bioplastics MAGAZINE 04-2015

ISSN 1862-5258

Jul / Aug Where will this journey take us? | 20

bioplastics

magazine

Vol. 10

100 % T? E P bio

04 | 2015

... or bio-PE F

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Highlights Blow Moulding | 16 Building & Construction | 10 Basics Foaming Plastics | 41

2 countries

... is read in 9

Sustainable packaging for sustainable products “Be the change you wish for this world.”

Inspired by these words, Regenbogenkreis produces and sells certified sustainable organic food supplements, tea and herbal blends.

To complete their concept of sustainability they decided to use packaging not based on fossil based raw materials such as oil. As a result, for their range of natural products they use Braskem’s Green PE. This offers their customers improved holistic solutions based on the principle of continual development of responsible environmental management which is committed to the future of life on this planet.

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

Editorial

dear readers ISSN 1862-5258

“Where will this journey take us?” That’s the question our cover girl is pondering, and with good reason. Who knows what the beverage bottles of the future will be made of? This, and more, are the questions we explore in the Blow moulding / Bottle Applications highlight of this 100 % issue.

ET? bio-P

Vol. 10

Another focus of this issue is Bioplastics in Building and Construction. And, while initially intended as the topic of this edition’s Basics article, Foam subsequently blossomed out to become a third highlight.

For this reason, I have reduced the actual basics article to a short, one-page piece.

As always, this latest issue of bioplastics MAGAZINE is once again complemented by a number of industry and applications news items.

Jul / Aug Where will this journey take us? | 20

bioplastics

MAGAZINE

While we hope that you are enjoying a well-deserved leisurely summer, our next event is already casting its shadow forward. The final programme for our first bio!CAR Conference on Biobased Materials for Automotive Applications (co-organized with the nova-Institute) has been announced. This conference will be held within the framework of the trade fair COMPOSITES EUROPE on September 24th and 25th in Stuttgart, Germany.

04 | 2015

... or bio-P

EF ?

Highlights Blow Moulding | 16 Building & Constructio n | 10 Basics Foaming Plastics | 41

Finally, I’d like to encourage all of you to send in proposals for the next Global Bioplastics Award (for details, see page 27). This “Bioplastics Oskar” will be presented this year for the 10th time during the 10th European Bioplastics Conference on November 5th in Berlin, Germany.

... is read in 92 countries

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We look forward to seeing you at one of the upcoming events, and until then, enjoy reading bioplastics MAGAZINE Sincerely yours

Michael Thielen

Like us on Facebook!

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bioplastics MAGAZINE [04/15] Vol. 10

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Content

Imprint Publisher / Editorial

04|2015

Dr. Michael Thielen (MT) Samuel Brangenberg (SB) contributing editor: Karen Laird (KL)

Head Office

July / August

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

Media Adviser

Events

Caroline Motyka phone: +49(0)2161-6884467 fax: +49(0)2161 6884468 cm@bioplasticsmagazine.com

8 bio!CAR announcement & programme

Building & Construction (photo: Sharpusa.com)

10 PLA blends in building and construction 12 WPC and NFC market trends 14 Forest based composites for façades and interior partitions

Blow Moulding

16 PEF, a biobased polyester with a great future

Print Poligrāfijas grupa Mūkusala Ltd. 1004 Riga, Latvia bioplastics MAGAZINE is printed on chlorine-free FSC certified paper.

Total print run: 3,800 copies

bM is published 6 times a year.

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

22 New biodegradable packages

bioplastics MAGAZINE is read in 92 countries.

for dairy products

24 The biobased future of beer packaging?

Every effort is made to verify all Information published, but Polymedia Publisher cannot accept responsibility for any errors or omissions or for any losses that may arise as a result. No items may be reproduced, copied or stored in any form, including electronic format, without the prior consent of the publisher. Opinions expressed in articies do not necessarily reflect those of Polymedia Publisher.

Foam

32 Foamed blocks from NF-reinforced starch 36 Sandwich panel from wood and bioplastics 38 Foams made from modified standard PLA

All articies appearing in bioplastics MAGAZINE, or on the website www.bioplasticsmagazine.com are strictly covered by copyright.

Basics

bioplastics MAGAZINE welcomes contributions for publication. Submissions are accepted on the basis of full assignment of copyright to Polymedia Publisher GmbH unless otherwise agreed in advance and in writing. We reserve the right to edit items for reasons of space, clarity or legality. Please contact the editorial office via mt@bioplasticsmagazine.com.

41 Plastics foaming

3 Editorial 5 News 28 Application News 42 Glossary 46 Suppliers Guide 49 Event Calendar 50 Companies in this issue

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

Ulrich Gewehr (Dr. Gupta Verlag) Max Godenrath (Dr. Gupta Verlag) Mark Speckenbach (DWFB)

ISSN 1862-5258

20 World’s first 100 % bio-based PET bottle

Layout/Production

bioplastics magazine

20 ALPLA showed first PEF bottles

Chris Shaw Chris Shaw Media Ltd Media Sales Representative phone: +44 (0) 1270 522130 mobile: +44 (0) 7983 967471

Like us on Facebook: https://www.facebook.com/bioplasticsmagazine

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

Envelopes

A part of this print run is mailed to the readers wrapped in I’m Green bio-polyethylene envelopes sponsored

by FKuR Kunststoff GmbH, Willich, Germany

Cover Jeanette Dietl / Fotolia Composing: Michael Thielen / Mark Speckenbach

daily upated news at www.bioplasticsmagazine.com

Newlight signs off-take agreement with Vinmar covering 8.6 mio tonnes PHA over 20 years Newlight Technologies (Costa Mesa, California, USA), a biotechnology company using an advanced biological carbon capture technology to produce sustainable materials, announced today that it has signed a take-or-pay off-take agreement with Vinmar International Ltd (headquartered in Houston, Texas, USA) Under the terms of the 20-year master off-take agreement, Vinmar will initially purchase and Newlight will sell 450,000 tonnes (1 billion pounds) of AirCarbon™ PHA. The Vinmar contract provides for the sale of 100 % of AirCarbon PHA from Newlight’s planned 22,000 t/a (50 million pounds) production facility for 20 years. The contract will also cover 100 % of the output from a 136,000 t/a (300 million pound) AirCarbon production facility and a 272,000 t/a (600 million pound) AirCarbon production facility for a total of up to 8.6 million tonnes (19 billion pounds) over 20 years.

AirCarbon is a PHA-based thermoplastic made from greenhouse gas that is used and being developed for use in a wide range of products, including films, caps and closures, furniture, electronics accessories, bottles and other applications.

Newlight produces AirCarbon by combining a breakthrough high-yield biocatalyst with air and captured methane-based greenhouse gas emissions to produce a biobased AirCarbon thermoplastic material that is cost competitive with petroleum-derived thermoplastics.

Earlier in June The Bodyshop (L’Oreal) and Newlight had announced a research and development partnership to introduce AirCarbon in The Body Shop® products. The Body Shop is the first company to commit to an effort to industrialization of AirCarbon in the beauty industry. Other companies that committed to use AirCarbon include Dell, Sprint (for exclusively produced iPhone®5 and 6 cellphone covers) and Virgin Mobile USA. KL/MT www.newlight.com Mark Herrera (Photo: Dan MacMedan, USA TODAY)

News

Producing PLA just got cheaper and greener PLA is already a part of our everyday lives. And yet, PLA is not yet considered a full alternative to traditional petroleum-based plastics, as it is costly to produce.

Researchers from the KU Leuven Centre for Surface Chemistry and Catalysis now present a way to make the PLA production process more simple and wastefree. Their findings were published in Science.

The production process for PLA is expensive because of the intermediary steps. “First, lactic acid is fed into a reactor and converted into a type of preplastic under high temperature and in a vacuum”, Professor Bert Sels explains. “This is an expensive process. The pre-plastic – a low-quality plastic – is then broken down into building blocks for PLA. In other words, you are first producing an inferior plastic before you end up with a high-quality plastic. And even though PLA is considered a green plastic, the various intermediary steps in the production process still require metals and produce waste.”

The KU Leuven researchers developed a new technique. “We have applied a petrochemical concept to biomass”, says postdoctoral researcher Michiel Dusselier. “We speed up and guide the chemical process in the reactor with a zeolite as a catalyst.

Zeolites are porous minerals. By selecting a specific type on the basis of its pore shape, we were able to convert lactic acid directly into the building blocks for PLA without making the larger by-products that do not fit into the zeolite pores. Our new method has several advantages compared to the traditional technique: we produce more PLA with less waste and without using metals. In addition, the production process is cheaper, because we can skip a step”.

Professor Sels is confident that the new technology will soon take hold. “The KU Leuven patent on our discovery was recently sold to a chemical company that intends to apply the production process on an industrial scale. Of course, PLA will never fully replace petroleum-based plastics. For one thing, some objects, such as toilet drain pipes, are not meant to be biodegradable. And it is not our intention to promote disposable plastic. But products made of PLA can now become cheaper and greener. Our method is a great example of how the chemical industry and biotechnology can join forces”. KL www.kuleuven.be

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News

daily upated news at www.bioplasticsmagazine.com

Partially biobased PP compound for injection molding applications FKuR Kunststoff GmbH (Willich, Germany and Lexington, Texas, USA) is now offering a PP compound partly made from renewable resources which maintains the typical characteristic and performance of PP. The grade offered under the brand name Terralene® PP 2509 is ideally suitable for injection molding. Terralene compounds are customized blends based on Braskem’s bio-polyethylene I´m Green. The flowability of the new material with an MFR of 42 – 47 [g/10 min], measured at 230 °C (Vicat A), is excellent for a bioplastic. With this material, it’s possible to produce complex parts with long flow paths.

“For us, it was important to develop a material which can be easily processed by injection molding, presenting PP characteristics but containing an appealing share of renewable resources“, says Carmen Michels, Managing Director at FKuR and responsible for technology and development.

The biobased carbon content of this grade is about 35 % and can be easily quantified by means of a 14C measuring method (according to ASTM D 6866). This enables a transparent communication of the renewable resource content to the end consumer. With Terralene PP 2509 manufacturers and brand owners are in the position to produce their PP products in a partially biobased version and occupy an important market niche. MT www.fkur.com

OLIMAX container in biobased PP for the collection of used cooking oil. Made by Mattiussi Ecologia, Italy

European Bioplastics welcomes the European Parliament‘s call for a paradigm shift towards a resource-efficient circular economy European Bioplastics (EUBP) welcomes the European Parliament’s (EP) adoption of the own-initiative report of Finnish MEP Sirpa Pietikäinen on ‘resource efficiency: moving towards a circular economy’. “The European Union needs to use natural resources more efficiently, and the European Parliament’s vote is a strong call for the European Commission to propose the necessary legislation by 2015,” says François de Bie, Chairman of the Board of European Bioplastics.

In its report, the EP demands binding waste-reduction and recycling targets and a mandatory separate collection and recycling of biowaste by 2020. Furthermore, the report calls to limit incineration to non-recyclable and non-biodegradable waste, to gradually ban landfilling, and to apply resource-use indicators in support of a 30 % improvement of resource efficiency by 2030. The Commission is also asked to review the current eco-design legislation and other relevant product policy legislation by the end of 2016 with regards to broadening its scope by covering all product groups and establishing minimum recycled material content in new products.

While calling for the implementation of an ambitious recycling target of 80 % of all packaging waste by 2030, the MEPs invite the Commission to assess the feasibility of gradually replacing food packaging with biobased and biodegradable, compostable materials in accordance with European standards. Additionally, the Parliament demands to apply the cascading principle for the use of resources, notably biomass.

According to the report, these measures could boost the EU’s gross domestic product by nearly one percent and create two million new jobs by 2030. “High-skilled jobs in bioplastic manufacturing, converting, and along the entire bioplastic value chain can be an important part of this growth,” says François de Bie.

www.european-bioplastics.org.

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News

European Bioplastics elected new Board The industry association European Bioplastics (EUBP) announced that a new Board had been elected by the General Assembly of EUBP members end of June to serve a two-year term. François de Bie (Corbion) has been re-elected for a second term as Chairman of the Board. Mariagiovanna Vetere (NatureWorks) and Stefano Facco (Novamont) have been designated as Vice Chairpersons.

Starting off his second term as Chairman of European Bioplastics, François de Bie says: “This is an important time for our industry as we leverage the potentials of bioplastics for the bioeconomy in Europe. Bioplastics can be a major driver to increase resource efficiency and efficient waste management in the envisioned circular economy. Over the past years, European Bioplastics has affirmed its role as an important and trusted player in the advancement of the bioplastics industry across Europe.

