07. September 2012 [4] Medina, L.: Naturfasern in Automobilanwendungen -Trends national und international. Biocomposites - natürliche Innovation aus RLP, IVW GmbH, Kaiserslautern, 1. Dezember 2011 [5] J. Dittrich & Söhne, Vliesstoffwerk GmbH, Thermoset-prepegs out of natural fibers, a successful synthesis of nature and technology (company presentation) [6] Bürgermeister, S.: Ganzheitliche Bereitstellungs-, Verarbeitungs- und FErtigungsstrategien von NAturFAserrohstoffen. AVK – Arbeitskreissitzung “Naturfaserverstärkte Kunststoffe“, Frankfurt am Main, 24. Mai 2012 [7] Pohl, T.; et.al: Properties of compression moulded new fully thermoset composites with aligned flax fiber textiles. Plastics, Rubber and Composites, Vol. 40, No. 6/7 (2011), S. 294-299 [8] Medina, L.: Natural Fiber Reinforced Composites – Key Chances and Advanced Solutions. IVW Colloquium, Kaiserslautern, 6-7 November 2012 [9] Medina, L.: Natural Fiber Reinforced Composites – Standard Materials, Applications, and New Trends. Academic Summit Workshop, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, 2-3 July 2012

Fig. 7: NF-mat (a), NF-fabric (b) and NF-non-crimp fabric (c)

bioplastics MAGAZINE [01/13] Vol. 8

21

Automotive

Ford Motor Company Ford Escape (all photos: Ford Motor Company)

F

ord Motor Company, headquartered in Dearborn, Michigan, USA has been working to replace components in their vehicles with recycled or renewable plastics parts for several years now. (Always keeping in mind, that Henry Ford was a pioneer in the use of soy based and other renewably sources materials already in the early twentieth century …)

Soy foam

Armrest (prototype) with shredded dollar bills (cotton/linen) and composite pellets

Following extensive in-house materials research and development of soy-based polyurethane foams, Ford Research introduced the soy in the seating foams of the Ford Mustang in 2008. Today, the seating foams used in all Ford vehicles that are produced in North America contain soy in the formulation of the foam, as Ellen C. Lee, Plastics Research Technical Expert of Ford Motor Company told bioplastics MAGAZINE. This saves about 5 million pounds (more than 2,000 tonnes) of petroleum per year and reduces the CO2 emissions by over 20 million pounds (about 9,000 tonnes) per year. In the meantime, Ford introduced the first lightweight headliner application made of soy foam in the Ford Escape, migrating this to other vehicles soon. Another application for soy foam is in head restraints. Currently, about 75% of all North American Ford vehicles use soy, including the Ford F-150, Taurus, Explorer and Fusion, targeting at getting this into all of the cars as well. Here foams with a higher bio-based content (25% of the polyol is soy based) are being used. “We’re not stopping at head restraints, either. There are still many other applications in which traditional foam can be converted to biobased soy foam on vehicles, such as energy-absorption areas, steering wheels and armrests”, said Debbie Mielewski, Technical Leader, Ford Plastics Research.

Bio-based foam mixed with ground tires In underhood applications, such as gaskets and seals, Ford is using a different formulation of bio-based foam that includes about 25% recycled ground tires. Over 2 million pounds (900 tonnes) of ground rubber from tires (equivalent to approx. 210,000 tires) have been used and thus diverted from landfills to date. The bio-based content including soy and corn oils makes up about 17% of the material. The new formulation is currently being used on 14 Ford vehicles.

Castor oil based polyamide 11

Dandelion is being investigated as a source for rubber replacement

22

bioplastics MAGAZINE [01/13] Vol. 8

The fuel lines of 95% of all North American Ford vehicles are made from castor oil based polyamide 11. This 100% bio-based nylon saves more than one million pounds (450 tonnes) of CO2 emissions every year compared to nylon 12.

Automotive Natural fiber The activities in the field of wheat straw filled polypropylene, as reported last year for one vehicle, continue towards implementation for more applications and more vehicle lines.

Another natural fiber application currently used for the Escape is a 50% kenaf fiber reinforced polypropylene that replaces over 300,000 pounds (140 tonnes) of fully petroleum based resins per year. In addition to this petroleum saving potential, a weight savings of 25% leads to even more fuel savings.

In 2012 Ford launched a 15% rice-hull filled polypropylene application. In addition to a wiring bracket, Ford is continuing to look at further potential applications for this material.

Of course, Ford is constantly evaluating more potential applications, materials, and material combinations such as numerous types of natural fibers (including wood, cellulose, or even retired U.S. dollar bills (cotton/linen) for injection molded interior, exterior, and underhood applications. The replacement of mineral filled and glass reinforced composites with natural fiber composites allows weight savings as well as the u se of renewable resources.

Bio-based rubbers In the field of rubbers, Ford is looking into renewable sources such as guayule (Parthenium argentatum) or russian

dandelion (Taraxacum kok-saghyz) for the production of caoutchouc products. Guayule is a plant that grows for instance in the Southwest of the USA or in Mexico and can be grown more sustainably than e.g., the Indian rubber tree (ficus elastic) and the Para rubber tree (Hevea brasiliensis).

Guayule does not contain the protein that can cause allergic reactions that hevea-derived rubber can cause. Russian dandelion (cf. bM 01/2012) is currently under investigation in cooperation with the Ohio Agricultural Research and Development Center (OARDC) at The Ohio State University.

Fordâ&#x20AC;&#x2122;s strategy In 2012, Ford Motor Company implemented a formal statement of their sustainable materials strategy. The strategy states that Fordâ&#x20AC;&#x2122;s vision is to ensure their products are engineered to enable sustainable materials leadership without compromise to product quality, durability, performance, or economics.

Ford has, and continues to grow, a comprehensive research and development program to complement this strategy, which helps the company reduce the impact of materials on the environment. MT www.ford.com

Bio meets plastics.

The specialists in plastic recycling systems.

An outstanding technology for recycling both bioplastics and conventional polymers

bioplastics MAGAZINE [01/13] Vol. 8

23

Automotive

Bio-PET fibres for Nissan electric vehicle

T

eijin Limited, Tokyo, Japan recently announced that its ECO CIRCLE Plantfiber bio-polyester has been selected for use in the seats and interior trim surface of the 100% electric Nissan LEAF, updated on November 20, 2012. It is the first time for Eco Circle Plantfiber to be used for the interior of a mass-produced vehicle. Eco Circle Plantfiber is plant-based polyethylene terephthalate (PET) fiber developed and launched by Teijin as the world’s first commercially produced partly bio-derived PET fiber.

The seat and interior trim surface were co-developed by Teijin, automotive seat manufacturer Suminoe Teijin Techno Co., Ltd. and Nissan Motor Company Ltd. Specifically, Eco Circle Plantfiber is used for the seats, parts of the door trim, headrests and center armrest.

Nissan Leaf, electric vehicle (Photos: Nissan)

About 30% of Eco Circle Plantfiber’s composition is made with biofuels derived from sugarcane. PET typically is made by polymerizing ethylene glycol (EG) and dimethyl terephthalate (DMT) or telephthalic acid (PTA), with EG accounting for roughly 30%. The EG contained in Eco Circle Plantfiber is bio-derived rather than oil-derived. Teijin’s bio-polyester fiber conserves fossil resources and lowers greenhouse gas emissions due to its carbon neutral effects, yet still offers the same characteristics and quality of oil-derived polyester. The Bio-PET fibres also can be recycled using Teijin’s Eco Circle closed-loop polyester recycling system, where polyester is chemically decomposed at the molecular level and then recycled as new DMT that offers purity and quality comparable to material derived directly from petroleum.

Eco Circle Plantfiber is available as fiber and textile. Teijin has been expanding global market for applications for this product ranging from apparel, car seats and interiors to personal hygiene products. The company aims to increase sales to over 50% of its total polyester fiber sales for automotive seats and interiors by 2015. MT www.teijin.co.jp/english

24

bioplastics MAGAZINE [01/13] Vol. 8

Automotive

bioplastics MAGAZINE [01/13] Vol. 8

25

Foam

Durable and eco-friendly foams by Léon Mentink and Jean-Luc Monnet Gaïalene Direction, Roquette Group Lestrem, France

T

he use of bioplastics for the production of flexible and semi-rigid foams is still today very limited. However these foams have extremely diverse applications when they are produced from oil-based plastics. The foams obtained from polyethylene or polypropylene represent a significant share of the volume of foams produced to date on account of their attractive price/performance ratio.

Polyolefin foams Flexible and semi-rigid foams are used in very varied fields, and in particular for packaging. They are applied here as protective packaging, separators, chips, display units etc.

Building and construction constitutes a second big industrial sector for these foams. They are used to produce thermal or phonic insulation partitions, seals, pipes, etc. They are also used in the automotive, sports and leisure, medical and electronics sectors.

Flexible and semi-rigid foams are manufactured using a foaming process in which the polyolefin is melted in an extruder in the presence of a physical or chemical foaming agent. During the process bubbles are created in the molten polymer, which will lead to the formation of foam when the polymer cools down. The process is simple and does not call for pre-expansion or formulation steps, as is the case with polystyrene or polyurethane foams.

The properties of these foams can vary according to specific factors and in particular according to the structure, density and diameter of the foam cells, but also and above, according to the inherent properties of the polymer used.

Thus the foams enable a great number of needs to be satisfied thanks to their mechanical, insulation and shock absorption properties.

Bio-based alternatives known Polyolefin foams have the two main drawbacks of using non-renewable fossil resources and having a fairly high carbon footprint. Work has been done to develop foams from renewable plant-based resources, in particular foams using biodegradable compositions or PLA. Biodegradable foams are used for certain specific markets, for example in the form of chips in water-tight packaging. With PLA, it is also possible to obtain good quality foams, but by using special grades and a specific preparation process. In this case the technology used is more akin to that used for polystyrene foams.

Gaïalene plant-based resin for foams The Roquette Group has developed and patented a plantbased resin reference tailored to the production of bio-based foams. It is an addition to the Gaïalene® range of resins already marketed by Roquette and produced from a nonGMO plant-based resource, widely available in Europe. These resins do not affect food resource availability and enable at

26

bioplastics MAGAZINE [01/13] Vol. 8

Foam

the same time the production of high-value ingredients for nutrition. Furthermore they have a very favourable environmental profile certified by an independent third party. Their carbon footprint is for example reduced by approximately 65 % compared with polyethylene. ‘’The first converters supplied have confirmed the ease with which our new Gaïalene resin can be worked.

It foams readily on existing extrusion equipment for polyolefins. In addition the foams possess excellent mechanical properties, similar to those of polyolefin foams. Our product thus offers many innovation possibilities‘’, explains Jean-Luc Monnet, Roquette’s Business Development Manager.

It is possible to obtain foams with densities from 30 to 300kg/m3 and compatible with a wide range of temperatures. They have excellent properties and are at the same time resilient, flexible, as well as water and grease resistant. It has been demonstrated that they are non-biodegradable and recyclable at the end of life without affecting conventional polyolefin streams.

Gaïalene foams already on the market This Gaïalene grade is today used on an industrial scale by various companies for the production of foams, for packaging and general industry. Innovative foams were for instance revealed at the last International Packaging Show 2012 in Paris.

The Sapronit company (IVEX Group) is one the first users of the new Gaïalene resin. The company has developed its Move by range of plant based packaging products which have been available since last autumn.

Sapronit was rewarded for this innovation by the OSEO Excellence Award in 2012. ‘’The Move by foam enables us to limit our dependence upon oil-based resources thanks to the use of renewable resources. With Move by, our customers can package and sell items with a much lower carbon footprint and thus satisfy an increasing demand from consumers. We now propose this innovation to all our customers. A famous brand of perfume has already chosen Move by for its packaging.’’ comments Jean-Charles Robin, the Chief Executive Officer of Sapronit.

With this major innovation, Sapronit is not only targeting the packaging markets, but also the luxury goods, automotive and building industries. The Move by range is marketed in the form of single or multi-layer rolls or sheets that can be shaped according to the needs, by cutting, bonding, rolling or coating. www.gaialene.com www.sapronit.com www.ivexpackaging.com

bioplastics MAGAZINE [01/13] Vol. 8

27

Foam

High temperature resistant PLA foams

S

cientists based at Crown Research Institute Scion in New Zealand have developed PLA foams with high dimensional stability at elevated temperatures. The research was led by Jean-Phillippe Garancher and Alan Fernyhough for the Biopolymer Network (BPN) Ltd, a research company with a keen interest in development and commercialisation of biofoams.

One of the major limitations of PLA foams in some applications is its poor dimensional stability (leading to squashing, deformation and collapse) when exposed to conditions above 60°C. This temperature corresponds to PLAâ&#x20AC;&#x2122;s glass transition temperature (Tg). Above its Tg, PLA softens and is therefore unable to sustain loads, leading to distortion of the moulded foam articles.

One of the ways to overcome this issue is to promote the crystallisation of PLA. Crystals will provide a rigid structure to PLA products used at elevated temperatures.

Increased crystallisation can be achieved using additives such as nucleating agents or controlling the monomer isomer composition in PLA (making it more pure in one isomeric form). If sufficiently crystallised, PLA is able to bear loads at temperatures significantly above its Tg. These approaches are not always compatible with a particle foaming process as crystalline regions in the PLA tend to restrict both blowing agent uptake and the polymer expansion.

Garancher demonstrated that highly crystalline grades of PLA could be successfully foamed and moulded to low densities. He achieved this by refining an already existing

28

bioplastics MAGAZINE [01/13] Vol. 8

particle foaming process developed by BPN, which used sub-critical CO2 and commercially-available predominantly amorphous PLA to produce mouldable particle foams.

This proprietary method involves absorption of CO2 by PLA followed by pre-expansion and then moulding similar to that used by the EPS industry. The trick to using crystalline grades of PLA is adjusting the CO2 impregnation parameters (the subject of an additional patent application).

The method was successful using commercial grades of PLA, with the grade of PLA selected depending on the final foam properties desired. Using off-the-shelf material, expanded PLA (EPLA) was produced with a high level of crystallinity, simultaneously with low density and fine cellular structure. These foams showed significantly higher dimensional stability at elevated temperatures compared with their amorphous alternatives.

This work provides an opening for EPLA to be used as a substitute for EPS and other polymer foams in a much wider range of applications where stability in higher temperature conditions is important, such as specialised sporting goods and packaging applications. In earlier work, EPLA had been shown to have thermal insulation properties and mechanical properties comparable to EPS at given density values.

As BPN moves closer to commercialising its foam technology, it has built a PLA foam pilot plant in Nelson, New Zealand. The plant will be used to fine-tune the production of PLA foam articles on EPS moulding equipment and to put PLA foam products in to the cold chain packaging marketplace.

Foam

By Paul Charteris Science Communicator Scion Rotorua, New Zealand

Research to produce environmentally friendly packaging options is a priority for the New Zealand fresh seafood industry which seeks to maintain a leadership position in the international market place.

The pilot plant consists of three machines: one for impregnation of the PLA beads, one to pre-foam the impregnated beads and another to produce moulded foam products. The impregnation machine performs the impregnation on a set cycle utilising CO2 as the blowing agent, which is a BPN proprietary process. The machine cycle allows excellent recovery of CO2 to minimise foam production costs. The beads are then foamed in the pre-foamer and transferred directly to the moulding machine.

A small semi-automatic moulding machine is being used, with three moulds operational – a fish box, a fish box lid and a small block mould. After only a few weeks of operation, a number of low density fish boxes and lids have been produced.

Moulding is being further optimised in early 2013 to achieve lower densities concurrently with large volume trials through a commercial plant. Based on early results, a number of New Zealand EPS moulders are keen to trial this process.

This research was funded by New Zealand’s Ministry for Science and Innovation from its BPLY 0801 programme.

Garancher and Fernyhough’s paper: Crystallinity effects in polylactic acid-based foams was published in Journal of Cellular Plastics September 2012 vol. 48 no. 5 387-397.

Info: Scion Scion is a New Zealand Government–owned Crown Research Institute that undertakes research, science and technology development in forestry, wood products, biomaterials and bioenergy. Scion‘s work contributes to beneficial economic, environmental and social outcomes for New Zealand. Formerly the NZ Forest Research Institute, Scion employs approximately 340 people and has its head office in Rotorua.

Biopolymer Network Ltd The Biopolymer Network Ltd (BPN) is a New Zealand research company dedicated to creating technologies to convert primary production outputs into a wide range of high performance, bio-based products.

BPN research is focused on creating products using renewable, natural materials instead of petrochemicals.

Biopolymer Network Ltd has, and continues to develop, its portfolio of intellectual property in biopolymers, specialty chemicals, bio-composites, bio-foams and moulded structures.

With key partners these products are being taken into the market place. The Biopolymer Network‘s research base is built from three of New Zealand‘s largest and leading research organisations, AgResearch, Plant and Food Research and Scion. This provides us with world leading scientific expertise and the largest focused research effort in this area in New Zealand.

www.scionresearch.com www.biopolymernetwork.com

bioplastics MAGAZINE [01/13] Vol. 8

29

Foam

Cellulose-based polymer foams Requirements, Processing and Characteristics by Florian Rapp and Anja Schneider Polymer Engineering – Foam Technologies Fraunhofer Institute for Chemical Technology ICT Pfinztal-Berghausen, Germany

Research focus

I

n the last decade Fraunhofer ICT has focused on a broad range of technologies in Polymer Engineering where one of the research activities is in the field of polymer foaming.

Usually foamed polymer products do not appear obvious in application but they can be found in many aspects of daily life, for example in insulation elements increasing the energy efficiency of a building, protecting goods as packaging elements and serving as functional elements in the automotive industry.

The activities of the Foam Technologies R&D group at Fraunhofer ICT have focused for more than ten years on new materials and processes for foamed thermoplastic polymers, in both particle foams and direct foam extrusion. Today biopolymer foams play an important role of research activities. Bio-based polymers offer high potential to substitute petrochemical polymers in several applications but also need research to adapt the properties of biopolymers to meet individual requirements.

The main elements of research at Fraunhofer ICT are: Material modification regarding foaming behaviour

RO

Processing technology (process modification and development)

O

RO

Material tailoring (property modification/improvement)

RO O

O

Characterization of matrix materials and foams O

Selected materials, processes and foams based on biopolymers will be detailed in this article.

O

Bio-Materials for foam products

OR

RO OR

n Fig. 1: Cellulose-ester

CP:

R = -H; -CO-CH2-CH3

CAB: R = -H; -CO-CH3 and –CO-CH2-CH2-CH3

Fig. 3: Cell morphology of cellulose-based foam particle

On the current market there is a huge range of biopolymers available. Apart from polylactide (PLA), which is well-known in many applications, there is, for example, polyvinyl alcohol (PVA), polycaprolactone (PCL), polyhydroxyalkanoate (PHA), starch-based polymers or fully or partly bio-based PE, PA or PP. Another product field is represented by cellulose-based polymers like cellulose acetate (CA), cellulose propionate (CP) and cellulose acetate butyrate (CAB). These thermoplastic cellulose moulding compounds are gained by esterification of cellulose with acetic acid, butyric acid and propionic acid (see Fig. 1). Their beneficial property profile (high impact strength, weather resistance, high level of transparency, etc.), and biodegradability of the material, offers high potential for various applications like insulation and packaging.

Special emphasis at Fraunhofer ICT is placed on material development and foaming behaviour of cellulose-based polymers, and the characteristics of bio-foam parts. The modification of polymer properties depends on the application. The latest research focus deals with environmentally friendly flame-retardants,

30

bioplastics MAGAZINE [01/13] Vol. 8

Foam

Fig. 2: left: particle foam extrusion line, right: tandem direct foam extrusion line

which is relevant in building insulation. For this purpose the interaction between phosphorus-based and nitrogen-based products, layered silicates and graphite with cellulose-based polymers are analyzed.

Cell morphology and density of bio-foams varies according to their implementation. These structures can be tailored by modifying type and content of nucleating and blowing agents. Very good results were achieved by using pentane as a blowing agent but there is also the possibility, by using nitrogen, or carbon dioxide.

Processing Technology For foaming thermoplastic polymers two principal continuous processing technologies are installed at the site of Fraunhofer ICT (see Fig. 2). On the one hand particle foams can be produced in continuous extrusion line using a twin screw extruder and under water pelletizer with a throughput of 8-30 kg/h. For further processing the entire process chain with pre-expansion equipment and two steam chest moulding machines is available to investigate the sintering behavior and to produce sample parts.

On the other hand semi-finished parts (boards) can be foamed using a tandem direct foam extrusion line (KraussMaffei Berstorff ZE30/KE60) with a throughput of 40-70 kg/h.

Characteristics of cellulose-based foam

The characteristics of the resulting foam beads are analyzed regarding bulk density, which ranges down to 25 kg/mÂł by using CAB and CP, and also cell morphology (see Fig. 3) and geometry. The moulded parts are tested for thermal conductivity as well as compression behaviour (e-modulus, compression strength). At component densities of about 40 kg/mÂł thermal conductivity measurement shows values up to 35 mW/(m*K) which is close to conventional EPS. However compression behaviour shows a difference in comparison to petrochemical polymers. The e-modulus is about 4.0 MPa and compression strength amounts about 0.03 MPa for a CAB-foamed or CP-foamed part at density of 40 kg/mÂł.

Investigations demonstrate that cellulose-based foams show equal processability to petrochemical based foams, which offers the possibility of using established processing technology. Foamed sample parts can be seen in figure 4.

Outlook Part of the future research will be the optimization of material properties, especially mechanical properties, and processing technologies in order to broaden the spectrum of applications for bio-based polymer foams. One focus is to replace conventional polymers in packaging and building insulation but also in technical parts with higher material requirements. www.ict.fraunhofer.de

Special attention is paid to the raw material properties by investigating thermal behaviour (DSC - differential scanning calorimetry), melt strength and elongation viscosity (Rheotens test) plus molecular weight distribution (GPC - gel-permeation chromatography). The melt strength of cellulose-ester (CAB, CP, CA) is equal or even higher than that of polystyrene, which suggests a promising foamability.

To improve the flame retardant requirements, new compounds based on the non-brominated additives mentioned above are developed and tested, reducing flame height, minimizing soot production and building an intumescence layer.

Fig. 4: Foamed biopolymer parts

bioplastics MAGAZINE [01/13] Vol. 8

31

Foam

Alginsulate foam by Bettina Reichl Verpackungszentrum Graz Graz, Austria

B

rown algae (seaweed), which are rapidly self-regenerative and which exist in unlimited quantities are conceivable as a raw material for many different products. In cooperation with the University of Technology in Graz, Austria, a new process for the production of an ecologically non-polluting foam material has been developed. ALGINSULATE FOAM is not soluble in water, but it is light and biodegradable or recyclable with waste paper. Air is used for foaming the Alginsulate Foam. The production process itself is very simple. Few appliances and machines are required and with very low investment costs it is economically possible to use a decentralised process even in smaller plants. Tests have shown that Alginsulate Foam also has natural fire resistant characteristics.

Project Description The almost inexhaustible resources of the oceans are becoming more and more interesting for various sectors of the economy.

Maritime farms can engage in the breeding of animals under the surface and use the sea-bed as an arable area. A rapidly self-regenerative raw material, available in unlimited quantity is offered by algae. The exploitation of such raw materials to develop ecologically meaningful products is the order of the day. Because of the constant reduction in resources ashore it is necessary to find a sustainable solution.

It is almost impossible to imagine life today without foamed plastics. Their uses are multifarious and, in certain sectors, they appear to be irreplaceable. Their range covers insulating materials via packaging materials, construction components and even as far as elements within safety technology etc... The advent of the Alginsulate process means that a foamed material can be produced in a manner which protects the environment.

Alginsulate Foam represents a completely new development. It is not a question of replacing an existing process by a new, ecologically more acceptable variant, but rather the realisation of a technical concept moving in the direction of permanent self-regeneration, a model in which the main effort is directed towards the maximum conservation of resources. The key element is the use of self-

32

bioplastics MAGAZINE [01/13] Vol. 8

Foam

regenerating raw materials. Thus only so much is taken out of the ecological system and can at the same time grow again.

This requirement is clearly fulfilled by the raw material algae..

Because algae are available all over the world, the process can be used practically anywhere. The rapid regeneration of algae flora – up to one metre in 12 hours – means that the resource is almost inexhaustible. The process can be used economically in small, decentralised plants so that factories are conceivable in developing countries, providing work as well as a means of subsistence. Because of the large volumes of foam involved transport distances should be kept as short as possible. This is not the case with the process currently being used for foam production. However, because the raw material proportion is very small, production even in countries without a sea coast will not be a problem because algae in a dried, powdered form can be used as raw material.

The groundwork for the so-called Alginsulate process was developed by the Institute for Process and Particle Engineering at the University of Technology in Graz, Austria, in cooperation with the Universidad de Magallanes Punta Arenasin, Chile.