I am honoured to assume this position and look forward to working closely with the entire board as well as our management team in continuing to push for a politically and economically favourable landscape in Europe for the bioplastics industry to strive in.”

Peter Brunk (BIOTEC) is another returning member of the Board. He will serve as treasurer. Michael von Ketteler (BASF), Henri Colens (Braskem), and Christophe Rupp-Dahlem (Roquette) were elected new members of the Board.

“On behalf of the entire Board and EUBP team I would like to express a special thanks to Johnny Pallot (Roquette), who will retire later this year, for his contributions to our association as Member of the Board over the past two years and his considerable efforts in advancing standardisation for our industry”, says de Bie.

(from left to right): Christophe Rupp-Dahlem (Roquette), François de Bie (Corbion), Henri Colens (Braskem), Mariagiovanna Vetere (NatureWorks), Stefano Facco (Novamont), Peter Brunk (Biotec), and Michael von Ketteler (BASF). © European Bioplastics

EUBP represents the interests of the European bioplastics industry. With a current growth rate of around 20 % per year, bioplastics are an innovative sector that can drive economic development and employment across Europe. Most importantly, bioplastics help to reduce greenhouse gas emissions and can be a major driver in a resource efficient circular economy.

www.european-bioplastics.org

Liquid Light to further advance its CO2-to-MEG Technology Liquid Light (Monmouth Junction, New Jersey) announced it has signed a technology development agreement with The Coca-Cola Company. The objective of the agreement is to accelerate the development of Liquid Light’s technology which can make mono-ethylene glycol (MEG) from carbon dioxide (CO2). Liquid Light’s approach enables more efficient use of plant material to make MEG. For example, a bio-ethanol production facility could make bio-MEG from the CO2 byproduct that results from converting plant material into ethanol. According to Liquid Light with less than US$ 80 per tonne of CO2 and 1.58 tonnes of CO2 needed for the production of 1 tonne of MEG, CO2 is the lowest cost feedstock for MEG. Thus the technology has the potential to reduce both the environmental footprint and the cost of producing MEG. MEG is one of the components used to make renewably sourced PET, e. g. for Coca-Cola‘s PlantBottle™.

Additional details of the agreement were not being disclosed at this time. MT www.llchemical.com

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Events

bioplastics MAGAZINE presents: The first bio!CAR Conference on Biobased Materials in Automotive Applications, organised jointly by bioplastics MAGAZINE and the nova-Institut is the must-attend conference for everyone interested in replacing petroleum based materials in automotive applications by alternatives made from renewable resources. The conference offers high class presentations from top individuals from raw material providers as well as from OEMs and Tier 1 suppliers already using biobased materials. The unique event also offers excellent networking opportunities along with a table top exhibition. Please find below the updated programme.

Find more details and register at the conference website.

Conference on Biobased Materials for Automotive Applications

24 – 25 sep. 2015

www.bio-car.info

Programme - ­bio!CAR: Conference on Biobased Materials in Automotive Applications Thursday, September 24, 2015 07:00 - 08:30 08:30 - 08:45 08:45 - 09:15

Registration, Welcome-Coffee Michael Thielen, Polymedia Publisher Christian Bonten, Univ. Stuttgart

09:15 - 09:40

Ralf Kindervater, BioPro Baden Württemberg Elmar Witten, AVK Michael Carus, nova-Institute Q&A 10:45 - 11:10 Coffee Break Gareth Davies, Composites Evolution

09:40 - 10:05 10:05 - 10:30 10:30 - 10:45 11:10 - 11:35 11:35 - 12:00 12:00 - 12:25 12:25 - 12:40 13:45 - 14:10 14:10 - 14:35 14:35 - 15:00 15:00 - 15:25 15:25 - 15:40 16:00 - 16:25 16:25 - 16.50 16:50 - 17:00 17:00 - 17:30

Hans-Josef Endres, Institute for Bioplastics & Biocomposites Mona Duhme, Fraunhofer UMSICHT and Amparo Verdú Solís, AIMPLAS Q&A 12:40 - 13:45 Lunch Nicolas Dufaure, Arkema Andreas Weinmann and Anna Hoiss, DSM Keiichirou Kanatani, Mitsubishi Chemical Sangeetha Ramaswamy, Institute of Textile Technology, Aachen Q&A 15:40 - 16:00 Coffee Break Oliver Ehlert, DIN Certco Luisa Medina and Florian Gortner Institut für Verbundwerkstoffe, Karlsruhe Q&A Panel discussion, t.b.c.

Welcome Remarks Keynote: Actual plastic innovations to meet current requirements and demands for the modern automotive industry The impact of biobased materials in the bioeconomy of tomorrow: mouse or elephant ?

Trends and Developments in the composites market Biocomposites in the Automotive Industry, markets and environment Hybrid carbon-biocomposite automotive structures with reduced weight, cost, NVH and environmental impact Biobased hybrid structures for automotive applications Review of ECOplast project: Research in new biomass-based composites from renewable resources with improved properties for vehicle parts moulding A long-term innovation to offer the widest range of biobased polyamides Capturing the performance of green Engineering biobased plastic, another solution for automotive applications Systematic integration of bio-materials in automotive Interiors

Bioplastics – Standards and Cerification Development of a new test tool to measure emissions and odors from NF composites

Future of automobile interior parts – Light weight, easy recyclable, bio-based or even bio-degradable? Where does the journey go?

09:00 - 09:25

Maira Magnani, Ford Motor Company

09:25 - 09:50 09:50 - 10:15 10:15 - 10:40

Francesca Brunori, Röchling Marc Mézailles, PolyOne Hans-Jörg Gusovius, Leibniz-Institute for Agricultural Engineering Q&A 10:55 - 11:20 Coffee Break Hans Hoydonckx, TransFurans Chemicals Marjan van Urk , Lanxess Stefano Facco, Novamont Q&A 12:50 - 14:00 Lunch Thibaud Caulier, Solvay Epicerol François Vanfleteren, Lineo Christian Fischer, Bcomp Lars Ziegler, Tecnaro Q&A Michael Thielen

10:40 - 10:55 11:20 - 11:45 11:45 - 12:10 12:10 - 12:35 12:35 - 12:50 14:00 - 14:35 14:35 - 14:50 14:50 - 15:15 15.15 - 15:40 15:40 - 15:55 15:55 - 16:00

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Filling the (technology) gaps to promote the use of bio-based materials: Ford Motor Company’s example Plantura, PLA compounds for automotive applications A new natural fiber reinforced solution Novel whole-crop raw materials for automotive applications

Latest innovations of TFC in the use of PFA resin systems Bio-based EP(D)M rubber for high performance automotive applications Renewable Oils, Esters and Fillers for Rubber compounding A bio-based building block to reduce the environmental footprint of the automotive industry A sandwich panel reinforced with flax fibers for the automotive Save weight and cost with powerRibs in interior and exterior Bio-based Thermoplastic Compounds and Composites Closing remarks

(subject to changes, visit www.bio-pac.info for updates)

Friday, September 25, 2015

bio CAR biobased materials for automotive applications

REGISTER NOW to reserve your seat

conference 24 – 25 September 2015

Stuttgart

» The amount of plastics in modern cars is constantly increasing. » Plastics and composites help achieving light-weighting targets. » Plastics offer enormous design opportunities. » Plastics are important for the touch-and-feel and the safety of cars.

BUT: consumers, suppliers in the automotive industry and OEMs are more and more looking for biobased alternatives to petroleum based materials.

That‘s why bioplastics MAGAZINE is organizing this new conference on biobased materials for the automotive industry. co-orgnized by

in cooperation with

www.bio-car.info

supported by

VK

Media Partner

PLA blends in building and construction By: Dan Sawyer Global Leader, New Business Segment NatureWorks Blair, Nebraska, USA

Performance, health, and sustainability drive biopolymer use in building material development and sales

I

n hospital corridors, patient rooms, and operating theaters, along corporate hallways, offices, and meeting rooms, and gracing modern sports stadiums, sustainable materials are being used on walls, floors, and for window treatments.

A number of trends motivate this new and growing interest in sustainable building and construction materials.

The rise of national and international programs such as The U.S. Green Building Council’s Leadership in Energy and Environmental Design (LEED) certification and Living Building Challenge (LBC) raise awareness and stimulate interest in new materials and energy conservation practices. Both governments and the public demand the use of intrinsically safe materials in terms of health and wellness. There is a greater understanding, appreciation, and need for smaller carbon footprint solutions and materials that contribute to these lower environmental impacts.

Suppliers in the building and construction industry have reached out to materials companies such as NatureWorks for new high performance solutions to master these changes. In the case of Ingeo™ biopolymer (PLA), durable products for wall and floor coverings have necessitated development of new blends and formulations. With the recent upgrades in manufacturing capabilities at the NatureWorks facility (Blair, Nebraska, USA), Ingeo PLA formulations utilizing newly offered durable grades are finding interest that can lead to higher bio-content in building products. Inpro and Alpar Architectural Products are two companies excelling at utilizing biobased products in building and construction materials with advanced formulations developed using Ingeo PLA.

Inpro Inpro (Muskego, Wisconsin, USA) is a global manufacturer of door and wall protection, washroom systems, expansion joint systems, privacy systems, elevator protection systems, and architectural signage.

The company is committed to making and servicing products that protect the appearance of buildings and the health and safety of the people who use them.

G2 BioBlend® is an internationally available option on hundreds of Inpro products, including rigid sheet wall cladding, corner guards, wall guards, handrails, and kickplates, to name just a few. G2 BioBlend is a composite Ingeo PLA/PETG formulation that offers a non-Polyvinyl Chloride (non-PVC) option in wall and door protection products – sheeting that resists dents and dings. G2 BioBlend has been tested and meets the requirements of the GreenGuard Environmental Institute (UL Environment, Marietta, Georgia, USA) and the State of California for low emitting products as tested by Air

Handrail (Photo: Alpar) 10

bioplastics MAGAZINE [04/15] Vol. 10

Fabric Sunshade Eneco (Photo: M+N)

Building & Construction

Building & Construction Quality Sciences (Atlanta, Georgia, USA). It is a USDA BioPreferred® material.

By introducing the industry’s first comprehensive recycling program for vinyl products in 2002, Inpro led the movement toward closing the loop in the manufacturing process – a key component of making building products more sustainable. Inpro includes G2 BioBlend in this recycling program. For every pound of used material that’s returned, Inpro will issue a $ 1.50 credit toward new Inpro products. Inpro has issued both an Environmental Product Declaration (EPD) and a Health Product Declaration (HPD) for G2 BioBlend to make public the composition of the material in order to establish its environmental health and safety attributes for optimum transparency.

Alpar Architectural Products Alpar’s mission is to provide high-performance building products that have the least possible environmental impact. The company from Wassaic, New York, USA was founded on the ideas that environmental and social responsibility should be central to its business strategy and that building product manufacturers have a duty to reduce toxins in the environment. As such, Alpar is committed to providing only products that are 100 % free of PVC and that contain renewable or recycled materials.

Alpar developed and introduced wall and corner guards, sheet wall protection, handrails, and crash rails

mistry.eu www.co2-che Carbon Dioxide as Feedstock for Chemistry and Polymers

made from an Ingeo blend developed by Stratsys Advanced Materials Center. These Ingeo products contain more than 90 % renewable content, exceed Class 1 requirements for flame spread and smoke density, and meet or exceed the mechanical performance requirements for wall protection. In 2014, National Sanitation Foundation (NSF) Sustainability, a division of the global independent public health organization NSF International (Ann Arbor, Michigan, USA), assessed and provided third-party verification of a Health Product Declaration for Alpar on the company’s natural color Ingeo-based wall protection products.

With the introduction of LEED v4 update and this standard’s emphasis on chemical composition reporting, Alpar used the Health Product Declaration process as a means to provide product transparency and help its customers achieve LEED v4 MRc, Option 1 and Option 2 requirements through this third-party verification, the first listed under NSF’s program.

M+N Textiles bioplastics MAGAZINE readers may also remember another building and construction material from M+N Textiles (Delfgauw, Netherlands) who launched the first sunscreen fabric in the world made from plants in 2012 (bM 06/2012). Their REVOLUTION® line of sunshades celebrated another first and was recently awarded with Cradle to Cradle Certified™ Gold certification. www.natureworksllc.com

4 th

29 – 30 September 2015, Essen (Germany) Conference Team Michael Carus CEO michael.carus@nova-institut.de

Barbara Dommermuth Programme, Poster session +49 (0)2233 4814-56 barbara.dommermuth@nova-institut.de Dominik Vogt Conference Manager, Organisation, Exhibition, Sponsoring +49 (0)2233 4814-49 dominik.vogt@nova-institut.de Jutta Millich Partners & Media Partners +49 (0)561 503580-44 jutta.millich@nova-Institut.de

Venue Haus der Technik e.V. Hollestr. 1 45127 Essen, Germany Tel: +49 (0) 201/18 03-1 www.hdt-essen.de

For the 4th year in a row, the nova-Institute will organize the conference „Carbon Dioxide as Feedstock for Chemistry and Polymers“ on 29 - 30 September 2015 in the “Haus der Technik” in Essen, Germany. CO2 as chemical feedstock is a big challenge and chance for sustainable chemistry. Over the last few years, the rise of this topic has developed from several research projects and industrial applications to become more and more dynamic, especially in the fields of solar fuels (power-to-fuel, Free booth – only a 2-days power-to-gas) – but also in CO2-based chemicals and polymers.

Several players are very active and will showcase some enhanced and also new applications using carbon dioxide as feedstock.

The conference will be the biggest event on Carbon Capture and Utilization (CCU) in 2015.

conference entrance ticket is needed!

Early Bird Reduction of 15% until the end of April 2015. Discount code: earlybird2015

Attending this conference will be invaluable for businessmen and academics who wish to get a full picture of how this new and exciting scenario is unfolding, as well as providing an opportunity to meet the right business or academic partners for future alliances.

More information can be found at www.co2-chemistry.eu Organiser

nova-Institute Chemiepark Knapsack Industriestraße 300 50354 Hürth, Germany

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Building & Construction

WPC and NFC market trends New European market and trend report is published

B

etween 10 – 15 % of the total European composite market is covered by Wood-Plastic Composites (WPC) and Natural Fibre Composites (NFC). Main authors of the latest WPC and NFC study are Michael Carus and Asta Eder, biocomposite experts of nova-Institute. The study points out the growth potential of WPC and NFC granulates for injection moulding for all kinds of technical applications and consumer goods as well as in the automotive industry. What’s more, biobased polymers in combination with wood and natural fibres take on greater significance – applied in everything from toys to automotive interiors.

The total volume of WPC production in Europe was 260,000 tonnes in 2012 (plus 90,000 tonnes of Natural Fibre Composites for the automotive industry, see Table 1). The table also shows the volume of traded granulates for extrusion and injection moulding. Direct extrusion is the dominant process in extruding, which does not require granulates as an intermediate material. Therefore, the share of granulates for extrusion is low. In contrast, granulates are used in most injection moulding applications and are traded between those involved in the process chain.

Interviews conducted during the FAKUMA 2014 plastics trade fair (Friedrichshafen, Germany) found a growing portfolio of fibre-filled granulates offered both by producers and retailers (Table 1); by now there are about 60 producers and retailers active on the European market. Table 1 also shows growth opportunities for WPC and NFC granulates in injection moulding for all kinds of technical applications and consumer goods. Accounting for improved technical properties, falling prices and higher delivery volumes, the authors predict an increase from 10,000 t in 2012 to 100,000 t in 2020. Additional incentives could probably more than double the size of the market. Compared with WPC, NFC granulates are predicted to gain only in niche markets with specific needs. The development of traditional WPC market in construction is less dependent on incentives as Table1 shows.

The level of market penetration of bio-based composites varies between different regions and application fields.

Germany leads in terms of number of companies as well as in production figures. The typical production process in Europe is extrusion of a decking profile based on a PVC or PE matrix. The increasing market penetration of WPC in decking has meant that WPC volumes have risen strongly and that today, Europe has reached a mature WPC market stage. The recent nova-study predicts growth, especially in the Germanspeaking area, on the back of a recovery in construction, especially in renovation, and a further increase of WPC share in the highly competitive decking market. Also, variations of WPC decking models, such as capped embossed full profiles or garden fencing are on the rise across Europe.

An example for innovative use of decking profiles is a basketball out-door field made of the WPC-decking board of the German company Novo-Tech (Fig. 1). The particular advantage of the WPC-outdoor sport flooring is that its technical properties are very close to the traditional indoor floor of sport halls and additionally WPC material offers weather-resistance and a non-slippery surface.

WPC is increasingly used to produce furniture, technical parts, consumer goods and household electronics, using injection moulding and also processes other than extrusion such as special forms of injection moulding, thermoforming and blow moulding. New production methods for extrusion of broad WPC boards are also being developed.

WPC boards are a more recent trend outside the automotive sector, but small-scale production has been available for over five years. These are produced in a continuous in-line extrusion process to manufacture the panels, which can be thermoformed in a second step. Alternatively, wood panel board equipment can be used to make WPC boards. Equipment is commercially available from e. g. Qingdao Guosen Machinery, China. Early developments in this sector are the work by Bison-Werke Bähre & Greten, Springe, Germany, who claimed

Table 1: Production of biocomposites (WPC and NFC) in the European Union 2012 and forecast for 2020, Source nova-Institut GmbH 2015 Biocomposites

Production in 2012

Forecast production in 2020 (without incentives for bio-based products)

Forecast production in 2020 (with strong incentives for bio-based products)

WPC 190,000 t

400,000 t

450,000 t

Automotive, compression moulding & extrusion/ thermoforming

Construction, extrusion

60,000 t

80,000 t

300,00 t

Technical applications, furniture and consumer goods, mainly injection moulding

10,000 t

100,000 t

>200,000 t

Traded granulates for extrusion and injection moulding

40,000 t

200,00 t

>300,000 t

90,000 t

120,000 t

350,000 t

2,000 t

10,000 t

>20,000 t

NFC Automotive, compression moulding Granulates, injection moulding

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bioplastics MAGAZINE [04/15] Vol. 10

Building & Construction

Figure 1: Megawood outdoor sport flooring. Source: Novo-tech 2015

a German patent DE2743873A “Verfahren zum Herstellen von plattenförmigen Formwerkstück-Rohlingen” (Method for making plate-shaped moulding material) as early as in 1977.

The latest innovation in boards are lightweight boards featuring two WPC skin layers with a thickness of up to 3 mm, combined with a honeycomb core of pure polymer. Very good thermoformability, easy processability, resistance to water and various chemicals, and recyclability describe the advantages of GORCELL, a product from the Italian business unit of German company RENOLIT COMPOSITES: RENOLIT GOR S.p.A., that can be used in various indoor and outdoor applications. The exhibition booth depicted in Fig. 2 shows the design possibilities of thermoformed WPC honey comb boards. www.nova-institute.eu By: Michael Carus and Asta Eder nova-Institute Huerth,Germany

The short version of the report can be downloaded for free at: www.bio-based.eu/markets.

Customers will receive a 30 % discount code for the Sixth WPC & NFC Conference Cologne, 16 – 17 December 2015 in Cologne, Germany. www.wpc-conference.com

Figure 2: T he latest innovation in terms of boards are lightweight WPC-boards for indoor and outdoor applications, Source: RENOLIT GOR S.p.A 2015

SHAPING SMART SOLUTIONS Register now!

5/6 November 2015 MARITIM proArte Hotel Berlin For more information email: conference@european-bioplastics.org

www.conference.european-bioplastics.org bioplastics MAGAZINE [04/15] Vol. 10

13

Building & Construction

Forest based composites for façades and interior partitions ...improve indoor air quality in new builds and restoration

O

ver the last decades indoor air quality and emissions from building materials have been a major challenge for scientists, industry and consumers. In recent years there is a growing trend to replace traditional brick and mortar construction materials in façades which contribute to contaminants such as VOCs (volatile organic compounds), formaldehyde, particulates and fibres by multilayer façades.

Biocomposite profile

Multifunction layer Weather resistant outdoor panel Light foam panel

Cork-based panel

Fire resistant panel

Waterproof membrane

Assembled modular multi-layer envelope based on biocomposites in which is integrated the developed biocomposite profile

They comprise several layers that provide the insulation and protection properties required in traditional façades and are usually designed to have an exterior finished ventilated façade and an interior part formed by plaster walls. The inner part of the façade consists of several panels that provide insulation, and also fire and water protection.

OSIRYS is an EC funded project which addresses this growing need to improve indoor air quality and energy efficiency by developing forest-based biocomposites and products, to be applied in retrofitting and new building construction. These will demonstrate a variety of functionalities able to meet the strictest requisites of the Building Code and will be also demonstrated in real-life applications.

The project consortium is working with new ecoinnovative building materials, which are able to provide a healthier indoor environment, to develop a holistic solution to the current emissions challenges facing the construction industry. These new materials will improve air quality by eliminating micro-organisms, increasing thermal and acoustic insulation and controlling breathability of the construction systems.

Some bioplastic profiles made by pultrusion process

The four year project is led by Tecnalia (project coordinators), in partnership with Acciona, AIMPLAS, ENAR and VISESA from Spain, NetComposites from the UK, Fraunhofer, SICC and Tecnaro from Germany, IVL from Sweden, Conenor and VTT from Finland, Omikron from Hungary, UNStudio from the Netherlands, Bergamo Tecnologie from Poland, Collanti Concorde from Italy, and Amorim Cork Composites from Portugal.

AIMPLAS’ role within the project is mainly related to the functionalization of graphene for its use with thermosetting resins, and pultrusion process with natural fibers and bioresins.

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 609067. bioplastics MAGAZINE will keep you up to date about the progress of the project. MT www.osirysproject.eu ∙ www.aimplas.es

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Blow moulding

PEF, a biobased polyester with a great future

A

vantium is a technology company which has established a leading market position in providing advanced catalysis services and systems to companies in the oil, gas, chemical, and renewable industry sectors.

From 2005 onwards, Avantium has used its capabilities to develop its own novel proprietary process and product platform for renewable plastics and chemicals under the name YXY. More recently, it started to undertake similar development projects into breakthrough technologies for renewable chemistry in its business unit New Chemistries.

This article will first dive deeper into the physical properties of PEF, before discussing specific application areas, and the value PEF brings to brand owners and consumers.

A small change in bond angle, a big difference in properties Recently, a PhD thesis at the Georgia Institute of Technology has taken a fundamental look into the difference in properties between PEF and PET, and has for the first time provided scientific evidence of their origin. It was found that the shorter bond length and the angle of the aromatic bond in PEF gives rise to a much more rigid and densely packed polymer chain, which is at the heart of many of PEF’s properties [1].

Avantium’s YXY technology comprises the catalytical conversion of plant based sugars into furan-2,5dicarboxylic acid (FDCA) and its polymerization to poly(ethylene furanoate), PEF. PEF is a novel polyester with a unique performance and sustainability profile. PEF is often compared to PET due to its similar chemistry; both polyesters are produced from the monomers ethylene glycol (MEG) and an aromatic diacid (FDCA or PTA respectively). Despite this similarity, however, PEF’s small molecular difference gives rise to a number of different properties.

Both the dense packing and the chain rigidity of PEF are the likely causes of the higher density of PEF and an intrinsically higher stiffness (Young’s Modulus) and maximum load before deformation starts (Yield stress).

Also the increased glass transition can be explained in this way, since a higher temperature is needed to get the more rigid PEF chains into motion. At the same time, the lack of motion slows down the process of crystallization, too high crystallization rates can cause haziness in many applications where transparency is desired. However, the most astonishing finding was that the rigidity of the chains is the main mechanism of inhibiting gasses from passing through the material. The result: a 10 times higher barrier to both oxygen and carbon dioxide for PEF compared to PET, intrinsic to the material without any stretching or forming process.

PEF is found to have a higher oxygen and CO2 barrier than PET (10x) and a higher water vapour barrier (2x). Also the glass transition temperature (+12 °C) and modulus of PEF (+60 %) are higher than for PET. These advantageous properties enable novel packaging opportunities and additional functionality for brand owners, retailers and consumers, where PET often does not meet the requirements.