The project was initiated by Verpackungszentrum Graz, a packaging wholesaler, specialising in ecologically acceptable packaging materials. For further development in the pilot plant, the firm Algotec was founded by Verpackungszentrum Graz in cooperation with the existing constructional engineering firm ATU Ferlach / Austria.

The following results were obtained: a complete calculation of the mass and energybalances of the process, the basic layout of apparatus and machines, an initial cost estimate combined with the resultant calculation of investment required. A further result is the basic definition of process parameters i.e. the determination of the optimum operating condition and the definition of the technically useful concentration areas of the raw materials used. The primary aim of current development is a final assessment of whether, and in which form, this process can be exploited industrially.

Studies completed so far have proved its practicability in principle. Further work will now proceed in the direction of technological development, above all towards modification of the process to achieve certain product characteristics by the use of supplementary materials and in the physical shaping of the end product.

The Process The fundamental elements of this process are an enormous reserve of natural raw material in the form of brown algae, an ecologically neutral foaming propellant, i.e. normal air, and as a reaction environment, - normal water. In addition, the inorganic materials sodium carbonate and calcium chloride are used in the production process, but in such a small quantity that they cannot have any negative effects on the environment. Thus, during the whole of the manufacturing process no ecologically harmful compounds can possibly be discharged into the environment.

For the production of the foams as such, two foaming systems are available, namely, the foaming of individual particles and the foaming of semifinished products or even finished shapes.

Independent of the foaming system, the production process consists of six phases: Preparation of the raw materials Saturation with air Foaming Drying Shaping These prosessing phases are followed by subsequent processing steps according to the finally intended use www.vpz.at

bioplastics MAGAZINE [01/13] Vol. 8

33

Foam

Bioplastic substrates in horticulture and agriculture Expanded PLA enables the production of sustainable substrates for agricultural produce, plants, trees and shrubs

N

ursery and greenhouse potting soil is widely used as a medium for plant growth. This relates especially to pots for cultivation under glass, container-shrubs and tree cultivation. They mainly use peat as a substrate. Peat, like oil, is considered to be a non-renewable resource and its use is under pressure. Also certain markets (UK) are increasingly asking for more durable substrates, that have to be stable in use, offer acceptable end of life solutions, and preferably being biodegradable, renewable and sustainable.

The Synbra Group has a leading position in Europe regarding expandable polystyrene (EPS) for Sustainable Insulation Systems and Industrial Products & Solutions. Synbra Technology bv, based in Etten-Leur, the Netherlands, is the in-house polymerization and R&D facility of the Synbra Group that recently developed BioFoam®, a biobased and biodegradable alternative for EPS.

Fig 1. A shrub grown in a pot with a soil mixture of peat and 40% BioFoam.

BioFoam, a polylactic acid foam (E-PLA) can be used as loose beads or as a moulded foam material and offers an alternative to materials currently available on the market. It has passed stringent stability test on e.g. mould resistance and attack by termites. It does not degrade at ambient temperature conditions, but it can be composted in industrial composting installations.

BioFoam has a huge advantage over most commodity plastics with regard to CO2 emissions. Comparing E-PLA and EPS a remarkable resemblance of mechanical properties is observed [1]. The development of BioFoam is steadily progressing and moulded parts for packaging applications, like the KelvinBox marketed by Cryostore, are produced by Synprodo for everyday use. IsoBouw has developed SlimFix®DecoBIO that can be used for interior (sloping) roof insulation and loose foamed beads can be used for cavity fill.

Synbra has together with the Sustainable Development Group of AkzoNobel conducted an ex-ante Life Cycle Assessment (LCA) of industrial scale BioFoam production (Borén and Synbra 2010) [2]. An LCA allows holistic and quantitative environmental impact evaluations of economic systems, and facilitates relating environmental impacts to a functional unit. An LCA can take into account many different environmental aspects of products, processes or services throughout their value chains (life cycles), from extraction of resources to end of life treatment. By conducting an LCA a holistic profile of a system’s environmental impact is generated. There are ISO standards on LCA; ISO 14040 and 14044.

Fig 2. Shrubs grown in hydro culture covered with a 5 mm open BioFoam sheet preventing any weeds from growing.

34

bioplastics MAGAZINE [01/13] Vol. 8

Research is now further widening to develop sustainable BioFoam applications for horticulture. Composting according to EN-13432 has been performed successfully with densities of up to 55 g/l.

The use of peat in horticulture is becoming controversial due to loss of natural habitats and the emission of carbon dioxide by extraction and

Foam

by Jan Noordegraaf, Jürgen de Jong, Peter Matthijssen all Synbra Technology bv Peter de Bruijn Synprodo bv Ton Baltissen, Karin Molenveld Wageningen University and Research Centre all: The Netherlands Fig 3. Hydroculture shrub growing with 20% BioFoam in the substrate

degradation. Finding sustainable and renewable alternatives that can be industrially and locally produced is in the interest of growers, governments and compost producers. It is especially relevant for pot growers who deliver to countries where the proportion of peat used has to be shown on the label (like the UK). The government seeks to address biodiversity concerns and provides guidance to enforce self-regulation in the sector. The compost producers seek alternatives to replace relatively scarce fractions (black peat and brown peat) which can provide for products with less fluctuation in quality due to weathering.

A formal R&D project was initiated to address these issues.

This development included the following components:

Fig 4. Eggplant (aubergines) grown on a water-permeable BioFoam cube shaped substrate replacing perlite, without any adverse effects to growth yield. It offers reduced value chain costs due to improved end of life options while preserving nutrients contained in the roots by composting.

Development of modified BioFoam suitable for substrates Development and production of substrates based on BioFoam Testing of the new substrate materials and products Technical and economic evaluation of production Communication of project results.

Biomaterials increasingly allow the agricultural and horticultural industry to develop new applications, particularly for the waste phase, allowing cost savings in the value chain (waste disposal and labour). For the substrate industry BioFoam can be used for the development of new products.

Synbra’s E-PLA is a material having similar properties to EPS, also called styrofoam, but is made from renewable resources and is biodegradable. A very promising avenue seems to be the use of BioFoam as a substitute for peat. The substrate must meet the high demands placed on a growth medium. Also for other applications such as transport filler and covers can also be suitable.

Within the project, various strategies were successfully investigated to produce modified BioFoam granules. This is covered by a pending patent. BioFoam was made in several variants that can absorb amounts of water and had adjustable densities and bead sizes, both in round and cubic shapes (see figs. 1 to 6).

Fig 5. Raspberries grown on 20, 40, 60 and 100% BioFoam substrates in a hydroculture application.

Fig 6. BioFoam greenhouse ground cover accelerates the growth of chrysanthemums due to better insulation and improved light reflection. After the growth BioFoam is mixed into the soil.

bioplastics MAGAZINE [01/13] Vol. 8

35

Foam Important characteristics of BioFoam containing substrates were investigated.

Research showed that the stability of BioFoam is comparable to that of fresh coconut and by adding a modified E-PLA with open cells the water retention (see infobox) can be adjusted.

For pF curves see graph.

It was also established that BioFoam granules are suitable as a filler when transporting perennials and bulbs (lily and phlox) and gave a better product than the current packaging (fig. 7).

These opportunities are now further explored and invitations are open to growers to be among the first users to participate in the industrialisation and scaling up.

This project was made possible under the umbrella of the BioBest programme enabled by the province of Gelderland with participation of Synprodo, Synbra Technology, WUR Food & Biobased Research and WUR Applied Plant-CSO. [1] J. Noordegraaf, J. de Jong, P.de Bruijn, R. Hartmann BioFoam: PLA Particle Foam (further) expaning in Europa; Paper presented at the International Conference Particle Foam Conference Berlin, Germany, 28 and 29 November 2012 [2] J. Noordegraaf, A Comparative LCA on building materials. bioplastics MAGAZINE Vol. 6, issue 02/2011 www.synbra-technology.nl www.wageningenur.nl/en.htm

Fig 7. Phlox after transport with traditional transport protection (1) and with BioFoam (5) leads to a much improved preservation and quality of the bulbs.

90 80 Water retention (vol %)

A test cultivation in a hydroculture gutter system with a variety of crops (pivots) and with BioFoam beads as a part of the substrate showed that the growth is fully comparable to a standard substrate. Up to 100% BioFoam was used as a substrate in a hydroculture application showing no loss of growth rate. At the end of life stage it offers the potential to retain the nutrients that are contained in the substrate (roots) by composting - nutrients that otherwise may become lost when using perlite or mineral wool.

70 60 50 40 30 20 10 0

Start

-10 cm -32 cm -50 cm column pressure (cm water)

Standard (peat) BioFoam

BioFoam Mod 1 BioFoam Mod 2

Refill

BioFoam Mod 3 BioFoam Mod 4

Graph 1. Water retention curves comparing various BioFoam modifications under investigation, compared with traditional peat.

Info: Waterretention curves are used to show how much water a given substrate can hold at various suction forces. The amount of water a given substrate can hold and the force a plant has to apply to take it up is very important for the growth. This amount is measured in volume% and the suction force (or how easy it is for a plant to take up water) is measured with a water column. -10 cm corresponds with 1 kPa suction pressure.

The graph clearly shows different water retention for the various substrates at the start of the experiment. By modifying BioFoam the water retention can be modified this way controlling the water uptake of the plants. The graph also shows that at the end of the experiment most substrates can be refilled to return to the starting amount of water.

36

bioplastics MAGAZINE [01/13] Vol. 8

ss e r g nce

on fere K off con

6

st .eu/ k r e sed

iowio-ba B . .b

6

w ww

th

www.bio-based.eu/conference

Int. Conference 2013

on Industrial Biotechnology and Bio-based Plastics & Composites

10 – 12 April 2013, Maternushaus, Cologne, Germany KBBPPS Project – Pre-standardization research for bio-based products in the EU: 1st Advisory Workshop, 9 April 2013, Maternushaus, Cologne: www.bio-based.eu/kbbpps

Highlights from the worldwide leading Countries in Bio-based Economy: USA & Germany More than 250 participants expected!

Entrance Fee

Conference incl. Catering

Programme: Three-day conference programme and more than 30 confirmed speakers!

The following high-profile companies, universities, institutes and organisations have already confirmed their participation:

USA:

Two Days (10 – 11 April 2013)

€ 750

Three Days (10 – 12 April 2013)

€ 900

First Day (10 April 2013): Policy and Industry

€ 450

Second Day (11 April 2013) Industry

€ 400

Germany: BASF SE // Bayer MaterialScience // Bioeconomy Council (of the Federal

Government of Germany) // Biotec GmbH // Clariant Produkte (Deutschland) // CLIB2021 // DIN CERTCO // European Bioplastics // FKuR Kunststoff GmbH // Institut für Kunststofftechnik // Johann Borgers GmbH & Co. KG // Max Planck Institute of Colloids and Interfaces // Research Institute Biopos // Tecnaro GmbH // The Fraunhofer Institute IAP // The Fraunhofer Institute IGB // The German Association of Biotechnology Industries (DIB) // University of Applied Sciences Bremen // University of Applied Sciences Hanover // University of Bayreuth // University of Stuttgart

Third Day (12 April 2013) € 350 Science & Technology plus 19 % VAT.

Contact person Michael Carus CEO nova-Institute GmbH +49 (0) 2233 48 14 40 contact@nova-institut.de

Venue

Beta Analytic Ltd. // Biotechnology Industry Organization (BIO) // Cornell University // DuPont // Light Light Solutions LLC // Michigan State University // Myriant Corporation // NatureWorks LCC // University of Texas // University of California // WSU Institute for Biological Chemistry

Innovation Award „Bio-based Material of the year 2013“ - Apply now!

Deadline 15 February 2013 Contact: Lena Scholz (lena.scholz@nova-institut.de) phone: +49 (0) 2233 48 14 48

Exhibition – Bio-based Chemicals, Plastics and Composites Exhibition booths starting at 800 €.

Contact: Dominik Vogt (dominik.vogt@nova-institut.de) phone: +49 (0) 2233 48 14 49

Maternushaus Cologne Kardinal-Frings-Str. 1-3 50668 Cologne, Germany Tel.: +49 (0) 221 16 310 E-Mail: info@maternushaus.de

Organiser

In Cooperation with

Sponsor of the Conference

Sponsor Innovation Award

www.biotec.de

www.coperion.com

The Biological Materials Group

www.nova-institute.eu

www.hs-bremen.de

Additional Sponsors for the Conference are very welcome!