Figure 1: Chemical structure of PEF (top) and PET (bottom), displaying the shorter overall repeating unit length of PEF and the rotation freedom of the benzene ring over the straight bond angle in PET, which is absent in PEF and gives the chain more rigidity O O

O

HO

H

O

PET

PEF

Density

1.36 g/cm3

1.43 g/cm3

O2 permeability*

BIF = 1 [2]

BIF = 11 [2]

CO2 permeability*

BIF = 1 [3]

BIF = 13 – 19 [3]

76 °C

88 °C

250 – 270 °C

210 – 230 °C

E-modulus

2.1 – 2.2 GPa [4]

3.1 – 3.3 GPa [4]

Yield strength

50 – 60 MPa [4]

90 – 100 MPa [4]

Tm

O O

H

*BIF = Barrier Improvement Factor compared to PET

O HO O

bioplastics MAGAZINE [04/15] Vol. 10

Property

Tg

O

16

Table 1: Intrinsic properties of amorphous PET and PEF

Blow moulding PEF as a packaging material – design by orientation

By: Nathan Kemeling Business Development Director and Jesper van Berkel Technical Application Manager

Packaging seems a logical application for a material which is both more sustainable (more details below) and has a gas barrier that is an order of magnitude higher than PET. The main areas of packaging are bottles, trays, cups, films and laminates, all of them existing in many different forms dependent on the end-use applications.

One thing that most of these forms have in common is that the material typically undergoes a stretching or forming process as part of the production. This allows plastics to become oriented, and some plastics – like PET and PEF – to develop strain induced crystallinity.

Both orientation and strain induced crystallinity have benefits to the final product properties.

In the development of PEF, controlled biaxial orientation is one of the key methods to evaluate the applicability of PEF resins in certain packaging applications. Biaxial orientation studies have highlighted that PEF requires different processing conditions than PET, such as temperature and stretch rate, and exhibits different behavior under these conditions. Both of these aspects should be accommodated in the design of a product and the set-up of a production process.

Furthermore, the studies bring to light how changes in the PEF production method can change the stretching behavior and the resulting oriented properties. The oriented properties of a basic PEF grade such as PEF A are shown in table 2 and table 3. Behavior such as PEF B can be achieved by increasing the molecular weight or the polymer chain architecture. Controlling the PEF production method to achieve the right behavior for the right application is one of the key aspects of the YXY technology.

Avantium Amsterdam, The Netherlands

Oxygen (O2) 10x Water vapour (H2O) 2x

Carbon dioxide (CO2) 4x

PEF, a drop-in with a twist Despite the differences between PEF and PET, their chemical similarity results in very similar production steps and quality control methods to PET and other

Figure 2: Biaxial orientation behavior of two PEF materials at two conditions, compared to PET

80 70

Bottle grade PET typical conditions

Force (N)

60 50

PEF B condition 2

PEF B condition 1

40 30

PEF A condition 2

20 10 0

PEF A condition 1 1

2

4

6

9 12 Areal stretch ratio

16

20

25

30

bioplastics MAGAZINE [04/15] Vol. 10

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Blow moulding

polyesters. Also processing can typically be done on equipment designed for PET, other polyesters and often even other plastics. In many cases, only changes in conditions are required, or minor adaptations to equipment that are common when switching to different materials or different grades of the same material.

Avantium in collaboration with partners has proven various processing techniques for PEF such as Injection Stretch Blow Molding (ISBM) for bottles, sheet extrusion and thermoforming for trays and cups, cast film extrusion followed by biaxial orientation for thin packaging films and PEF fiber spinning for applications ranging from apparel and carpets to technical fibers for tire cords and seat belts. As described in the previous section similar to PET the processing of PEF follows an injection or extrusion process followed by an orientation process to create the strain induced crystallization, optionally followed by a heat set. The lower melt point of PEF typically allows lower processing temperatures than PET which can save energy costs, while the processing window is wide enough to typically allow smooth operation. Furthermore, PEF is similar enough to PET to allow recycling according to the same processing steps that are found in the many PET recycling processes.

technologies. This meets the current consumer preference for smaller packaging performance, reducing calorie intake. Another example are PEF beer bottles for sports or other events, where conventional packaging such as glass or cans are usually not allowed for safety reasons, and a high oxygen barrier is needed to avoid staling of the beer.

Glass

Aluminium

Foil

The PET bottle market alone amounts to US$ 40 billion. However, the excellent properties of PEF as demonstrated above and its sustainability credentials create opportunities in the wider packaging field, as an alternative not just for PET or plastics but for a broader range of packaging materials, depending on its application and the relevance of the PEF properties. PEF is well positioned to compete across many of the other packaging segments (glass packaging, food/beverage in pouch, food in tray, beverage and food in metal cans, beverage and food in carton). Global trends, such as sustainability, health and convenience in the food packaging world underscore the long term potential for PEF.

PEF in bottles and beyond The improved barrier properties of PEF have been confirmed time after time in the bottles, which was PEF’s first target application. PEF’s mechanical properties allow for more design options and better shaping of bottles, as well as the possibility to make the walls thinner while maintaining the integrity of the bottle during top-load and handling. The combination of barrier and strength brings the potential for making lighter bottles than what is possible today with PET, as well as smaller bottles with a higher surface to volume ratio without compromising the shelf-life. This opens up bottle applications where only non-PET or multilayer structures can be used today, which are more costly and less sustainable.

Sustainability of PEF PEF is produced using fully renewable resources which initially will be corn or wheat based sugars (first generation bio-feedstock). Over time, second generation (cellulosic biomass) sources of industrial sugars such as (waste) wood, wheat-straw, corn stover or bagasse will become economically viable to further strengthen the sustainable supply chain. The environmental footprint compared to petro-based plastics as well as other materials can be reduced significantly (e. g., PEF can reduce carbon emissions with 50 – 70 % compared to petroleum based PET and 50 % reduction in non-renewable energy use when produced at industrial scale) [7].

For example, using PEF in small soft-drink containers will allow these to meet the shelf life requirements that today can only be achieved in PET structures with barrier

Table 2: Barrier properties of basic BOPEF compared to PET, PP and PL Material OTR, cc-mm/m2-day-atm CO2 TR, cc-mm/m -day-atm 2

WVTR, g-mil/100in2-day

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Carton

BOPEF [4]

BOPET [4]

BOPET [5]

BOPP [6]

BOPLA [7]

0.15 – 0.51

2.4 – 3.3

2.0 – 6.0

42

17

1.4 – 2.6

24 – 28

21 – 22

100

70

0.6

1.3

1.0 – 2.0

0.25 – 0.4

24

Blow moulding

PEF is 100 % recyclable, and can be sorted from PET and other plastics by conventional infrared sorting technologies. Recycling studies have been performed to determine the acceptable levels of PEF that can be blended in the PET stream, which will be reviewed with the recycling industry’s organization bodies.

To bring PEF to the consumer, Avantium is currently performing engineering studies for the first commercial PEF plant which is targeted to go into production three years from now. This plant will focus on those applications where the sustainability advantages and performance benefits of PEF can bring the highest value. As next step Avantium will license out the PEF technology or partner with chemical manufacturing companies to construct and operate industrial scale PEF plants. At industrial scale PEF will be cost competitive to current packaging materials allowing for a broader introduction of PEF into commodity markets.

In order to use PEF as a material for food and beverage packaging food contact approvals are required. Avantium has completed the required test protocols successfully and received a positive scientific opinion from the EFSA, the European regulatory body. The EFSA advised the European Commission to include PEF in the legislation as an accepted material for food and beverage packaging in 2014, which will be effective by the end of 2015. The US FDA process has been initiated after completion of the EFSA filing and is targeted to be completed in 2017, and should be based on the final resin composition taken into production.

In summary PEF shows an outstanding performance on all fronts: sustainability, properties and manufacturability, and can therefore truly be considered the polyester of the future. www.avantium.com

The barrier properties of PEF help to extend product shelf life, which can reduce economical losses and food and beverages waste by spoiling during transport and storage.

References [1] S. Burgess et al., Macromolecules, 2014, funded by The Coca-Cola Company

PEF: the next generation polymer with blockbuster potential

[2] S. Burgess et al., Polymer, 2014, funded by The Coca-Cola Company [3] S. Burgess et al., Macromolecules, 2015, funded by The Coca-Cola Company

The world is changing and the growing world population is accelerating its consumption rapidly. The consumer is becoming more concerned about the sustainability of products and production and is demanding a larger variety in products and packaging options meeting health and lifestyle trends.

[4] Internal results YXY technologies [5] Osborn & Jenkins, “Plastic Films: Technology and Packaging Applications”, CRC Press, 1992 [6] Natureworks Technical data sheet 4043D [7] A.J.J.E. Eerhart et al., Energy and Environmental Science, 2012

PEF a 100 % biobased material with a large performance benefits over PET, can meet this consumer demand. Avantium is therefore collaborating with partners to develop new packaging applications which take advantage of the PEF performance characteristics and resonate with the consumers demands. Avantium is collaborating with ALPLA, Danone, and The Coca-Cola Company on PEF bottles, with OMV/Polytype on PEF thermoforming, and with undisclosed partners on PEF thin films and fibers.

Table 3: Mechanical properties of basic BOPEF compared to PET, PP and PLA Material

BOPEF [4]

BOPET [4]

BOPET [5]

BOPP [6]

BOPLA [7]

Tensile modulus, GPa

4.5 – 8.0

3.9 – 5.3

3.3 – 3.5

2.4

3.6

Max tensile Strength, MPa

120 – 250

170 – 250

140 – 180

184

123

40 – 80

60 – 120

90 – 110

80

130

Elongation at break, %

bioplastics MAGAZINE [04/15] Vol. 10

19

Bottle News

ALPLA showed first PEF bottles As part of EXPO 2015 (1 May – 31 Oct), the innovative and creative nation of Austria is present at the Triennale Design Museum in Milan, Italy. ALPLA (Hard, Austria), leading international specialist in packaging solutions, is part of the Austrian Design Explosion exhibition with its PEF plastic bottles. The 100 % bio-based plastic PEF (polyethylene furanoate) is the packaging material of the future, as it is made from renewable materials (see pages 16 – 19 for more details).

“For ALPLA, as a specialist in packaging solutions, sustainability and the use of materials made from renewable resources are some of the most fundamental bases for the next generations. We have a responsibility to drive innovation in this area,” says ALPLA CEO Günther Lehner. In 2013 the company joined Coca-Cola and Danone in a development collaboration with Avantium for the bio-based plastic PEF. As a technological leader, ALPLA brings its decades of experience in plastics processing to the fore for the continued development of PEF. PEF (polyethylene furanoate) has an exceptional gas barrier (e. g., 10 times higher barrier properties for oxygen compared to PET). Together with its higher strength this enables the development of thinner and lighter bottles. In addition, PEF is more heatresistant and it can also be processed at lower temperatures. With these superior properties it has the potential to prolong the shelve life of certain food products and beverages. This 100 % bio-based and 100 % recycleable new polymer is expected to be the packaging material of the future.

“PEF is suitable for the production of extremely thin and light, yet strong, packaging, such as for drinks and foods,” the ALPLA CEO explains.

“This technology offers our customers added value, and also has benefits for consumers and for the environment.

We are proud to bring this pioneering technology to the market together with distinguished partners.” MT www.alpla.com www.avantium.com

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World’s first 100 % bio-based PET bottle On June 3rd, 2015 also during EXPO 2015, The Coca-Cola Company unveiled the world’s first PET plastic bottle made entirely from plant materials at the World Expo – Milan. PlantBottle™ packaging pushes the boundaries on sustainable innovation by using groundbreaking technology to create a fully recyclable plastic bottle made from renewable plant materials.

Nancy Quan, Global Research and Development Officer, The Coca-Cola Company, said, “Today is a pioneering milestone within our Company’s packaging portfolio. Our vision was to maximize game-changing technology, using responsibly sourced plant-based materials to create the globe’s first fully recyclable PET plastic bottle made entirely from renewable materials. We are delighted to unveil the first bottles here at World Expo – a world-class exhibition where sustainable innovation is celebrated.”

In response to this announcement, Erin Simon, Sustainable Research and Development Manager of the WWF (World Wildlife Fund) stated: “With every technological advance made in the bioplastic industry comes the opportunity to continue to scale the impact of more sustainable production for the materials we depend on today.

“We’re working with major companies around the world, including The CocaCola Company, to consider all the tradeoffs involved with plant-based plastics.

We all want to make sure that as we shift from fossil fuel based feedstocks to biobased feedstocks for materials we provide net positive solutions without putting additional strain on precious land and water resources.

“Plant-based plastics, if responsibly produced, allow us to continue to benefit from the tremendous value that plastics provide but without the negative environmental effects of using fossil fuels.”

In addition to biobased PET CocaCola is also pursuing and supporting Avantium’s approach to develop a 100 % bio-based PEF resin. MT www.coca-colacompany.com

4th PLA World Congress 24 – 25 MAY 2016 MUNICH › GERMANY

PLA

is a versatile bioplastics raw material from renewable resources.

It is being used for films and rigid packaging, for fibres in woven and non-woven applications.

Automotive industry and consumer electronics are thoroughly investigating and even already applying PLA. New methods of polymerizing, compounding or blending of PLA have broadened the range of properties and thus the range of possible applications.

That‘s why bioplastics MAGAZINE is now organizing the 4th PLA World Congress on:

24 – 25 May 2016 in Munich / Germany Experts from all involved fields will share their knowledge and contribute to a comprehensive overview of today‘s opportunities and challenges and discuss the possibilities, limitations and future prospects of PLA for all kind of applications. Like the three congresses the 4th PLA World Congress will also offer excellent networking opportunities for all delegates and speakers as well as exhibitors of the table-top exhibition.

The conference will comprise high class presentations on

Call for Papers

› Latest developments

bioplastics MAGAZINE invites all experts worldwide from material development, processing and application of PLA to submit proposals for papers on the latest developments and innovations.

› Market overview

Please send your proposal, including speaker details and a 300 word abstract to mt@bioplasticsmagazine.com.

› Additives / Colorants

The team of bioplastics MAGAZINE is looking forward to seeing you in Munich.

› Fibers, fabrics, textiles, nonwovens

› Online registration will be available soon.

Watch out for the Early–Bird discount as well as sponsoring opportunities at

www.pla-world-congress.com

organized by

› High temperature behaviour › Barrier issues

› Applications (film and rigid packaging, textile, automotive,electronics, toys, and many more)

› Reinforcements › End of life options (recycling,composting, incineration etc)

bioplastics MAGAZINE [04/15] Vol. 10

21

Blow moulding

New biodegradable packages for dairy products

T

he aim of the European BIOBOTTLE project is to develop new biodegradable materials suitable to produce monolayer and multilayer plastic bottles and pouches for packaging different types of dairy products (e. g. fresh milk, pasteurized milk and UHT dairy products), that offer the same shelf life as traditional packages. At the same time they should be compostable after their use without having to empty and clean them.

With an average of 261 kg per year (FAO, 2011), the European countries are the biggest consumers of dairy products in the world. The packaging materials used are completely recyclable and the post-consumer waste management should not be a problem. However, in fact only about 10 % to 15 % are actually being recycled (according to 2012 data). In addition recycling of such packaging requires exhaustive washing to eliminate any product and/or residual subsequent odors.

Therefore, it is especially interesting for the dairy industry to develop packaging products that can be composted together with their own residues using organic wastes.

The different packaging types to be developed within the project, must fulfill different characteristics in terms of thermal, mechanical, microbiological or organoleptic properties, depending on the type of dairy products and their required shelf-life. Table 1 summarizes some of these specific requirements.

One of the main difficulties with which the researchers of this project must deal, is that the traditional packages used today require thermal treatments such as sterilization or pasteurization. Some of the commercially available biodegradable materials show thermal resistances of up to approx. 65 °C whereas the current thermal treatments reach temperatures up to 90 – 95 °C. The packaging products to be developed shall fulfill the following requirements:

Guarantee the properties of dairy products throughout their shelf-life.

Ensure mechanical and thermal properties similar to the current materials used.

Be processed on conventional processing equipment.

Be fully biodegradable under composting conditions, according to ISO 14885, EN 13432 Be suitable for use as a fertilizer, according to the compostability standard EN 13432.

Be competitive, in comparison to the current packaging materials.

Be suitable for food contact.

Maintain the organoleptic properties, such as aroma (smell), colour, taste and texture.

The development scheme in figure 1 shows the work being carried out in the BIOBOTTLE project:

Partners Seven companies and technological centers from five different countries comprise the consortium which is being coordinated by AIMPLAS; Germany (VLB), Belgium (OWS), Italy (CNR), Portugal (VIZELPAS and ESPAÇOPLAS) and Spain (ALMUPLAS and ALJUAN). The Plastics Technology Center AIMPLAS (Valencia, Spain) is a non-profit research association acting as a technological partner with companies in all sectors related to plastics, customizing integral and personalized solutions through the coordination of R&D projects and technological services (analysis, testing, technical assistance, competitive and strategic intelligence and training).

Project development The project has now run halfway down its expected shelflife and during the first period some chemical modifications have been carried out on different biodegradable materials (based on PLA) available in the market. The materials obtained at pilot plant level were studied in order to assess their processability in both conventional extrusion lines; extrusion blow molding and blown film extrusion to obtain pouches and bottles respectively.

Table 1: Requirements of the selected dairy products to be studied.

22

Fresh milk (flexible pouches)

Probiotic yougurt products (bottles)

Organic UHT milk (bottles)

Required shelf-life

4 – 7 days at <8 °C

2 – 3 weeks at <8 °C

3 – 4 months

Thermal treatment

Pasteurized 72 – 75 °C, 15 – 40 s

Pasteurized 72 – 75 °C, 15 – 40 s

Package structure

Multilayer (3 layers)

Monolayer (with HDPE)

Multilayer (3 layers) (HDPE / black HDPE/HDPE)

Manufacturing process

Blown film co-extrusion

Extrusion blow moulding

Co-extrusion blow moulding

Additional requirements

Withstand vertical form-fill-seal

Lid sealing

Lid sealing and injection moulding caps

bioplastics MAGAZINE [04/15] Vol. 10

Bottle 90 – 95 °C, 4 – 20 s

Product 135 – 150 °C, 4 – 20 s

The materials and final products obtained at pilot plant level with the biodegradable materials developed were modified by a crosslinking reaction in the reactive extrusion step in order to get a branched polymer with enhanced thermal properties.

During this reactive extrusion process a reticulate agent was added to promote the radical reaction of the polymer chain. These radicals are necessary for the branching process between polymer chains to occur. The products were characterized and the results are shown in tables 2 (for bags/ pouches) and 3 (bottles). Additionally, for caps/closures for bottles, new biodegradable blends were obtained taking into account their processability by injection moulding. Table 4 shows the hardness range of these blends in comparison with the reference material, polypropylene (PP).

By: Chelo Escrig Rondán Head of Extrusion Department AIMPLAS (Technological Institute of Plastics) Paterna, Spain

Figure 1: BIOBOTTLE planned scheme of work

Biodegradability The biodegradability tests were carried out with the new developments and first measurements showed good results.

Other tests to evaluate the compostability are exhibiting ongoing promising results.

Biodegradable grades Reticulate agents

Future steps

Chemical modification by reactive extrusion

Final products Pouches by blown film extrusion

In the second part of the project, the packaging characterization (pouches and bottles) will continue and their validation will start taking into account their functionality regarding microbiological analysis, migration and organoleptic aspects. On the other hand, the scale-up of new bio-compounds and the obtaining of pouches, bottles (monolayer and multilayer) and caps will be carried out.

Bottles by extrusion blow moulding: - Small bottles, probiotic products - Big bottles for milk

Extrusion process, monolayer and multilayer blown film and extrusion blow moulding, injection moulding for caps

Acknowledgement This project has received funding from the European Union´s Seventh Programme for Research, Technological Development and Demonstration (FP7 / 2007 – 2013) under grant agreement nº [606350].

Table 4: Hardness of the new developments Properties Hardness (Shore D)

www.biobottleproject.eu

Standard

Reference material

New developments

EN ISO 868

69 – 72

65 – 77

Reference material

Commercial bio-material

New developments

100 – 115

62 – 70

90 – 100

17 – 20

18 – 34

18 – 32

850 – 940

550 – 750

650 – 800

2 – 3

3 – 4

4,5 – 5,5

Reference material

Commercial bio-material

New developments

110 – 125

62 – 70

90 – 100

25 – 30

28 – 40

29 – 34

650 – 800

530 – 750

500 – 700

No break

No break

No break

Table 2: Thermal and mechanical properties in bags.

Properties

Standard

Thermal resistance

Vicat temperature (°C) Stress at break (MPa)

Mechanical properties *

Elongation at break (%) Puncture resistance (mJ)

UNE-EN ISO 306 UNE-EN ISO 527-2 UNE-EN ISO 527-2 UNE-EN 14477

(*) Mechanical properties were measured in 125 microns film.

Table 3: Thermal and mechanical properties in bottles.

Properties Thermal resistance

Standard Vicat Temperature (ºC) Stress at break (MPa)

Mechanical Properties

Elongation at break (%) Compression

UNE-EN ISO 306 UNE-EN ISO 527-2 UNE-EN ISO 527-2 Internal procedure (*)

(*) Maximum stress 10 N.

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Blow moulding

The biobased future of beer packaging?

Fiber bottles from sustainably sourced wood-fiber could be a solution

D

esigning zero-waste products with future lifecycles in mind provides a logical way to mitigate rising demand in a world of limited resources. The Carlsberg Circular Community is bringing partners together to develop innovative solutions that, it hopes, will benefit business, society, and the environment in equal measure. A biobased bottle from wood fiber is one of these solutions.

The aim is to develop the next generation of packaging products which are pre-optimised for recycling and reuse, while, at the same time retaining or improving their quality and value. The approach is increasingly referred to as upcycling.

In the future we will, both as businesses and individuals, face increasing pressure on natural resources due to rising demand for consumer goods.

This, along with pressures on supply chains and cost, means that businesses that are able to use materials more efficiently will have much to gain. Carlsberg has always been good at using resources efficiently, as can be seen by their strong performance in terms of water and energy use as well as their levels of CO2 emissions.

This is clearly good for the planet, but also for business, as it reduces costs and is something that Carlsberg’s employees can take pride in.

Arkema: Glass bottle coatings

The companies working together with Carlsberg are: Rexam: Cans

O-I: Glass packaging RKW: Shrink Wrap MWV (MeadWestvaco): Paperboard Multipacks Petainer: PET kegs for draught beer EcoXpac: Packaging company specialised in woodfiber To achieve the right level of C2C expertise and quality assurance, Carlsberg has partnered with EPEA Internationale Umweltforschung GmbH, the institute founded by Professor Michael Braungart, who created the C2C Design Protocol together with William McDonough. EPEA contributes by both providing inspiration and technical know-how when assessing and optimising materials and processes for the Circular Economy.

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Inspired by Circular Economy concepts, last year the Danish Brewery launched the Carlsberg Circular Community (CCC) (fig. 1), a cooperation between Carlsberg and selected partners which pursues a zero-waste, beneficial society using the Cradle to Cradle® (C2C) design framework when developing and marketing new products.

Carlsberg Circular Community

DISPOSAL & COLLECTION

KNOCK ON WOOD A biobased bottle made from sustainably sourced wood-fiber.

BREWING & BOTTLING

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Inspired by Cradle-to-Cradle®

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AS GOOD AS GREEN Strong, durable material, 100% compliant with the strictest food and beverage regulations.

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IN THE NAME OF BEER LOVE Will contribute to spreading sustainable beer love everywhere in partnership with ecoXpac.

Fig. 2:

0%

ZERO WASTE Will be 100% biodegradable and generate 0% waste.

Blow moulding

By: Jim Daniell Director, Media Relations Carlsberg Breweries A/S Copenhagen, Denmark

Commenting on the CCC initiative, Professor Michael Braungart says: “Carlsberg and its partners are taking an important step on the roadmap towards creating new benefits with packaging. This co-operation is a great example of companies planning together for the future, creating solutions to the global challenges that face us all. I encourage companies to join Carlsberg in its efforts to develop innovative packaging and rethink the concept of waste.”

In order to increase the reach and scale of the initiatives, Carlsberg’s target is to cooperate with 17 partners and to launch three C2C-certified products by 2017. The first certification came in January 2015, when Carlsberg, along with Rexam, obtained Cradle-toCradle Bronze Certification for Somersby and Carlsberg cans in the UK, underlining the strong recyclability profile of the aluminium can.

The aim is to be able to provide higher quality products with restorative impacts, less input of natural resources and less waste, and to build a resilience while preparing for future growth.

Biobased beer packaging innovation: The Green Fiber Bottle At the World Economic Forum in Davos, Switzerland in January 2015, Carlsberg announced an agreement to develop the world’s first fully biodegradable wood-fiber bottle for beverages. The project will be a three-year project with packaging company ecoXpac (one of the newest members of the Carlsberg Circular Community), with the additional collaboration of Innovation Fund Denmark and the Technical University of Denmark. The aim is to develop a biodegradable and biobased bottle made from sustainably sourced wood-fiber, to be known as the Green Fiber Bottle (fig. 2). All materials used in the bottle, including the cap, will be developed using bio-based and biodegradable materials – primarily, sustainably sourced wood-fibers – allowing the bottle to be responsibly degraded.