Materials

Biocomposite uses Green PE

Copolyester for consumer electronics

T

A

o meet the growing demand for environmentally friendly and high-performing materials, Rhe Tech, Inc. (Whitmore Lake, Michigan, USA) has expanded its RheVision® line of biocomposites. RheTech is using Braskem’s (São Paulo, Brazil) new generation of polyethylene which utilizes sugar cane instead of oil or natural gas that typically is used as the base feedstock.

As with its other RheVision products, RheTech’s latest offerings have a substantially lower carbon footprint than traditional reinforced olefins. The biocomposites are also lighter weight and offer unique aesthetic characteristics.

In mid-2010, RheTech launched the RheVision line, which uses bio waste material as a sustainable alternative to traditional mineral and glass-reinforced polypropylene. The initial lineup of biofiber reinforced polypropylenes featured wood flour, ground rice hulls and flax fiber. Agave fiber and coconut fiber-based products were added in early 2012.

RheTech has done extensive testing of the new sugar canebased polyethylene. To date, the company has developed wood flour and flax fiber compounds. The wood flour compound (WP30E109-00) is 30% pine wood flour reinforced green polyethylene, while the flax fiber (FF10E109-00) is 10% flax fiber reinforced green polyethylene. Typical physical properties are noted below.

Wood Flour: Wood Flour: WP30E109Units 00WP30E109-00

Flax Fiber: Flax Fiber: FF10E109-00 Units

Density

1.05

g/cm3

0.97

Flexural Modulus

2,630 (380,000)

MPa (psi)

1,345 (195,000) MPa (psi)

KJ/m2

3.0

Izod Impact – Notched 2.8 at 23°C

g/cm3

KJ/m2

There already has been considerable interest in this new product line. RheTech is currently in the sampling/ development stage for a variety of consumer applications.

Automotive and heavy-duty truck applications are planned for the future. RheTech believes there is tremendous potential for this product and looks forward to developing new applications that can utilize the benefits of both the waste bio fiber and the new green polyethylene developed

by Braskem. MT

from left: maple wood, flax fiber, pine wood

38

bioplastics MAGAZINE [01/13] Vol. 8

rnitel© Eco thermoplastic copolyester from DSM has been used successfully in soft touch surfaces by a world leading manufacturer of consumer electronics. Applied to the surface using a 2K molding technique, enabling cost efficient mass production, Arnitel Eco helps to create an almost skin-like feeling to the surfaces of electronic devices, like notebooks and tablets. The application represents the first use in consumer electronics of this breakthrough material.

Arnitel Eco is a high performance thermoplastic copolyester (TPC) with 20% - 50% of its content derived from renewable resources. These renewable resources are made from rapeseed oil. Arnitel Eco delivers a carbon footprint reduction of up to 50% when compared to classic copolyester solutions, thus supporting the need of brand owners for more sustainable material solutions.

Francis Aussems, Project Manager Bio-Polyesters for DSM, says: “In consumer electronics, there is a growing awareness of more sustainable material solutions.

DSM is at the forefront with the the development of halogen free materials for cables and connectors, the introduction of recycled materials, and, last but not least, the introduction of bio-based polymers like Arnitel Eco and Ecopaxx.”. MT www.dsmep.com

Bringing the Best and Brightest from over 100 Companies spanning 4 Continents

Join us at this Conference on a journey through the world of ”BioPlastics: The ReInvention of Plastics”; an adventure we have not seen in the chemical industry since the 1960’s.

Sessions Include: Green Plastics: Techno-Commercial Update BioPolymers in Packaging Applications Brand Owners on BioPlastics Advances in Biobased Building Blocks BioPlastics Modification Value Creation from BioPlastics

In Las Vegas’ Luxurious Caesars Palace March 4-6 For Registration Information, Please visit www.BioPlastConference.com Phone: +001 (973)446-9531 E-Mail: info@InnoPlastSolutions.com

Foam

ReBioFoam Project Innovative packaging solution

O

fficially launched in February 2009, the ReBioFoam project (Renewable Bio-polymer Foams), financed by the European Union as part of the 7th Framework Programme, has just entered in its final phase. As its title suggests, the project targeted the development of a new biobased and biodegradable foam to be applied as a protective packaging solution alternative to expanded materials of fossil origin, traditionally used in the sector. The expansion of the biopolymers has been obtained by using microwave technology, which takes advantage of the inner water content of the material as expanding agent.

With a targeted density of as low as 40 kg/mÂł, the novel biobased material will be used for the production of biodegradable 3D-shaped foamed package systems. These new products do compete with currently applied technologies such as various moulded, semi-rigid and foamed plastics, which are generally less protective and less expensive than resilient foams. As a result, from the technical perspective, the targeted reference market for the novel biodegradable foamed packaging is the one related to the distribution packaging of higher volume consumer goods such as toys, light electronics, computers and computer peripherals, stereo equipment and small appliances.

The ReBioFoam project has been coordinated by Novamont, Novara, Italy worldwide leading company in the area of materials and biochemicals developed through the integration of chemistry and agriculture. It has involved a 10 companies-strong consortium made up of partners from 8 different countries. R&D activities have been carried out in their major part by a core group of research and knowledge intensive industrial partners (Novamont, C-Tech Innovation, FEN and Chemtex Italia), in cooperation with a limited group of research centres of excellence (Fraunhofer Institut Institute of Applied Polymer Research, Czech Technical University and ITENE), packaging producing companies (Complas Pack and Recticel) and a large player in the area of household appliances (Electrolux).

40

bioplastics MAGAZINE [01/13] Vol. 8

Foam

By Fererica Mastrianni Project Funding Officer Danielen Turati R&D Materials Technologist Novamont Novara, Italy

From a technical point of view, the process that leads to the production of the new bio-foams can be described by two main steps: (I) formulation and processing, i.e. the extrusion of the base materials with small quantities of biobased and/ or renewable additives and subsequent conditioning, in order to produce pellets with specific tailored parameters for the following expansion phase; (II) microwave assisted expansion and moulding. During this second step, pellets are transferred into a microwave-transparent mould and further processed by microwaves at controlled temperature. Rapid dielectric heating of the pellets causes the pellets to foam in the mould, thus resulting in a 3-D shaped foamed product.

The feasibility of the foaming process has been demonstrated on a semi-industrial scale through the development of an automated pilot line able to produce the defined demonstrator (porthole spacer for washing machine) with the required density (40 kg/m3). In parallel, a new packaging element with corner shape has been designed, characterized by different bearing surfaces which may be assembled in different ways to have elements with different shapes.

The pilot line consists of four sequential stations. In the first, pellets are stored in a stirred tank and dosed properly in a bottom-half mould. The mould is then introduced into the ovenâ&#x20AC;&#x2122;s cavity and closed mechanically: microwave irradiation automatically switches on and the pellets do expand inside the rotating mould, releasing steam. During the third step, the bottom-half mould is pulled out from the oven and transferred to an extraction unit, where the foamed product is removed by two mechanical extractors and a manipulator. The fourth and last stage consists of a conditioning unit, where the mould is transferred and thermally conditioned through an IR lamp or an air jet before restarting a new process cycle.

The tests performed demonstrated that the biofoam has good good mechanical as well as thermal and electrical insulating properties, confirming the possibility to effectively use it as protective packaging for small as well for big appliances.

The success of the ReBioFoam project opens up new important routes in terms of environmental sustainability and limitation of the use of non-renewable resources.

Biodegradation and compostability tests have been carried out onto a 3D-shaped ReBioFoam demonstrator according to CEN Standard on Biodegradability and Compostability (EN 13432:2004). Disintegration under Home Composting conditions has been additionally evaluated according to UNI 11355:2010, demonstrating that ReBioFoam material does disintegrate even at low temperature conditions.

The outcomes of the Life Cycle Analysis applied to the new packaging system show that its use would offer significant advantages in terms of reduction of GHG emissions (e.g. fossil CO2) and the use of non renewable resources (e.g. oil).

From a waste management perspective, the use of biobased and compostable expanded packaging systems, compared to conventional expanded products, helps to divert these innovative packaging from landfill and conventional polymer recycling schemes to existing organic recycling systems.

Landfill would pass from about 52% (current scenario with conventional packaging systems) to 37% (alternative scenario with a compostable packaging system), whereas recycling would pass from 0,5% (conventional product) to 40% (compostable prototype), without modifying the waste collection schemes currently in place, also with beneficial effects on associated direct and indirect waste management costs. www.rebiofoam.eu

The foamed starch has been characterized in terms of mechanical properties standards of packaging materials.

bioplastics MAGAZINE [01/13] Vol. 8

41

Application News

Compostable chocolate wrapper An Italian consortium, of organic producers and farmers, has chosen compostable NatureFlex™ from Innovia Films to wrap its range of Fair Trade chocolate.

Alce Nero, part of Alce Nero Mielizia SpA, and its members share a common ethos for regionality, innovation and the environment. The choice to farm organically has characterised the organisation since its inception in 1978.

Today the company represents farmers, beekeepers and Fair Trade producers, all members of the company. Real organic food from around the world, not just Italy, is promoted by Alce Nero.

“We decided to move from standard plastic to a biodegradable and compostable alternative to wrap our chocolate bars.

Metallised NatureFlex™ from Innovia Films was a perfect fit for us due not only to its environmental attributes but also its excellent barrier properties to keep our organic Fair Trade chocolate in premium condition,” explained Nicoletta Maffini, Marketing Manager, Alce Nero.

The consortium’s chocolate bars are made with cocoa from plants grown in Costa Rica, in the heart of Central America, by the partner COOP Sin Fronteras, a network of small Fair Trade producers. The cocoa pods are harvested, the beans are roasted and the exceptional skill of a long established Swiss maison chocolatier, Chocolate Stella of Chocolate Bernrain Group, subsequently transforms them into delicious products.

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. It is also confirmed as suitable for emerging ‘waste to energy’ techniques such as anaerobic digestion.

“Our metallised NatureFlex film is used to good effect here by Alce Nero as it fits in with their brand image, protects the product and is compostable,” said Giorgio Berton, TS&D Specialist, Innovia Films. www.innoviafilms.com www.NatureFlex.com www.alcenero.it

Skin-touch screw caps In response to growing demands from consumers, cosmetic products are increasingly based on natural products, even sometimes on organic ingredients and additives. Due to this evolution, more and more cosmetic companies are looking for the right packaging, more ecofriendly and made from renewable resources instead of finite fossil resources.

Well known as cosmetic and pharmaceutical supplier, RUBA Thermoplast AG (Zuzgen-Switzerland) has recently announced that it has developed a bio-based version of its wide range of screw caps dedicated to face and body care tubes.

Ruba has a large knowledge of plastic molding injection as well as mold design and construction. Since more than 50 years, Ruba’s main activity is the production of cosmetic and pharmaceutical screw caps. The company offers a versatile range of caps for tube diameters from 16 to 50 mm.

With this new range of bio-based screw caps, Ruba brings innovation to its customers. The company has chosen a Gaïalene® grade delivered by Roquette. This resin presents the advantage of being produced in Western Europe from a local and non-GMO plant-based resource. ”This resin is well designed for our needs. It allows getting nice caps for a full range of forms, colors and finishing. Moreover, our bio-based caps have a reduced carbon footprint and can be produced at an attractive price. A Swedish company has already selected our biobased caps because of their very interesting skin touch valuable on markets.” comments Serge Blauel, Ruba’s Deputy Director.

These new tube caps have successfully passed qualification tests. They are ready for production and delivery in several references for sustainable and ecofriendly packaging. The bio-based range is available in different versions with various finishes like all Ruba screw caps.

These top quality bio-based screw caps underlines Ruba’s commitment to reduce environmental footprint and to bring innovative solutions for cosmetic and pharmaceutical industries.

The Alce Nero chocolate bars are wrapped in compostable metallised NatureFlex from Innovia Films.

42

bioplastics MAGAZINE [01/13] Vol. 8

www.ruba-thermoplast.ch www.gaialene.com

Application News

Edible lamp

Transparent bio-film Plastiroll, from Ylöjärvi, Finland, one of the leading European producers of biodegradable films and bio waste bags has developed biodegradable, transparent packaging film, which extends the shelf life of fresh produce such as fruits and vegetables.

The New York based designer Victor Vetterlein recently introduced an edible and biodegradable plastic LED desk lamp called BITE ME. When the lamp is no longer useful or desired, the lighting strip is removed and the lamp may be eaten or thrown onto the garden compost heap. The design is inspired by a book by E.S. Stevens, a Professor of Chemistry at the State University of New York, called “Green Plastics-An Introduction to the New Science of Biodegradable Plastics”.