The innovative impulse drying technology being used to develop the bottle aims to ensure that energy consumption during production does not exceed that used in existing product alternatives. In fact, it is estimated that final energy consumption will be lower than that required for existing HDPE and paper technologies. Though it might seem strange to drink beer from a wood-fiber bottle, the pioneers at Carlsberg have high hopes for the project, as they believe that the

Fig. 3: Green Fiber Bottle Prototype – Carlsberg Group.

The final bottle design will look different.

This is only a prototype picture

bioplastics MAGAZINE [04/15] Vol. 10

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Blow moulding consumers will be looking for innovative, highly sustainable packaging solutions in the future (fig. 3).

Fig. 4: Technical and biological cycles - C2C (Source: EPEA GmbH 2008)

Production

Plants

Product

Biological nutrients Use

Biological degradation

Biological cycle for products for consumption

The coming years will bring various technical challenges, including further development of the impulse drying technology that will be key to creating a cost-efficient wood-fiber mould. And needless to say, the end-product must meet requirements for classification as a food contact material, passing testing of organoleptic properties, and must live up to Carlsberg’s own high quality standards.

After use, the green fiber bottle should of course be collected, so that the materials can be either re-used, or what’s coming to be called upcycled. Up-cycling means converting a used material into a product of the same or higher value – for instance using recycled aluminium to create a new can or, in the case of biobased products, ensuring that they can reenter the biological cycle without any negative environmental impact (fig. 4).

Even though the green fiber bottle will be biodegradable, Carlsberg would still want consumers to hand in the used bottles at the right collection point, or sorting bin, to avoid this great innovation becoming branded waste.

So how does the future look?

Production

Technical nutrients

Return, disassembly

Product

Use

Technical cycle for products for service

One of the learnings from the work with the Carlsberg Circular Community is that the scale and scope of what can be achieved in partnership with others goes way beyond what one company could do alone. When Carlsberg was founded back in 1847 in Copenhagen, Denmark, J. C. Jacobsen defined the company’s mission as a constant struggle for perfection in the art of beer-making. That goal has served and continues to serve Carlsberg well.

But they also recognise that in order to thrive and flourish in the future, companies need to understand and develop sustainable solutions now. The Circular Economy offers opportunities to redesign the way we consume and live, and, through the Carlsberg Circular Community, Carlsberg is committed to playing a part in that (r)evolution. A revolution that will bring you beer in wood-fiber bottles, and other exciting innovations. http://www.carlsberggroup.com

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bioplastics MAGAZINE [04/15] Vol. 10

2015

P R E S E N T S

THE TENTH ANNUAL GLOBAL AWARD FOR DEVELOPERS, MANUFACTURERS AND USERS OF BIOBASED PLASTICS.

Call for proposals

til Please let us know un

August 31

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and does rvice or development is 1. What the product, se win an award or development should ce rvi se t, uc od pr is th 2. Why you think ganisation does oposed) company or or pr e th (or ur yo at Wh 3. ay also (approx. 1 page) and m s rd wo 0 50 ed ce ex t d/or Your entry should no marketing brochures an t be s, ple m sa , hs ap gr oto es mus be supported with ph nt back). The 5 nomine se be ot nn (ca ion tat technical documen 30 second videoclip prepared to provide a 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 10th European Bioplastics Conference November 5-6 2015, 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

Application News

First bio-based plastic smartphone screen

New matt cellulosebased film

Mitsubishi Chemical Corporation (MCC, headquartered in Chiyoda-ku, Tokyo, Japan) recently announced that its biobased engineering plastic DURABIO™ has been chosen by Sharp Corporation (Osaka, Japan) for the front panel of its new smartphone, the AQUOS CRYSTAL 2, slated to go on sale in the middle of July 2015). The choice marks a world-first as bio-based engineering plastic has ever been used on the front panel of any smartphone.

Innovia Films (Wigton, Cumbria, UK) has added NatureFlex™ NK Matt to its range of compostable cellulose-based packaging films. The film has a premium natural paper appearance. It has been developed primarily as a lamination grade.

NatureFlex™ NK Matt is ideal as the outer web of duplex and triplex structures. It is also suitable for use in laminations to other bio-polymers (including grades of NatureFlex™) and for extrusion coating.

Most front panels of smart­phones are made of glass, and their susceptibility to cracking has been an ongoing problem.

This has led manufacturers to consider poly­carbonate and other plastics for the front panels because of their light weight and increased durability com­pared to glass. Unfortunately, some traditionally available plastics offered excellent optical properties, but were more prone to cracking upon impact, while others that were impact-resistant tended to have poor optical properties.

Therefore, as there was a need for considerable improvement in the plastics, the vast majority of smartphone m a n u ­f a c t u re r s relied on glass for the front panels of their phones.

(photo: Sharpusa.com)

MCC-developed Durabio is a bio-based engi­ neering plastic made from plant-derived isosorbide, which features excellent performance as it offers higher resistance to impact, heat, and weather than con­ ventional engi­ neering plastics.

In addition, it has excellent trans­ parency and low optical distortion.

Recently, Durabio has received high evaluations from Sharp as a plastic with superior shock resistance and optical character­istics, which led to the company’s selection of Durabio for the front panel of the AQUOS CRYSTAL 2. SB www.sharp-world.com www.m-kagaku.co.jp

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Organic and Fairtrade companies are already trialling NatureFlex™ NK Matt for products in the confectionery, dry foods, snacks and beverage sectors.

The natural look and sleek feel of NatureFlex™ NK Matt in such a packaging enables the products to grab the attention of consumers on a crowded shelf.

These new matt films, along with the other NatureFlex NK grades, with 97 % renewable content (ASTM D6866 Carbon Testing) and fully compostable according to EN 13432 / ASTM D6400, provide an excellent barrier to gases, aromas and mineral oils.

This high gas barrier film gives products the protection they need. Advantages offered for packing and converting by NatureFlex™ NK Matt include inherent dead-fold, anti-static properties, printability and resistance to grease.

“Compostable and renewable NatureFlex™ NK Matt offers manufacturers of natural and organic goods a way to align their packaging message with the spirit of their product marketing at point of sale. If you are looking for a tactile quality pack with sustainable credentials, NatureFlex™ NK Matt is the answer,” stated Clare McKeown, Innovia Films’ Market Manager. www.innoviafilms.com www.natureflex.com

Visions become reality.

COMPOSITES EUROPE 22. – 24. Sept. 2015 | Messe Stuttgart 10. Europäische Fachmesse & Forum für Verbundwerkstoffe, Technologie und Anwendungen www.composites-europe.com

Organised by

Partners

Application News With the new accessories, you don‘t need to place your pencils in a glass anymore (picture: fotolia)

Biodegradable coffee capsules Just in time for Environment Day on June 05, 2015 the Bremen/Germany based coffee capsule company Velibre introduced biodegradable coffee capsules, compatible with all the major Nespresso®* machines.

Since its foundation, it has been the company’s goal, to produce environmentally friendly capsules. Velibre’s newest generation of bio coffee capsules consist of an EN13432 certified M·VERA® grade, i. e. a blend of different aliphatic biopolyesters, developed and produced by Cologne/Germany based BIO-FED.

New bioplastic office products Vancouver, Canada based Solegear Bioplastic Technologies Inc., in partnership with Columbia Plastics Ltd., a leading Canadian plastic injection molding company, have completed a commercial agreement with TOPS Products Canada to convert six of their Starmark branded desk organizer and accessory products to Solegear’s plant-based materials.

“We’re very excited to be taking the next step with Columbia Plastics to convert the TOPS Products Canada Starmark brand to Solegear’s Polysole LV bioplastic injection molding grade,” said Paul Antoniadis, CEO of Solegear. “The desk organizer and office accessory market in Canada is valued at an estimated 100 million dollars and as businesses seek out new ways to decrease their carbon footprint and fulfill customer expectations when it comes to corporate social responsibility, Solegear’s products are positioned to meet those needs and surpass expectations.”

The six Starmark desk organizing and accessory products to be launched include the Clip-Mate™, Memo-Mate™, FileMate™, Pencil-Mate™, Self-Stacker and Desk Tray. TOPS Products Canada will be launching these six initial products or SKUs for its commercial channel customers, which include Canadian office retailers such as Staples, Staples Advantage, Office Depot, Office Pro and Office Plus, Basic Office Products and BuroPlus. These products will be available in late 2015.

Solegear’s Polysole is made by combining a base polymer (PLA), with a natural additive formulation which increases various mechanical, processing and physical performance characteristics of the material. Polysole LV bioplastic injection molding grade includes a suite of bioplastic resins that can be processed on conventional injection molding equipment. With plant-based content ranging from 65 % to 100 %, Polysole LV is designed to replace petroleum-based Polypropylene, High Impact Polystyrene and ABS plastics while maintaining performance and the highest possible levels of annually renewable material. KL www.solegear.ca

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“A primary goal of this development was to ensure biodegradability not only in industrial composting facilities but also at ambient temperature” as Sebastian Thomsen, Senior Business Development Manager of BIO-FED – Branch of AKRO-PLASTIC, told bioplastics MAGAZINE. “Due to its composition, the material has the potential to biodegrade when exposed to bacteria such as in soil or in a normal household compost”. The lidding material as well as the barrier pouch used as part of the packaging for the capsules are made from NatureFlex™ by Innovia Films.

Those components ensure the capsule is biodegradable and the coffee keeps its great aroma.

According to Velibre, customers can discard the new coffee capsules with a happy conscience in their home compost. In addition to the bio capsules the external packaging is made from 100 % recycled paper. “For coffee lovers, friends of good taste and people who stand up for a sustainable life, this new generation of the coffee capsule is a must. We do not want to rest after the product launch, but aim to further optimize the capsules, e. g. by increasing the bio-content of the materials used, working on the biodegradation profile and very importantly getting third party certification for Endof-Life options”, enthused Velibre CEO David Wolf-Rooney.

“The future product development and the expansion of Velibre will be financed through involvement in the German crowdfunding scene which will begin in the next few weeks.

Customers can order five delicious coffees ranging from mild to very strong in their intensity. The premium coffee packaged in the capsules comes from Tanzania, Brazil, Ethiopia, Uganda, and Java and ensure an excellent mix”.MT www.velibre.com | www.bio-fed.com | www.natureflex.com * Nespresso® is the brand of a third party and has no connection to the Velibre GmbH

Market study on Bio-based Building Blocks and Polymers in the World

Capacities, Production and Applications: Status Quo and Trends towards 2020

Fast Growth Predicted for Bio-based Building Blocks and Polymers in the World – Production Capacity will triple towards 2020 The new comprehensive 500 page-market study and trend reports on “Bio-based Building Blocks and Polymers in the World – Capacities, Production and Applications: Status Quo and Trends Towards 2020” has been released by German nova-Institut GmbH. Authors are experts from the nova-Institute in cooperation with ten renowned international experts.

million t/a

Bio-based polymers: Evolution of worldwide production capacities from 2011 to 2020 20

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http://bio-based.eu/markets

actual data 10

Constant Growth of Bio-based Polymers is expected: Production capacity will triple from 5.1 million tonnes in 2013 to 17 million tonnes in 2020, representing a 2% share of polymer production in 2013 and 4% in 2020.

Bio-based drop-in PET and the new polymers PLA and PHA show the fastest rates of market growth. The biobased polymer turnover was about € 10 billion worldwide in 2013. Europe looses considerable shares in total production to Asia.

What makes this report unique?

forecast 2% of total polymer capacity

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2011

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2013

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PTT

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PBAT

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PLA

-Institut.eu | 2015

2019

2020

Full study available at www.bio-based.eu/markets

■ The 500 page-market study contains over 200 tables

and figures, 96 company profiles and 11 exclusive trend reports written by international experts.

■ These market data on bio-based building blocks and polymers are the main source of the European Bioplastics market data.

■ In addition to market data, the report offers a complete and in-depth overview of the bio-based economy, from policy to standards & norms, from brand strategies to environmental assessment and many more.

■ A comprehensive short version (24 pages) is available for free at http://bio-based.eu/markets

To whom is the report addressed?