The Bite Me lamp is made from bio-plastic that consists of: agar-a vegetable based gelatin made from sea algae, vegetable glycerin, purified water, food coloring, and natural flavoring. The lamp is available in four organic extract flavors: orange, cherry, blueberry, and apple. Bite Me comes with a LED lighting adhesive strip where the electrical power to the LED circuit board is provided through two laser cut sheet metal strips in the form of script that are placed between two clear plastic sheets. The lamp is sold with two electric cords, one that connects to the low voltage power converter and another that plugs into a computer.

At the end of the life of the Bite Me lamp the bio-plastic parts are consumed or composted.

The lighting strip easily peels away from the lamp frame for re-use. After cleaning the frame with organic soap and water, the lamp must be submerged in purified water for one hour to soften before eating. Alternately, the lamp may be placed directly into the garden as compost. Agar is low in sodium and very low in saturated fat as well as cholesterol.

It is also a good source of vitamin E (alpha tocopherol), vitamin K, pantothenic acid, zinc and copper, and a very good source of folate, calcium, iron, magnesium, potassium and manganese. MT

Following two years of research and development work, Plastiroll is introducing a new transparent packaging film ‘Transparent Future 506’ that is an ideal packaging solution for fresh produce such as fruit and vegetables. The film is coextruded from combination of corn starch based materials which results in a film which forms a breathable membrane that is biodegradable (EN 13432) and GMOfree with good strength properties. ”Our new bio-film is an ecological alternative to conventional plastic films with the same physical properties. There is a demand for packaging materials with good green credentials as long as they perform as well as or better than conventional films,” points out Jani Avellan, Product Development Manager at Plastiroll. ”For our customers this is a solution that offers significant cost savings through longer shelf life, less waste and lower disposal costs.”

As the bio-film is biodegradable it can be easily disposed of along with the food waste.

Optimum balance for fresh produce The packaging film is sealable and can be used on its own or as part of a carton box or tray. Depending on customer requirements it can be supplied in different thickness and roll width for use in most types of packaging machinery.

The performance has been rigorously tested with customers in Europe who have reported significantly increased shelf-life extensions of fresh produce. This is because the packaging film helps create an optimum balance between humidity control and oxygen and carbon dioxide permeability which, in turn, contributes to slowing product degradation. Also, due to the fact that sealing temperature of bio-films is lower than of conventional plastic films, less energy and lower temperatures are needed during the bio-film packaging process.

The company’s development of multilayer materials based on sandwiches of biomaterials with different properties that can be tailored to customer requirements are key to the new clear packaging product. By combining the right mixtures it is possible to create stronger products with a better tolerance of grease, water vapour and gases.

The introduction of the transparent bio-film follows the company’s significant investment in production capacity for biodegradable films in 2010 that doubled the company’s production capacity and supported an increased range of products. www.plastiroll.fi

www.victorvetterlein.com

bioplastics MAGAZINE [01/13] Vol. 8

43

Application News

Bio-tiles

Innovative office chair

Even tiles can be organic – if they are made of renewable raw materials. They are more resource efficient than their ceramic counterparts and unlock new creative options for design. The bio-tiles consist of a mixture of linseed oil epoxy, various natural fibres and diatomaceous earth, a material that is procured from fossilized diatoms.

The Generation by Knoll® work chair revolutionized the world of office seating with significant support from material science, processing and expert application development at DuPont. The chair embraces the idea of elastic design – where a product rearranges itself in response to its user. Knoll Inc. is headquarted in East Greenville, Pennsylvania, USA.

New bio-based tile systems, like the ones designed at the Fraunhofer Institute for Mechanics of Materials IWM in Halle, Germany, are more environmentally friendly, lighter-weight and – depending on their manufacturing and material properties – more resource- and energy-efficient than conventional ceramic materials. “The composite is not hard as glass and brittle like conventional epoxy, but flexible and more pliable instead. This makes it easier to work with the tiles,” as Andreas Krombholz, scientist in the natural composites division at IWM, describes another advantage.

They also put a completely new spin on architectural perspectives. In the moulding process, they can be shaped on an entirely customized basis, and shaped into squares, triangles or circles, for example. Even patterns and colours can be tailor-made.

Key to the chair’s flexing and supportive features is the use of high-performance DuPont thermoplastics in the form of renewably sourced DuPont™ Hytrel® RS TPC-ET for the Flex Back Net with no compromise on properties and other DuPont materials (TPC-ET, PBT) for the Dynamic Suspension control.

Another design advantage: By adding fluorescent pigments to the blend, they are transformed into light tiles.

This means they can be used both outdoors and indoors, serving as illuminated guideposts on floors and walls.

The same bio-tiles can also be installed in kitchens and bathrooms and can serve as indoor floor coverings. There are cost benefits to both producer and customer here: this is because the tiles can handle the impact noise abatement directly, so an entire work step can be dropped from the production process. MT www.iap.fraunhofer.de

Designed by Formway Design of New Zealand, Generation uses high-performance DuPont materials in a way that had never before been seen in the furniture industry. The Flex Back Net and the Dynamic Suspension control work together to give the chair its flexibility and structure – allowing it to move to suit the extended range of motion required in a contemporary working environment – and yet still retain the memory of its original position.

The Flex Back Net, which deploys renewably sourced Hytrel, supports many different postures and allows for a wide range of multi-dimensional movement – not just from front-to-back, but also from side-to-side. Users also can push against the Flex Top of the backrest and it will bend over to support their arm as they turn and chat with a colleague.

Thanks, in part, to its use of renewably sourced materials from DuPont, Generation was the first product in the furniture industry to be rated Sustainable Platinum by the SMaRT© Consensus Sustainable Product Standard, a comprehensive, transparent, sustainable product standard that measures a product’s environmental, economic and social benefits over its life cycle and throughout its global supply chain, from raw materials extraction through reclamation or re-use. MT www.knoll.com www.dupont.com

This bio-tile not only comes with an excellent ecological balance, it even unlocks new design options.

Using the inherent properties of Hytrel RS TPC-ET for the Flex Back Net,the chair literally flexes as you change position, responding to your movements (Image: Knoll, Inc.)

44

bioplastics MAGAZINE [01/13] Vol. 8

From Science and Research

Efficient drug release by an absorbable foam

I

n a novel approach for the treatment of common diseases of the urinary bladder (e.g. overactive bladder) a system for the controlled release of drugs (drug delivery system, DDS) is currently being developed using a special polylactide based foam material. The system is placed directly into the urinary bladder. Thus, the active medical agent has a locally lasting effect in the bladder and wonâ&#x20AC;&#x2122;t affect the whole body like with orally administered tablets. Also a regular catheterization in short time intervals (several times a day) is not required. The DDS consists of drug-loaded polymer matrix (so called microspheres), which are embedded in a foamed, absorbable carrier system (cf picture). The drug release and the excretion of the system are controlled by the degradation of the carrier system. In this joint research project the development of the foamed carrier system is a scope of the Institute of Plastics Processing (IKV) at the RWTH Aachen University.

Other project partners are Dr. Pfleger GmbH, Hemoteq AG, DWI at the RWTH Aachen and the urology of the hospital of the RWTH Aachen (all Germany).

The carrier system is manufactured in a so-called CESPprocess (Controlled Expansion of Saturated Polymers). The technology of the CESP-process enables the possibility of processing temperature-sensitive materials, like the used

polymermatrix with drug

microsphere

poly (D,L-lactide-co-glycolide)-co-PEG (here Resomer RGP d5055 or d50155 resp. by Evonik, Darmstadt, Germany).

The material can be processed in a CO2 atmosphere at high pressure (approx. 50 bar) at low temperatures of approx. 50 °C. By an extension of the CESP-process a powdery polymer microsphere mixture can be foamed specific via a pressure controlled, continuous variable discharge. The adjustment of the degradation of the carrier system to medically necessary periods is possible by the termination of the foam structure.

For reproducible manufacturing of the carrier system in the range of micrograms a dosing unit and adapted cavities are integrated into the process chain.

Because of the extension of the CESP-process by a reproducible dosing of the materials and an optimized controlling several more applications in the scope of absorbable, drug-eluting implants, such as porous osteosynthesis plates or stents are possible.

The investigations set out in this report received financial support from the German Federal Ministry of Education and Research (BMBF) (No. 13 N 11306). MT www.ikv-aachen.de

carriersystem with microspheres

bioplastics MAGAZINE [01/13] Vol. 8

45

Basics

PTT

by Michael Thielen

P

TT (Polytrimethylene terephthalate) is a semicrystalline polyester, closely related to the more common thermoplastic polyesters, PET (Polyethylene Terephthalate) and PBT (polybutylene terephthalate) but typically less expensive [1].

Toyota launched the ‘Prius a‘ with interior components made of Sorona EP in Japan in May 2011. The parts are used on the instrument-panel air-conditioning system outlet. (Photo: Toyota)

The aromatic polyester is generally prepared by a polycondensation reaction of terephthalic acid (C6H4(COOH)2) with 1,3-propanediol (HO(CH2)3OH)) compared to PET (polyethylene terephthalate, which is made with ethylene glycol as opposed to 1,3-propanediol) and to PBT (polybutylene terephthalate, which is made with 1 ,4-butane diol as opposed to 1,3-propanediol). PTT was first synthesized by Whinfield and Dickson in 1941 [3]. Further commercialization was slowed by a lack of readily available, inexpensive 1,3-propanediol [4]. Today the 1,3-propanediol (PDO) component can be derived from renewable resources such as technical starch in a fermentation process and is marketed as Bio-PDO™ [5, 6]. When eventually a biobased terephthalic acid becomes available, even 100% biobased PTT seems viable.

PTT was first launched onto the market mainly in the form of spun fibres and textiles. Because they are particularly soft and yet can bear heavy wear the principal area of application was for domestic carpets and carpets for the automobile industry [7].

The New generation SIM-Drive SIM-WIL electric vehicle features features interior components made from Sorona. Photographs are not yet available (Picture: SIM-Drive Corporation ).

46

bioplastics MAGAZINE [01/13] Vol. 8

PTT can be injection molded and extruded, it shows performance such as a very good surface finishing, better mechanical properties at elevated temperatures, low warpage and good dimensional stability.

The material is very attractive in a range of uses for, electrical and electronic components such as connectors, switches, plugs and housings (appliances, audio equipment, lighting systems, business machines), snapfit parts for automobiles or computers, knobs, and keyboards or instrument-panel air-conditioning system outlet [7, 8, 9, 10, 14]. Key markets include existing PBT (or PET) resin and alloy applications where aesthetics, cost, and/or performance are insufficient [10].

DuPont is one of the companies offering PTT in a broad range of products. DuPont™Sorona® EP thermoplastic polymers contain between 20% to 37% (by weight) renewably sourced Susterra™

Basics

C6H4(COOH)2 + HO(CH2)3OH + 1,3 propanediol

→ [O2CC6H4CO2(CH2)3)]n

+ 2 H2O 12000 Tensile/Flex Modulus, MPa

→ PTT (polytrimethylene terephthalate) + water

O O O O

n

10000 8000 6000 Sorona®Polymer 15-30% Glass

4000 2000 0

PLA Starch Based Bio-Polymer

Source: [13]

terephthalic acid

0 20 40 60 80 100 120 140 160 180 Tensile Strength, MPa

Polycondensation of PTT

1,3 propanediol (bio-PDO) produced by DuPont/Tate&Lyle currently derived from technical starch.

Sorona EP thermoplastic polymer starts with the basic Sorona polymer (fibre) chemistry and then uses a proprietary formulation technology to create high-performance engineering polymer resins.

Compared to PBT, Sorona EP filled with glass fibers shows better mechanical properties such as strengtht and stiffnes, improves the surface appearance, provides lower warpage and good dimensional stability. Sorona EP exhibits performance and molding characteristics similar to highperformance PBT, it can be moulded using conventional injection moulding machines. DuPont offer different types of Sorona from fibre/fabric grades through 15 and 30% glass fibre reinforced grades to food contact compliant types with 15% glass fibre reinforcement.

When extruded as a fibre, Sorona holds an odd cross section – necessary for moisture management – better than traditional polyester – so moisture is transported away from the body efficiently and effectively in activewear. Since fibres and fabrics made with the new polymer are fade resistant, activewear colors remain bold and vivid through many workouts and adventures, not to mention washings. Most agree that the comfort stretch and full recovery of fabrics made with Sorona also lead to freedom of movement – a necessity in activewear.

Cotton / Sorona blends offer softness and a comfort stretch and recovery to provide freedom of movement through the shoulders and elbows where consumers need it most. In other words, Sorona blends easily with other fibres – both synthetic and natural - to enhance and maximize both performance and style.

Fabrics with Sorona can be dyed at a lower temperature and maintain their color fastness. With Sorona, black underclothes stay a lush, rich black while white intimates hold their crisp, fresh white. Colors are vibrant, saturated, and remarkably fade resistant. Sorona intimate apparel is bleachable. Unlike other intimate apparel textiles, PPT fabrics require no special delicate clothes dryer settings or hand washing.

With Sorona, denim and jeans manufacturers can deliver stretch denim fabric, which provides freedom of movement.

Most importantly, the PTT fabric retains both the individual shape and personalized fit of denim garments even after frequent washes.

Apparel made from Sorona PTT fibres (photos: DuPont)

Fleece reaches new levels of softness. With fibres from Sorona microdenier softness is achieved at larger deniers making processing easier.

When blended with other fibres, Sorona continues to offer valuable attributes. Blended with wool it offers softness and drape along with resistance to wrinkles – perfect for the business traveler who goes from plane to meeting.

bioplastics MAGAZINE [01/13] Vol. 8

47

Basics

Intimate apparel

As a carpet fibre, the new material offers outstanding performance including durability, crush resistance and resilience. Best of all, is the benefit of permanent, natural stain resistance that won’t wash or wear off as topical stain treatments are prone to do. Even tough stains like mustard, ketchup and red wine will not penetrate carpets made with PTT fibres. Carpets made with Sorona are bleach- and UVresistant to reduce fading.

DuPont has partnered with leading carpet and rug manufacturers across the globe to bring this environmentally friendly material into residential and commercial markets: SmartStrand® & What Moves You by Mohawk, eco+® Soft to Touch™ by Godfrey Hirst, Amaize by Balta, SENS luxury rugs from HBC Bulckaert, Starck by Fletco. DuPont is also working with the automotive industry to offer similar stain resistant carpets to automotive manufacturers for carpeting and car mats [12].

In March of 2009, the U.S. Federal Trade Commission (FTC) issued a new subgeneric – ‘triexta’ – for fibres made from PTT polymers. Triexta fibres can be used for apparel as well as for carpet applications.

Stretch jeans

Mohawk smart strand carpet (Photo: Mohawk))

48

bioplastics MAGAZINE [01/13] Vol. 8

[1] N.N.: http://www.rtpcompany.com/info/apps/stories/volvo.htm], Internet access 10 Jan 2013 [2] N.N.: WO/PCT patent 2009020947 [3] N.N.: British Patent 578,079, 1941 [4] Brown, H.S.; Casey P.K.; Donahue, J.M.: Poly(Trimethylene Terephthalate) Polymer for Fibres (found in http://www.technica.net/NF/NF1/eptt.htm, internet access 10 Jan. 2013) [5] N.N.: Bioseparation of 1,3-propanediol; http://en.wikipedia.org/wiki/ Bioseparation_of_1,3-propanediol, internet access 10 Jan. 2013 [6] N.N.: DuPont Performance Polymers; The industry’s broadest portfolio of renewably sourced materials, Brochure RSE-A1090500-A1010-PRINT (10/10), DuPont de Nemours [7] Thielen, M.: Bioplastics: Basics. Applications. Markets, Polymedia Publisher, 2012 [8] N.N.: Sorona EP for new Toyota compact van, bioplastics MAGAZINE, Vol. 6, Issue 04/2011 [9] N.N.: http://www2.dupont.com/Renewably_Sourced_Materials, Internet access July 2011 [10] N.N.: http://www.rtpcompany.com/info/flyers/ptt.pdf [11] N.N.: U.S. Patent 2,465,319, 1949 [12] Winch, D.E.: Fibre and Fabric Applications using DuPont Sorona Renewably Sourced Polymer, bioplastics MAGAZINE, Vol 3, issue 04/2008 [13] N.N.: DuPont Sorona EP thermoplastic polymer, renewably sourced material solutions, DuPont brochure K-16836 (10/07) [14] N.N.: Toyota Adopts Renewably Sourced DuPont Sorona EP Polymer For New Hybrid ’Prius α’ Vehicle , Dupont Performance Polymers press release, News.dupont.com

2 nd C o n f e r e n c e o n

istry.eu

CO2

chem www.co2-

7 – 9 October 2013, Essen (Germany)

Carbon Dioxide as Feedstock for Chemistry and Polymers

The main topics will be:

Entrance Fee

7 October:

Congress incl. Catering

Political and technical challenges

8 October:

Two days (7-8 October 2013)

€ 790

CO2-based polymers

9 October:

CO2-based chemicals and fuels

Three days (7-9 October 2013):

€ 945

First day (7 October 2013):

€ 470

A new paradigm for the industrial chemical production has arisen over the last few years: the CO2 economy. According to this vision, CO2 is no longer seen as a waste product with dangerous environmental effects but increasingly as a feedstock for chemicals, fuels and polymers.

Second Day (8 October 2013):

€ 420

Third Day (9 October 2013):

€ 370

(incl. dinner Buffet) (incl. dinner buffet) (incl. dinner buffet)

plus 19 % VAT. Undergraduate and PhD students can attend the conference with a 50 % discount.

Dominik Vogt +49 (0) 22 33 4814 - 49 dominik.vogt@nova-institut.de

For the second year in a row, the conference „CO2 as chemical feedstock - a challenge for sustainable chemistry“ will concentrate on this issue. It will be held on 7-9 October 2013 in the „Haus der Technik“ in Essen, Germany and will be the biggest event on Carbon Capture and Utilization (CCU) in 2013. More than 300 participants from the leading industrial and academic players are expected to attend the conference.

Venue

Haus der Technik e.V. Essen, Germany www.hdt-essen.de

nova-Institute

for Ecology and Innovation GmbH Chemiepark Knapsack

IIndustriestraße nstitute 300 50354 Huerth for Ecology and Innovation

New ‘basics‘ book on bioplastics This new book, created and published by Polymedia Publisher, maker of bioplastics is now available in English and German language.

MAGAZINE

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 blowmoulding 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

Basics

Glossary 3.1

updated

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

Since this Glossary will not be printed in each issue you can download a pdf version from our website bioplastics MAGAZINE is grateful to European Bioplastics for the permission to use parts of their Glossary (see [1]) Readers who would like to suggest better or other explanations to be added to the list, please contact the editor. [*: bM ... refers to more comprehensive article previously published in bioplastics MAGAZINE)

Bioplastics (as defined by European Bioplastics e.V.) is a term used to define two different kinds of plastics: a. Plastics based on → renewable resources (the focus is the origin of the raw material used). These can be biodegradable or not. b. → Biodegradable and → compostable plastics according to EN13432 or similar standards (the focus is the compostability of the final product; biodegradable and compostable plastics can be based on renewable (biobased) and/or non-renewable (fossil) resources).

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

Aerobic - anaerobic | aerobic = in the presence of oxygen (e.g. in composting) | anaerobic = without oxygen being present (e.g. in biogasification, anaerobic digestion) [bM 06/09]

Anaerobic digestion | conversion of organic waste into bio-gas. Other than in → composting in anaerobic degradation there is no oxygen present. In bio-gas plants for example, this type of degradation leads to the production of methane that can be captured in a controlled way and used for energy generation.

[14] [bM 06/09] Amorphous | non-crystalline, glassy with unordered lattice Amylopectin | Polymeric branched starch molecule with very high molecular weight (biopolymer, monomer is → Glucose) [bM 05/09]

Amylose | Polymeric non-branched starch molecule with high molecular weight (biopolymer, monomer is → Glucose) [bM 05/09] Biobased plastic/polymer | A plastic/polymer in which constitutional units are totally or in part from → biomass [3]. If this claim is used, a percentage should always be given to which extent the product/material is → biobased [1] [bM 01/07, bM 03/10]

50

bioplastics MAGAZINE [01/13] Vol. 8

Biobased | The term biobased describes the part of a material or product that is stemming from → biomass. When making a biobasedclaim, the unit (→ biobased carbon content, → biobased mass content), a percentage and the measuring method should be clearly stated [1] Biobased carbon | carbon contained in or stemming from → biomass. A material or product made of fossil and → renewable resources contains fossil and → biobased carbon.

The 14C method [4, 5] measures the amount of biobased carbon in the material or product as fraction weight (mass) or percent weight (mass) of the total organic carbon content [1] [6] Biobased mass content | describes the amount of biobased mass contained in a material or product. This method is complementary to the 14C method, and furthermore, takes other chemical elements besides the biobased carbon into account, such as oxygen, nitrogen and hydrogen. A measuring method is currently being developed and tested by the Association Chimie du Végétal (ACDV) [1] Biodegradable Plastics | Biodegradable Plastics are plastics that are completely assimilated by the → microorganisms present a defined environment as food for their energy. The carbon of the plastic must completely be converted into CO2 during the microbial process.

The process of biodegradation depends on the environmental conditions, which influence it (e.g. location, temperature, humidity) and on the material or application itself. Consequently, the process and its outcome can vary considerably. Biodegradability is linked to the structure of the polymer chain; it does not depend on the origin of the raw materials.

There is currently no single, overarching standard to back up claims about biodegradability. As the sole claim of biodegradability without any additional specifications is vague, it should not be used in communications. If it is used, additional surveys/tests (e.g. timeframe or environment (soil, sea)) should be added to substantiate this claim [1].

One standard for example is ISO or in Europe: EN 14995 Plastics- Evaluation of compostability - Test scheme and specifications [bM 02/06, bM 01/07]

Biomass | Material of biological origin excluding material embedded in geological formations and material transformed to fossilised material. This includes organic material, e.g. trees, crops, grasses, tree litter, algae and waste of biological origin, e.g. manure [1, 2] Blend | Mixture of plastics, polymer alloy of at least two microscopically dispersed and molecularly distributed base polymers Bisphenol-A (BPA) | Monomer used to produce different polymers. BPA is said to cause health problems, due to the fact that is behaves like a hormone. Therefore it is banned for use in children’s products in many countries.

BPI | Biodegradable Products Institute, a notfor-profit association. Through their innovative compostable label program, BPI educates manufacturers, legislators and consumers about the importance of scientifically based standards for compostable materials which biodegrade in large composting facilities.

Carbon footprint | (CFPs resp. PCFs – Product Carbon Footprint): Sum of → greenhouse gas emissions and removals in a product system, expressed as CO2 equivalent, and based on a → life cycle assessment. The CO2 equivalent of a specific amount of a greenhouse gas is calculated as the mass of a given greenhouse gas multiplied by its → global warmingpotential [1, 2] Carbon neutral, CO2 neutral | Carbon neutral describes a product or process that has a negligible impact on total atmospheric CO2 levels. For example, carbon neutrality means that any CO2 released when a plant decomposes or is burnt is offset by an equal amount of CO2 absorbed by the plant through photosynthesis when it is growing.

Carbon neutrality can also be achieved through buying sufficient carbon credits to make up the difference. The latter option is not allowed when communicating → LCAs or carbon footprints regarding a material or product [1, 2].

Carbon-neutral claims are tricky as products will not in most cases reach carbon neutrality if their complete life cycle is taken into consideration (including the end-of life).

If an assessment of a material, however, is conducted (cradle to gate), carbon neutrality might be a valid claim in a B2B context. In this case, the unit assessed in the complete life cycle has to be clarified [1] Catalyst | substance that enables and accelerates a chemical reaction Cellophane | Clear film on the basis of → cellulose [bM 01/10] Cellulose | Cellulose is the principal component of cell walls in all higher forms of plant life, at varying percentages. It is therefore the most common organic compound and also the most common polysaccharide (multisugar) [11]. C. is a polymeric molecule with very high molecular weight (monomer is → Glucose), industrial production from wood or cotton, to manufacture paper, plastics and fibres [bM 01/10] Cellulose ester| Cellulose esters occur by the esterification of cellulose with organic acids.

The most important cellulose esters from a technical point of view are cellulose acetate

Basics (CA with acetic acid), cellulose propionate (CP with propionic acid) and cellulose butyrate (CB with butanoic acid). Mixed polymerisates, such as cellulose acetate propionate (CAP) can also be formed. One of the most well-known applications of cellulose aceto butyrate (CAB) is the moulded handle on the Swiss army knife [11] Cellulose acetate CA| → Cellulose ester CEN | Comité Européen de Normalisation (European organisation for standardization) Compost | A soil conditioning material of decomposing organic matter which provides nutrients and enhances soil structure. [bM 06/08, 02/09]

Compostable Plastics | Plastics that are → biodegradable under ‘composting’ conditions: specified humidity, temperature, → microorganisms and timefame. In order to make accurate and specific claims about compostability, the location (home, → industrial) and timeframe need to be specified [1].