■ The whole polymer value chain: agro-industry,

feedstock suppliers, chemical industry (petro-based and bio-based), global consumer industries and brands owners ■ Investors ■ Associations and decision makers Two years after the first market study on bio-based polymers was released, Germany’s nova-Institute is publishing a complete update of the most comprehensive market study ever made. This update will expand the market study’s range, including bio-based building blocks as precursor of bio-based polymers. The nova-Institute carried out this study in collaboration with renowned international experts from the field of bio-based building blocks and polymers. The study investigates every kind of bio-based polymer and, for the first time, several major building blocks produced around the world, while also examining in detail 112 companies that produce biobased polymers.

Content of the full report This 500 page-report presents the findings of nova-Institute’s market study, which is made up of three parts: “market data”, “trend reports” and “company profiles” and contains over 200 tables and figures.

The “market data” section presents market data about total production capacities and the main application fields for selected biobased polymers worldwide (status quo in 2013, trends and investments towards 2020). This part not only covers bio-based polymers, but also investigates the current bio-based building block platforms.

The “trend reports” section contains a total of eleven independent articles by leading

experts in the field of bio-based polymers.

These trend reports cover in detail every important trend in the worldwide bio-based polymer market.

The final “company profiles” section includes 96 company profiles with specific data including locations, bio-based polymers, feedstocks and production capacities (actual data for 2011 and 2013 and forecasts for 2020). The profiles also encompass basic information on the companies (joint ventures, partnerships, technology and bio-based products). A company index by polymers, with list of acronyms, follows.

Order the full report The full report can be ordered for 3,000 € plus VAT and the short version of the report can be downloaded for free at: www.bio-based.eu/markets

Bio-based Building Blocks and Polymers in the World Capacities, Production and Applications: Status Quo and Trends towards 2020

PP

PE

EPDM

PVC PMMA PET-like

PC PHA PTT

Dipl.-Ing. Florence Aeschelmann +49 (0) 22 33 / 48 14-48 florence.aeschelmann@nova-institut.de

PA

THF

Glucose

Starch

Lysine

PBS

PEF

1,4 Butanediol Succinate

Adipic Acid

HMDA

PU

p-Xylene Isobutanol

1,3 Propanediol Lactic acid

PU

PBT

Teraphtalic acid

SBR Ethanol

Sorbitol

Isosorbide

PLA

Contact

Ethylene

Vinyl Chloride Methyl Metacrylate

PU

PET

MEG

Propylene

PBAT

Saccharose

Superabsorbent Polymers

3-HP

Lignocellulose Acrylic acid

Natural Rubber

Caprolactam

Plant oils

Fructose

Fatty acids

Glycerol

HMF FDCA

Epichlorohydrin Polyols

Natural Rubber Starch-based Polymers Lignin-based Polymers Cellulose-based Polymers Epoxy resins

Other Furan-based polymers

Diacids (Sebacic acid)

PHA PU

PU

PA

Florence Aeschelmann, Michael Carus, Wolfgang Baltus, Howard Blum, Rainer Busch, Dirk Carrez, Constance Ißbrücker, Harald Käb, Kristy-Barbara Lange, Jim Philp, Jan Ravenstijn, Hasso von Pogrell

Foam

Foamed blocks from NF-reinforced starch Biodegradable foamed blocks based on starch reinforced with natural fillers and produced using microwave radiation.

M

aking materials lighter is one of the main challenges of society today because it involves cutting down on the use of raw materials, reducing fuel consumption in vehicles and increasing the thermal insulation performance of buildings, to name but a few examples. This is why foamed plastics, which can weigh even 40 – 45 times less than their solid counterparts, are slowly gaining more importance in our daily lives. They are produced from fossil-based polymers such as polystyrene, polyurethane, polyvinylchloride and polyolefins.

However, another important challenge of our society and at the same time one strategic policy of the European Union [1] is to make our economy less dependent on fossilbased materials. The use of bioderived and biodegradable polymers for foaming applications could contribute to fulfilling this objective. Their global production, which was around 1.6 million tonnes in 2013, is expected to increase up to 6.7 million tonnes in 2018 [2]. Nevertheless, their use in the foam industry has been restricted so far due to their poor foaming performances and to their high cost. Although there are products in the market based on PLA foams such as food-packaging trays they have not reached a significant market share. This fact provides a unique opportunity for a natural polymer such as starch.

As this polymer is easily extracted from plants such as cereals and tubers, its cost is lower than that of PLA and PHAs. Starch can act as a filler when used in its original form (semicrystalline granules) or can be transformed into a thermoplastic material, which is known as thermoplastic starch (TPS). TPS features properties similar to those of conventional fossil-based polymers used for foaming applications such as polystyrene and it is foamed by similar processes such as extrusion foaming [3]. In fact, the first starch-based foams produced by extrusion were

snack foods (fig. 1) because foaming varies their texture and makes them more appetizing and crisp [4]. For quite some years starch foamed products have also been used as packages. Starch-based loose fill chips and boards, which are produced by extrusion foaming are widely employed for protective packaging applications (fig. 1).

Moreover, food plates based on starch foams have been produced by baking a process similar to that employed for the production of waffles.

More recently, a lab-scale foaming process based on microwave radiation has been developed by Cellmat Technologies (Valladolid, Spain). This company is a spinoff founded by the initiative of researchers from CellMat Laboratory (University of Valladolid). The process allows starch-based foamed blocks reinforced with natural fillers to be produced with lower energy consumption and lower cycle times than in the aforementioned processes.

This process basically consists of three steps (fig. 2): firstly, starch is plasticized by water in a twin-screw extruder. Secondly, the pellets obtained are thermoformed in a hot-plates press so as to produce a solid sheet. This sheet is placed into a PTFE mould where the foaming process occurs. PTFE was chosen as the material for the mould because it avoids the starch sticking, it is heat-resistant and last but not least, it is transparent to microwave radiation. Finally, the mould with the solid TPS sheet inside is placed into a microwave oven chamber and microwave radiation at constant power is applied for a few seconds. During this short period of time, the interaction of microwaves with water molecules produces the heat necessary to soften the polymer matrix and to vaporize water, which in turn brings about the sudden expansion of the polymer. It is obvious that water is the most important element in this process because it acts not only as the plasticizer of starch but also as the blowing agent.

Figure 1: Starch-based foam applications: cereals, snacks, loose-fill chips and boards.

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Foam Starch undergoes several physical transitions in this process as shown in the SEM micrographs of figure 2. At the beginning, starch is a semi-cristalline granule (1), which cannot be processed by conventional plastic equipment because its degradation occurs before melting. For this reason, starch requires a transformation process (plasticization) in which the granule is disrupted by the action of a plasticizer (water in this case) and the high mechanical energy applied along the extruder barrel. An amorphous thermoplastic (2) with a glass transition temperature even lower than ambient temperature (depending on the amount of plasticizer used) is obtained. This flexible material turns into a dry foamed product due to water loss caused during the time in which microwaves are applied. Water goes from the polymer within the cell walls and struts to the interior of the cells expanding the material and in the end, stabilizing the cellular structure (3).

By: Alberto Lopez Gil CellMat Technologies Centro de Tecnologías y Transferencia Aplicadas (CTTA) Valladolid, Spain

These same physical transitions are undergone by starch when other foaming processes such as baking and extrusion foaming are used. However, the way in which heat transfer evolves is different. When microwaves are used, heat comes from multiple spots distributed along the solid precursor, which corresponds to the water molecules, and it is later transferred to the whole volume of the material by conduction (fig. 3). Therefore, heat is originated in the interior of the material and not in the exterior, which is the case in extrusion foaming and baking.

Figure 2: Microwave foaming process developed by CellMat Technologies.

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200 µm

40 µm Natural fillers

Water

Starch granules 40 µm TPS pellets

Plasticization of starch (TPS) and dispersion of natural fillers in a twin-screw extruder

Thermoforming in a hot-plate press

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Foamed starch block reinforced with natural fillers

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Foam This involves a faster and more homogeneous heating that is reflected in low energy consumption, low cycle times and in more homogeneous cellular structures. Moreover, shapedfoams can be produced (fig. 4), which means a high potential to be applied for the packaging of household-appliances (for instance). There were previous attempts to produce these kinds of foams, using pellets as solid precursors (trying to simulate the production of EPS or EPP foams) instead of a solid-sheet as in the process developed by CellMat technologies. Pellets expand isotropically during exposure to microwaves and are finally fused together forming a foamed block, which is very similar to the ones produced from EPS [5]. However, the union between the expanded pellets is weaker than in the case of these synthetic foams, hence their mechanical properties are very poor. The employment of a single solid sheet as a solid precursor constituted a step forward because the foams obtained are continuous blocks with superior mechanical performances in terms of stiffness, strength and energy absorption.

Another interesting aspect of this technology is the possibility of using lignocellulosic fibres as fillers because of their good chemical compatibility with starch (both polymers are constituted by the same repeating unit: glucose).

These natural fillers represent waste from the agricultural industry, which can acquire an added value when used in this application. Moreover, they are easily incorporated into the polymer matrix during the plasticization process of starch (two different processes in one single step) and induce not only an improvement of the mechanical properties but also positive cellular structure modifications such as reduction in the cell size.

This microwave foaming process, in spite of its numerous advantages, requires high investments so as to be scaled-up to industry. There are industrial microwaves ovens with high potential to be employed as foaming ovens but so far, they are only used for drying purposes.

For this reason, CellMat Technologies is also focused on the development of foamable compounds based on TPS and blends with other biodegradable polymers such as PLA, with similar properties to that of polyolefin-based polymers and polystyrene (polymers usually employed in the foam industry). For instance, a TPS-based compound has recently been developed, which is foamable by chemical and physical blowing agents in an extrusion foaming process. Hence, this biodegradable compound allows the use of the same industrial machinery currently employed for the production of fossil-based foams without further significant investment. www.cellmattechnologies.com

References [1] A resource-efficient Europe–Flagship initiative of the Europe 2020 Strategy. http://ec.europa.eu/resource-efficient-europe/ [2] http://en.european-bioplastics.org/market/ [3] Alavi, S. H.; Gogoi, B. K.; Khan, M.; Bowman, B. J. and Rizvi.

S. S. H. Structural properties of protein-stabilized starch-based supercritical fuid extrudates. Food Research International. 32, 107 – 118. (1999).

[4] Moraru, C. I. and Kokini, J. L. Nucleation and expansion during extrusion and microwave heating of cereal foods. Comprehensive Reviews in Food Science and Food Safety. 2, 147 – 165. (2003).

[5] Zhou, J.; Song, J. and Parker, R. Microwave-assisted moulding using expandable extruded pellets from wheat flours and starch.

Carbohydrate Polymers. 69, 445 – 454. (2007).

Figure 3: Heat transfer in conventional and microwave ovens.

Microwave radiation

Sample surface

To_ gradient

Conventional oven

Hot spots

Microwave oven

Figure 4: From EPS foams and starch foams constituted by expanded pellets to starch foamed blocks produced from solid sheets.

CellMat technologies

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Diameter Height

Foam

Tomorrow is NOW! 30

First day

days

60 days

120 days

180 days

Bioplastic for Paper Coating Naturally Compost . Recycle

Excellent Heat sealability

Heat resistance up to

100 C

Runs well with LDPE machine

*This test was conducted under natural condition in Bangkok, Thailand.

Paper packaging coated with BioPBS™ can be disposed of along with organic waste. It is compostable without requiring a composting facility, and it has no adverse effects on the environment.

PBS from MCC technology (GS Pla™) is certified by Biodegradable Product Institute (BPI) for ASTM D6400 in North America, by Vincotte for OK COMPOST (EN13432) and OK COMPOST HOME marks in European Union, and by Japan Bioplastics Association (JBPA) for GreenPla Mark in Japan. PBS coated paper is recyclable and repulpable at 96% yield certified by Western Michigan University.

For more information info@pttmcc.com www.pttmcc.com PTT MCC Biochem Co., Ltd. A Joint Venture Company of PTT and Mitsubishi Chemical Corporation 555/2 Energy Complex Tower, Building B, 14th Floor, Vibhavadi Rangsit Road, Chatuchak, Bangkok 10900, Thailand

T: +66 (0) 2 140 3555 I F: +66(0) 2 140 3556 I www.pttmcc.com

Foam

Sandwich panel f rom wood and bioplastics By:

Hendrik Roch Fraunhofer UMSICHT, Oberhausen, Germany Dr. Jan Lüdtke Thünen-Institut für Holzforschung, Hamburg, Germany

W

ood is a sought-after raw material for energy generation as well as for material utilization.

One of the major consumers is the wood-based panels industry, producing for example particleboard for furniture manufacturing and interior housing work. A new form of wood-based sandwich panels consists of a hybrid structure with a lightweight foamed core layer and particleboard cover layers, still creating a strong structure.