Several national and international standards exist for clearer definitions, for example EN 14995 Plastics - Evaluation of compostability Test scheme and specifications. [bM 02/06, bM 01/07] Composting | A solid waste management technique that uses natural process to convert organic materials to CO2, water and humus through the action of → microorganisms.

When talking about composting of bioplastics, usually → industrial composting in a managed composting plant is meant [bM 03/07] Compound | plastic mixture from different raw materials (polymer and additives) [bM 04/10) Copolymer | Plastic composed of different monomers.

Cradle-to-Gate | Describes the system boundaries of an environmental →Life Cycle Assessment (LCA) which covers all activities from the ‘cradle’ (i.e., the extraction of raw materials, agricultural activities and forestry) up to the factory gate Cradle-to-Cradle | (sometimes abbreviated as C2C): Is an expression which communicates the concept of a closed-cycle economy, in which waste is used as raw material (‘waste equals food’). Cradle-to-Cradle is not a term that is typically used in →LCA studies.

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

Crystalline | Plastic with regularly arranged molecules in a lattice structure Density | Quotient from mass and volume of a material, also referred to as specific weight DIN | Deutsches Institut für Normung (German organisation for standardization) DIN-CERTCO | independant certifying organisation for the assessment on the conformity of bioplastics Dispersing | fine distribution of non-miscible liquids into a homogeneous, stable mixture Elastomers | rigid, but under force flexible and elastically formable plastics with rubbery properties EN 13432 | European standard for the assessment of the → compostability of plastic packaging products

Energy recovery | recovery and exploitation of the energy potential in (plastic) waste for the production of electricity or heat in waste incineration pants (waste-to-energy)

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

Enzymes | proteins that catalyze chemical reactions

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

Ethylen | colour- and odourless gas, made e.g. from, Naphtha (petroleum) by cracking, monomer of the polymer polyethylene (PE) European Bioplastics e.V. | The industry association representing the interests of Europe’s thriving bioplastics’ industry. Founded in Germany in 1993 as IBAW, European Bioplastics today represents the interests of over 70 member companies throughout the European Union. With members from the agricultural feedstock, chemical and plastics industries, as well as industrial users and recycling companies, European Bioplastics serves as both a contact platform and catalyst for advancing the aims of the growing bioplastics industry.

Extrusion | process used to create plastic profiles (or sheet) of a fixed cross-section consisting of mixing, melting, homogenising and shaping of the plastic.

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

FSC | Forest Stewardship Council. FSC is an independent, non-governmental, not-forprofit organization established to promote the responsible and sustainable management of the world’s forests.

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

Genetically modified organism (GMO) | Organisms, such as plants and animals, whose genetic material (DNA) has been altered are called genetically modified organisms (GMOs). Food and feed which contain or consist of such GMOs, or are produced from GMOs, are called genetically modified (GM) food or feed [1] Global Warming | Global warming is the rise in the average temperature of Earth’s atmosphere and oceans since the late 19th century and its projected continuation [8]. Global warming is said to be accelerated by → green house gases.

Glucose | Monosaccharide (or simple sugar).

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

Greenhouse gas GHG | Gaseous constituent of the atmosphere, both natural and anthropogenic, that absorbs and emits radiation at specific wavelengths within the spectrum of infrared radiation emitted by the earth’s surface, the atmosphere, and clouds [1, 9] Greenwashing | The act of misleading consumers regarding the environmental practices of a company, or the environmental benefits of a product or service [1, 10] Granulate, granules | small plastic particles (3-4 millimetres), a form in which plastic is sold and fed into machines, easy to handle and dose.

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

IBAW | → European Bioplastics Industrial composting | Industrial composting is an established process with commonly agreed upon requirements (e.g. temperature, timeframe) for transforming biodegradable waste into stable, sanitised products to be used in agriculture. The criteria for industrial compostability of packaging have been defined in the EN 13432. Materials and products complying with this standard can be certified and subsequently labelled accordingly [1, 7] [bM 06/08, bM 02/09]

Integral Foam | foam with a compact skin and porous core and a transition zone in between.

ISO | International Organization for Standardization JBPA | Japan Bioplastics Association LCA | Life Cycle Assessment (sometimes also referred to as life cycle analysis, ecobalance, and → cradle-to-grave analysis) is the investigation and valuation of the environmental impacts of a given product or service caused. [bM 01/09]

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

Molecule | group of at least two atoms held together by covalent chemical bonds.

Monomer | molecules that are linked by polymerization to form chains of molecules and then plastics Mulch film | Foil to cover bottom of farmland PBAT | Polybutylene adipate terephthalate, is an aliphatic-aromatic copolyester that has the properties of conventional polyethylene but is fully biodegradable under industrial composting. PBAT is made from fossil petroleum with first attempts being made to produce it partly from renewable resources [bM 06/09] PBS | Polybutylene succinate, a 100% biodegradable polymer, made from (e.g. bio-BDO) and succinic acid, which can also be produced biobased [bM 03/12].

PC | Polycarbonate, thermoplastic polyester, petroleum based, used for e.g. baby bottles or CDs. Criticized for its BPA (→ Bisphenol-A) content.

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

PE | Polyethylene, thermoplastic polymerised from ethylene. Can be made from renewable resources (sugar cane via bio-ethanol) [bM 05/10]

PET | Polyethylenterephthalate, transparent polyester used for bottles and film

bioplastics MAGAZINE [01/13] Vol. 8

51

Basics PGA | Polyglycolic acid or Polyglycolide is a biodegradable, thermoplastic polymer and the simplest linear, aliphatic polyester. Besides ist use in the biomedical field, PGA has been introduced as a barrier resin [bM 03/09] PHA | Polyhydroxyalkanoates are linear polyesters produced in nature by bacterial fermentation of sugar or lipids. The most common type of PHA is → PHB. PHB | Polyhydroxybutyrate (better poly-3-hydroxybutyrate), is a polyhydroxyalkanoate (PHA), a polymer belonging to the polyesters class. PHB is produced by micro-organisms apparently in response to conditions of physiological stress. The polymer is primarily a product of carbon assimilation (from glucose or starch) and is employed by micro-organisms as a form of energy storage molecule to be metabolized when other common energy sources are not available. PHB has properties similar to those of PP, however it is stiffer and more brittle.

PHBH | Polyhydroxy butyrate hexanoate (better poly 3-hydroxybutyrate-co-3-hydroxyhexanoate) is a polyhydroxyalkanoate (PHA), Like other biopolymers from the family of the polyhydroxyalkanoates PHBH is produced by microorganisms in the fermentation process, where it is accumulated in the microorganism’s body for nutrition. The main features of PHBH are its excellent biodegradability, combined with a high degree of hydrolysis and heat stability. [bM 03/09, 01/10, 03/11] PLA | Polylactide or Polylactic Acid (PLA), a biodegradable, thermoplastic, linear aliphatic polyester based on lactic acid, a natural acid, is mainly produced by fermentation of sugar or starch with the help of micro-organisms.

Lactic acid comes in two isomer forms, i.e. as laevorotatory D(-)lactic acid and as dextrorotary L(+)lactic acid. In each case two lactic acid molecules form a circular lactide molecule which, depending on its composition, can be a D-D-lactide, an L-L-lactide or a meso-lactide (having one D and one L molecule). The chemist makes use of this variability. During polymerisation the chemist combines the lactides such that the PLA plastic obtained has the characteristics that he desires. The purity of the infeed material is an important factor in successful polymerisation and thus for the economic success of the process, because so far the cleaning of the lactic acid produced by the fermentation has been relatively costly [12].

Modified PLA types can be produced by the use of the right additives or by a combinations of L- and D- lactides (stereocomplexing), which then have the required rigidity for use at higher temperatures [13] [bM 01/09] Plastics | Materials with large molecular chains of natural or fossil raw materials, produced by chemical or biochemical reactions.

PPC | Polypropylene Carbonate, a bioplastic made by copolymerizing CO2 with propylene oxide (PO) [bM 04/12] Renewable Resources | agricultural raw materials, which are not used as food or feed, but as raw material for industrial products or to generate energy Saccharins or carbohydrates | Saccharins or carbohydrates are name for the sugar-family.

Saccharins are monomer or polymer sugar

52

bioplastics MAGAZINE [01/13] Vol. 8

units. For example, there are known mono-, di- and polysaccharose. → glucose is a monosaccarin. They are important for the diet and produced biology in plants.

Semi-finished products | plastic in form of sheet, film, rods or the like to be further processed into finshed products Sorbitol | Sugar alcohol, obtained by reduction of glucose changing the aldehyde group to an additional hydroxyl group. S. is used as a plasticiser for bioplastics based on starch.

Starch | Natural polymer (carbohydrate) consisting of → amylose and → amylopectin, gained from maize, potatoes, wheat, tapioca etc. When glucose is connected to polymerchains in definite way the result (product) is called starch. Each molecule is based on 300 -12000-glucose units. Depending on the connection, there are two types → amylose and → amylopectin known. [bM 05/09] Starch derivate | Starch derivates are based on the chemical structure of → starch. The chemical structure can be changed by introducing new functional groups without changing the → starch polymer. The product has different chemical qualities. Mostly the hydrophilic character is not the same.

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

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

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

One of the most often cited definitions of sustainability is the one created by the Brundtland Commission, led by the former Norwegian Prime Minister Gro Harlem Brundtland.

The Brundtland Commission defined sustainable development as development that ‘meets the needs of the present without compromising the ability of future generations to meet their own needs.’ Sustainability relates to the continuity of economic, social, institutional and environmental aspects of human society, as well as the non-human environment).

Sustainability | (as defined by European Bioplastics e.V.) has three dimensions: economic, social and environmental. This has been known as “the triple bottom line of sustainability”. This means that sustainable development involves the simultaneous pursuit of economic prosperity, environmental protection and social equity. In other words, businesses have to expand their responsibility to include these environmental and social dimensions.

Sustainability is about making products useful to markets and, at the same time, having societal benefits and lower environmental impact than the alternatives currently available. It also implies a commitment to continuous improvement that should result in a further reduction of the environmental footprint of today’s products, processes and raw materials used.

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

Thermoplastic Starch | (TPS) → starch that was modified (cooked, complexed) to make it a plastic resin Thermoset | Plastics (resins) which do not soften or melt when heated. Examples are epoxy resins or unsaturated polyester resins.

Vinçotte | independant certifying organisation for the assessment on the conformity of bioplastics WPC | Wood Plastic Composite. Composite materials made of wood fiber/flour and plastics (mostly polypropylene).

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

References: [1] Environmental Communication Guide, European Bioplastics, Berlin, Germany, 2012 [2] ISO 14067. Carbon footprint of products Requirements and guidelines for quantification and communication [3] CEN TR 15932, Plastics - Recommendation for terminology and characterisation of biopolymers and bioplastics, 2010 [4] CEN/TS 16137, Plastics - Determination of bio-based carbon content, 2011 [5] ASTM D6866, Standard Test Methods for Determining the Biobased Content of Solid, Liquid, and Gaseous Samples Using Radiocarbon Analysis [6] SPI: Understanding Biobased Carbon Content, 2012 [7] EN 13432, Requirements for packaging recoverable through composting and biodegradation. Test scheme and evaluation criteria for the final acceptance of packaging, 2000 [8] Wikipedia [9] ISO 14064 Greenhouse gases -- Part 1: Specification with guidance..., 2006 [10] Terrachoice, 2010, www.terrachoice.com [11] Thielen, M.: Bioplastics: Basics. Applications. Markets, Polymedia Publisher, 2012 [12] Lörcks, J.: Biokunststoffe, Broschüre der FNR, 2005 [13] de Vos, S.: Improving heat-resistance of PLA using poly(D-lactide), bioplastics MAGAZINE, Vol. 3, Issue 02/2008 [14] de Wilde, B.: Anaerobic Digestion, bioplastics MAGAZINE, Vol 4., Issue 06/2009

Events

Event Calendar

Subscribe now at bioplasticsmagazine.com

BIO-raffiniert VII

20.02.2013 - 21.02.2013 - Oberhausen (Rhld.), Germany Fraunhofer UMSICHT

the next six issues for €149.–1)

www.umsicht.fraunhofer.de

Bioplastics - The Re-Innovation of Plastics

Special offer for students and young professionals1,2) € 99.-

04.03.2013 - 06.03.2013 - Las Vegas, USA Cesar‘s Palace www.bioplastconference.com

23. Stuttgarter Kunststoff-Kolloquium

06.03.2013 - 07.03.2013 - Stuttgart, Germany University of Stuttgart

2) aged 35 and below.

Send a scan of your student card, your ID or similar proof ...

www.ikt.uni-stuttgart.de

BioKunststoffe 2013

06.03.2013 - 07.03.2013 - Duisburg, Germany Haus der Unternehmer www.hanser-tagungen.de/biokunststoffe

Kunststoffe im Automobilbau 2013

13.03.2013 - 14.03.2013 - Mannheim, Germany Rosengarten www.kunststoffe-im-auto.de

Green Polymer Chemistry 2013

19.03.2013 - 21.03.2013 - Dongguan, Guangdong Maritim Hotel www.amiplastics.com/events/Event.aspx?code=C499&sec=2855

6th Int. Conference on Industrial Biotechnology and Bio-based Plastics & Composites 10.04.2013 - 12.04.2013 - Cologne, Germany Maternushaus www.bio-based.eu/conference

Chinaplas 2013

20.05.2013 - 23.05.2013 - Guangzhou, China China Import and Export Fair Complex www.chinaplasonline.com

K‘2013

16.-23.10.2103 - Düsseldorf, Germany Visit bioplastics MAGAZINE in Hall 7a, Booth 7aB10 www.k-online.com

Innovation Takes Root 2014

17.-19.02.2014 – Orlando, Florida, USA Orlando World Center Marriott www.innovationtakesroot.com

You can meet us!

Please contact us in advance by e-mail.

+

or

Mention the promotion code ‘watch‘ or ‘book‘ and you will get our watch or the book3) Bioplastics Basics. Applications. Markets. for free 1) Offer valid until 31 Dec. 2013 3) Gratis-Buch in Deutschland nicht möglich, no free book in Germany

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

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

Natur-Tec® - Northern Technologies 4201 Woodland Road Circle Pines, MN 55014 USA Tel. +1 763.225.6600 Fax +1 763.225.6645 info@natur-tec.com www.natur-tec.com

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:

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. No.33 Kefeng Rd, Sc. City, Guangzhou Hi-Tech Ind. Development Zone, Guangdong, P.R. China. 510663 Tel: +86 (0)20 6622 1696 info@ecopond.com.cn www.ecopond.com.cn FLEX-162 Biodeg. Blown Film Resin!

Bio-873 4-Star Inj. Bio-Based Resin!

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

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

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.

Jincheng, Lin‘an, Hangzhou, Zhejiang 311300, P.R. China China contact: Grace Jin mobile: 0086 135 7578 9843 Grace@xinfupharm.com Europe contact(Belgium): Susan Zhang mobile: 0032 478 991619 zxh0612@hotmail.com www.xinfupharm.com 1.1 bio based monomers

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

190

200

210

1.2 compounds

220

230

240

250

www.facebook.com www.issuu.com

260

www.twitter.com 270

54

www.youtube.com

bioplastics MAGAZINE [01/13] Vol. 8

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

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

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

Guangdong Shangjiu Biodegradable Plastics Co., Ltd. Shangjiu Environmental Protection Eco-Tech Industrial Park,Niushan, Dongcheng District, Dongguan City, Guangdong Province, 523128 China Tel.: 0086-769-22114999 Fax: 0086-769-22103988 www.999sw.com www.999sw.net 999sw@163.com

WinGram Industry CO., LTD Great River(Qin Xin) Plastic Manufacturer CO., LTD Mobile (China): +86-13113833156 Mobile (Hong Kong): +852-63078857 Fax: +852-3184 8934 Email: Benson@wingram.hk 1.3 PLA

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

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

BIOTEC Biologische Naturverpackungen Werner-Heisenberg-Strasse 32 46446 Emmerich/Germany Tel.: +49 - 2822 - 925110 info@biotec.de www.biotec.de

Suppliers Guide 1.6 masterbatches

3. Semi finished products

4. Bioplastics products

3.1 films

ROQUETTE Frères 62 136 LESTREM, FRANCE 00 33 (0) 3 21 63 36 00 www.gaialene.com www.roquette.com

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

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

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

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

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

2. Additives/Secondary raw materials

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

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

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

3.1.1 cellulose based films

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

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

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

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

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

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

bioplastics MAGAZINE [01/13] Vol. 8

55

Suppliers Guide 7. Plant engineering 10

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

20

30

40

EREMA Engineering Recycling Maschinen und Anlagen GmbH Unterfeldstrasse 3 4052 Ansfelden, AUSTRIA Phone: +43 (0) 732 / 3190-0 Fax: +43 (0) 732 / 3190-23 erema@erema.at www.erema.at

6. Equipment

50

Simply contact:

Tel.: +49 2161 6884467

60

6.1 Machinery & Molds

suppguide@bioplasticsmagazine.com 70

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

Molds, Change Parts and Turnkey Solutions for the PET/Bioplastic For only 6,– EUR per mm, per issue you Container Industry 284 Pinebush Road can be present among top suppliers in Cambridge Ontario the field of bioplastics.

Canada N1T 1Z6 Tel. +1 519 624 9720 For Example: Fax +1 519 624 9721 info@hallink.com www.hallink.com

80

90

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

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 8. Ancillary equipment

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

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

Sample Charge for one year:

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

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 ProTec Polymer Processing GmbH extends automatically if it’s not canceled Stubenwald-Allee 9 three month before expiry.

64625 Bensheim, Deutschland

Tel. +49 6251 77061 0 Fax +49 6251 77061 500 info@sp-protec.com www.sp-protec.com

190

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

6.2 Laboratory Equipment

200

210

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

220

230

240

250

www.facebook.com www.issuu.com

260

www.twitter.com 270

56

www.youtube.com

bioplastics MAGAZINE [01/13] Vol. 8

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

nova-Institut GmbH Chemiepark Knapsack Industriestrasse 300 50354 Huerth, Germany Tel.: +49(0)2233-48-14 40 E-Mail: contact@nova-institut.de

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

UL International TTC GmbH Rheinuferstrasse 7-9, Geb. R33 47829 Krefeld-Uerdingen, Germany Tel: +49 (0)2151 88 3324 Fax: +49 (0)2151 88 5210 ttc@ul.com www.ulttc.com 10. Institutions 10.1 Associations

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

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

10.2 Universities

IfBB – Institute for Bioplastics and Biocomposites University of Applied Sciences and Arts Hanover Faculty II – Mechanical and Bioprocess Engineering Heisterbergallee 12 30453 Hannover, Germany Tel.: +49 5 11 / 92 96 - 22 69 Fax: +49 5 11 / 92 96 - 99 - 22 69 lisa.mundzeck@fh-hannover.de http://www.ifbb-hannover.de/

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

2013

P R E S E N T S

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

Call for proposals

til Please let us know un

August 31st:

d does ce or development is an rvi se t, uc od pr e th at an award 1. Wh velopment should win de or ce rvi se t, uc od pr 2. Why you think this nisation does osed) company or orga op pr e th (or ur yo at 3. Wh also be prox 1 page) and may (ap s rd wo 0 50 ed ce ex or techniYour entry should not keting brochures and/ ar m s, ple m sa , hs ap prepared supported with photogr e 5 nominees must be Th ). ck ba nt se be ot nn cal documentation (ca videoclip nd co se 30 a to provide ded from try form can be downloa More details and an en ine.de/award www.bioplasticsmagaz

The Bioplastics Award will be presented during the 8th European Bioplastics Conference November 2013, Berlin, Germany

supported by

Sponsors welcome, please contact mt@bioplasticsmagazine.com

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

Companies in this issue Company

Editorial Advert

Editorial Advert

Company

A&O FilmPAC

55

FNR

10

Plastic Suppliers

Adsale (Chinaplas)

17

Formway Design

44

plasticker

1, 10

Plastiroll

Akzo Nobel

34

Four Motors

Alce Nero

42

Fraunhofer IAP

40

polymediaconsult

Altuglas

6

Fraunhofer ICT

30

PolyOne

Antibioticòs

7

Fraunhofer IWM Halle

44

API

54

Fraunhofer UMSICHT

Arkema

55

FTC

56

PSM

55

48

Purac

48

Grabio Greentech

Bio Base Europe Pilot Plant

6

Grafe

BioAmber

5

Guangdong Shangjiu

54

Rhein Chemie

Bioplymer Network

28

Hallink

56

RheThech

55

Roll-o-Matic

55 54, 55

Hallstar

40

Recticel

40

45

Hemoteq

45

Roquette

BMELV

10

HLC Bulcart

48

Ruba Thermoplast

BMW

19

Hospital of RWTH Aachen

45

38

Cereplast

Innovia Films

55 38 56 4, 26, 42

56

55

Sapronit

27 28

39

Scion

42

55

Shenzhen Esun Industrial Co.

54

1, 10

56

Showa Denko

54

56

Sidaplax

Chemtex Italia

40

Institut for bioplastics & biocomposites (IfBB)

Chocoalte Benrain Group

42

Institut für Kunststofftechnik

Chocolate Stella

42

Institut für Kunststoffverarbeitung IKV

45

SIM-Drive

46

Complas

40

Institut für Verbundwerkstoffe IVW

19

Suminoe Teijin Techno Co

24

COOP sin Fronteras

42

ITENE

40

Synbra

34

Johnson Controls Interior

19

Taghleef Industries

Cortec

55

C-Tech Innovation

40

Kingfa

Czech Tech. Univ.

40

Knoll

Daimler

18

Limagrain Céréales Ingrédients

Dittrich & Söhne Vliesstoffwerk

19

Mercedes Benz

18

Dr. Pfleger

45

Metabolix

7

Dräxlmaier Group

20

Michigan State University

DSM

38

Minima Technology

DuPont

11, 44, 46

44 54

55

TAKATA

14

Teijin

24

TianAn Biopolymer

55

Toyota 55

Uhde Inventa-Fischer

56

UL Thermoplastics

55, env.

46 55 56

Universidad Magellanes Punta Arenosin

33

Mitsubishi Chemical

5

University of Technology Graz

33

Mohawk

48

Verpackungszentrum Graz

32

DWI at RWTH Aachen

45

Myriant

5

Victor Vetterlein

43

Electrolux

40

narocon

Wageningen (WUR)

35

Erema

54

54

55

5, 15

DuPont Tate & Lyle

23, 56

European Bioplastics

56

Faurecia

5, 18

FEN

40

FKuR

2, 54

Fletco

48

Editorial Planner

56

NatureWorks

6

Natur-Tec

54

Nissan

24

nova-Institut

6

37, 49, 56

Novamont

40

55, 60

Piedmond Chemical

5

Wei Mon

25, 56

WinGram

54

Wuhan Huali

27

Xinfu Pharm

54

2013

Subject to changes

Issue

Month

Publ.-Date

edit/ad/ Deadline

Editorial Focus (1)

Editorial Focus (2)

Basics

Fair Specials

02/2013

Mar/Apr

01.04.13

01.03.13

Rigid Packaging

Material combinations

Bio-Refinery

Chinaplas Preview

03/2013

May/Jun

03.06.13

03.05.13

Injection moulding

PLA Recycling

succinic acid

Chinaplas Review

04/2013

Jul/Aug

05.08.13

05.07.13

Bottles / Blow Moulding

Bioplastics in Building & Construction

Land use for bioplastics (update)

05/2013

Sept/Oct

01.10.13

01.09.13

Fiber / Textile / Nonwoven

Designer‘s Requirements for Bioplastics

biobased (12C / 14C vs. Biomass)

K'2013 Preview

06/2013

Nov/Dec

02.12.13

02.11.13

Films / Flexibles / Bags

Consumer Electronics

Eutrophication (t.b.c)

K'2013 Review

www.bioplasticsmagazine.com

bioplastics MAGAZINE [01/13] Vol. 8

Follow us on twitter!

www.twitter.com/bioplasticsmag

55

42

Saida

Huhtamaki Films Innoplast Solutions

54

54

ReBioFoam

BMBF

Braskem

56 50, 55

48

Balta

56

16 43

55

Godfrey Hirst

BPI

55

ProTec Polymer Processing

33

54

Editorial Advert

President Packaging 56

ATU Ferlach

Biotec

58

Company

Be our friend on Facebook!

www.facebook.com/bioplasticsmagazine

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

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

Edited by Srikanth Pilla

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

Engineering Applications

The state of the art on Bioplastics

Handbook of Bioplastics and Biocomposites 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

00*

69.

€1

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*

79,

€2

44*

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

79,

€2

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*

9.0

€9

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