At present, the core consists of plastics from fossil resources. Fraunhofer UMSICHT (Oberhausen, Germany) together with Thünen Institute for Wood Research (Hamburg, Germany) is now developing a novel sandwich panel based on renewable materials.

Figure 1: Sandwich panels are usually used in lightweight construction

Figure 2: Granules containing gas before and after foaming

For the production of the sandwich panel a continuous process was developed by the wood researchers. Plastic granules, loaded with a blowing agent, are scattered on a bottom layer of agglutinated wood particles. Then, a second layer of agglutinated wood particles is spread on top. By heat and pressure the cover layers are compacted and the adhesive cures. In parallel, the polymer phase softens, followed by the activation of the blowing agent. To allow for the expansion of the polymer foam, the hot press opens to a predefined distance. The lightweight foam core is formed and simultaneously bonds to the facings forming a three layered sandwich panel.

In future without fossil resources?

The research teams of Fraunhofer UMSICHT and Thünen Institute for Wood Research have adapted this process to a new bioplastic. “The use of the new innovative lightweight construction material based on natural resources allows the complete substitution of fossil based polystyrene in sandwich panels”, explained Hendrik Roch from the department Bio-based Plastics at Fraunhofer UMSICHT. Figure 3: Foamed samples from biobased plastics (left) and fossilbased reference (right)

As a result of the first trials at Fraunhofer UMSICHT i. e. the combination of cellulose acetate butyrate (CAB) with a citrate plasticizer (a promising substitute for harmful phthalic acid based plasticizer) turn out as a promising formulation. Thus, a bioplastic compound with a melting temperature of 110 °C, similar to polystyrene (PS), can be achieved. As an exemplary result of the material development table 1 shows a comparison of the material properties of PS and CAB with plasticizer.

The comparison demonstrates higher stiffness and strength of PS against plasticized CAB, but the latter reveals better elongation properties and double to triple impact strength. These are good conditions for the foamability of the material.

Parallel to the material development, the basic expansion properties of the material, depending on

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Foam pressure, temperature and blowing agents, are tested.

First trials to produce expandable bioplastics beads in a process similar to EPS production were successful. The basic material (compound) is mixed in an extruder with the blowing agent. The granules containing blowing agent are tested regarding their foamability. In a mould tool water vapour heats the granules, with the result that the gas in the granules expands. A light, foamed and stable core structure from bioplastics is produced, fused to a moulded part in a closed aluminum mould. After cooling, the finished part is ejected from the mould.

Process optimizing Followed by the material development and foaming trials the production of the final biobased sandwich panels is tested at Thünen Institute for Wood Research.

The aim is the production of a highly compressed facing, which achieves the best possible bonding to the core.

Therefore, the process (considering core layer granules, material moisture, adhesive type and amount, pressing time and power, etc.) has to be developed in such a way, that an optimized formation of facing and boundary layer occurs. Next steps in the project will be the optimization of the new products to substitute EPS without changing the processing parameters. Additionally, the researchers will further improve the material properties concerning temperature resistance, strength, etc.

Polystyrene

CAB/Pl.

1,040 kg/m

1,180 kg/m³

3,000 – 3,600 MPa

1,000 – 1,100 MPa

46 – 60 MPa

24 MPa

3 – 4 %

14 %

Charpy notched impact strength

2 – 5 kJ/m2

8.9 kJ/m2

Glass transition temperature

60 – 100 °C

110 – 140 °C

Biodegradability

No

Yes

Density E-Modulus

3

Tensile strength Elongation at break

Table 1: Comparison of the material properties of unexpanded PS and plasticized CAB

Table 2: Comparison of material and energy input for 1 cubic meter of typical particleboards and sandwich materials Particleboard (650 kg/m3)

Sandwich hybridpanel (370 kg/m3)

Wood

570 kg/m3

280 kg/m3

Resin & additives

80 kg/m3

45 kg/m3

-

45 kg/m3

100 %

~ 50 %

Polymer Energy (thermal & electrical)

www.umsicht.fraunhofer.de · www.ti.bund.de/en

Material and energy demand during production A parallel, critical observation by means of life cycle analysis (LCA) evaluates the product and eventually adjusts the project. Table 2 shows a comparison of material and energy demand during production between a standard particleboard and a sandwich hybrid-panel.

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Sandwich panel economics The panel price strongly depends on the application in which the sandwich construction is to be used. While particleboard is a rather low cost and low value standard product, substitute products gain a considerable benefit if they can be adapted to special applications where dedicated features (e. g. low weight, embedded thermal and sound insulation etc.) provide an added value to the customer. As the facing particles are exchangeable with fibres, strands or other types of particular material a great variety of products can be achieved. All types of hybridpanels comprise the one or the other special feature, so that they will be able to compete in these niche markets against the cheaper standard particleboard.

Funding The research project “Material and process development for the production of a wood bioplastics sandwich panel based on renewable resources” is funded by the Forest Climate Fund, jointly coordinated by the Federal Ministry of Agriculture (BMEL) and the Federal Ministry of the Environment (BMUB). Project management agency is the Federal Office for Agriculture and Food (BLE), funding code 28WB304002.

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bioplastics MAGAZINE [04/15] Vol. 10

37

Foam

Foams made from modified standard PLA

N

owadays, polymer foams are widely used because the cellular structure leads to a low thermal conductivity and specific impact resistance, which are necessary for applications such as insulation or packaging (fig. 1 and fig. 2). In fact, thanks to the material reduction, weight and costs can be saved as well as CO2 emissions lowered.

Still, the disposal of polymer foams causes environmental issues in countries without a good waste system, because most foamed moldings are used in relatively short-lived applications like transport packaging, e. g. electronic devices or disposable dishes. Usually, these are made of petroleum-based extruded polystyrene foam (XPS).

However, already things are changing. In attempt to green up the City of New York has banned XPS.

Figure 1: XPS as thermal insulation material in buildings

By: Svenja Göttermann, Sandra Weinmann, Christian Bonten Institut für Kunststofftechnik, University of Stuttgart, Germany

Tobias Standau, Volker Altstäd Department of Polymer Engineering, University of Bayreuth, Germany

Figure 2: Loosefill packaging chips for product protection

The use of biodegradable and biobased plastics, especially in short-lived packaging, allows an alternative disposal route and can replace fossil-based raw materials.

Until today, the price of mass produced PLA had already dropped to less than 2 €/kg even for small quantities. This is still more expensive than polystyrene. But in return, PLA is a promising bioplastic, because it is based on natural resources and at the same time is biodegradable. But a main drawback of conventional, cost-effective PLA is its low melt strength, which is among other properties disadvantageous in terms of foaming. There are special PLA types for foaming on the market. However, they are not easy to handle and are cost-intensive.

As part of a project funded by the German Research Foundation, the Institut für Kunststofftechnik (IKT) in Stuttgart, Germany in cooperation with the department of Polymer Engineering of University Bayreuth, Germany, are working together on modified standard PLA compounds for foaming. Within the research consortium new modifiers are being investigated that induce crosslinking, chain extension or grafting to increase the molecular weight and the melt properties (shear and elongational viscosity).

The material used in this study was a commercially available cost-effective PLA from NatureWorks. The chosen resin is specifically designed for the use in injection/stretch blow moulded applications. Different modifiers with different functionalities were used for these tasks. The modifiers were added on a twin-screw extruder (fig. 3) in the compounding lab of the IKT. Table 1 shows an overview of the produced materials. The selected modifier concentration is based on preliminary examinations.

At the department of Polymer Engineering at University Bayreuth the batch foaming process of the modified PLA was performed on round melt-pressed samples in a heated high pressure autoclave with CO2 as the physical blowing agent. Here, foaming of the gas-loaded specimens

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Foam is initiated by a thermodynamic disequilibrium due to a sudden pressure drop.

PLA

Modifier

To determine the characteristic properties of the modified PLA and the foamed samples different thermal, rheological, chemical and morphological tests were performed.

Granulator

Results In table 2 the results of the molecular weight determination (GPC MALLS) and the calculated crystallinity (α) from thermal characterization by differential scanning calorimetry (DSC) are shown.

The molecular weight of the materials and the polydispersity index of the materials were increased due to the modifications. So, the reaction between the linear PLA chains and the modifiers took place, which result in an altered chain structure. In PLA1 and PLA2 the highest molecular weights are observed, with an increase of 82 or 54 % compared to the initial molecular weight. The lowest change of 2 % occurred in PLA3.

Waterbath

Figure 3: Principle of the PLA modification process on a twin-screw extruder

Table 1: Overview of the produced modified PLA Material

Modifier (concentration in %)

The modified samples show lower crystallinity, except for PLA4. The decrease can be attributed to the fact that benzene rings are present in the modifiers. Due to the steric hindrance defects are induced in the crystal lamellae, so that the crystallization is inhibited. This effect is most pronounced for the materials PLA2 and PLA3.

PLA ex

-

PLA1

Organic peroxide (0.2)

PLA2

Multifunctional epoxide (1.0)

PLA3

Styrene maleic anhydride (0.7)

PLA4

Isocyanurate + diisocyanate (0.2/0.2)

As already mentioned, the modifiers lead to altered chain structures in the form of branching, crosslinking and chain extension, so the rheological properties and therefore the processing characteristics are affected.

Hence the rheological behaviour under shear (fig. 4) and elongation (fig. 5) was investigated.

PLA5

Bisoxazoline + diisocyanate (0.2/0.2)

PLA1 and PLA2 have a very different flow behaviour, which is due to their significantly greater average molecular weight and broader molecular weight distribution. PLA2 shows an s-shaped curve without forming a Newtonian plateau, which indicates the presence of a partially crosslinked structure. PLA1, however, shows a typical shear thinning behavior as well, while the Newtonian plateau is only indicated in the low frequency range.

The transient elongational viscosity (ηE+) curves indicate, that all investigated materials show strain hardening, except PLA4 which was not measurable due to its brittle nature. While PLA3 and PLA5 behaved more or less like the neat material, PLA1 as well as PLA2 showed drastically higher extensional viscosities. This is due to their significantly greater molecular weight and broader molecular weight distribution as mentioned before.

Besides the differences in the rheological behavior (shear and elongation) all materials were foamable.

By means of batch foaming, the influence of the modifications on foamability and foam morphology was investigated. Figure 6 shows the SEM images of the batch foamed modified PLAs compared to the unmodified PLA.

Material

Mw in g/mol

Mn in g/mol

PD

α in %

PLA

130400

98340

1.326

26

PLA1

237600

144700

1.642

19

PLA2

200600

116200

1.727

7

PLA3

133500

99860

1,337

3

PLA4

166900

118400

1.470

25

PLA5

149600

101600

1.472

20

Figure 4: Complex viscosity from rheological measurements in shear deformation 106

Complex viscosity |η*| in Pas

Within the materials, two different groups are visible. All materials of the first group (PLA ex, PLA3 – PLA5) show a typical shear thinning behavior. Here, it is striking that the modified materials have a lower zero shear viscosity than the extruded, unmodified PLA, which should have a linear structure.

Table 2: Characteristic properties of the modified PLAs

PLA1 PLA4 PLA3 PLA2 PLA5 PLA ex

105

104

103

Temperature 180 °C

102 10

-2

10

-1

10

0

10

1

102

103

Frequency ω in rad/s

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Foam

Transient elongational viscosity ηE+ (t) in Pas

106

The foam density and the cell size were also determined (tab. 3).

Temperature = 160 °C Strain rate = 0.5 s-1

Strain hardening

10

5

104

PLA ex PLA1 PLA2 PLA3 PLA5

103

102 10-2

10-1

100

101

Time in s

Figure 5: Transient elongational viscosities

d in µm

Besides PLA2, all other modifications lead to an increased expansion ratio and larger cell sizes when foamed. Compared with the neat PLA foam a further reduction of the density was possible except for PLA3.

As a result of the high molecular weight and weight distribution, good transient elongational flow properties such as high extensional viscosity and a well-pronounced strain hardening PLA1 shows the largest cell growth. PLA1 and PLA5 have the lowest density. This expanded PLA could be appropriate as insulation or packaging material.

Table 3: Characteristic foam properties of the PLA foams

ρ in g/cm3

The right choice of modification foam properties can be improved. In general foams with fine, uniform and closed cell structure in a density range of 0.11 to 0.43 g/ cm3 were achieved. A density reduction up to ~ 25 % was possible. The experiments further showed, that the foamed materials have haptic properties that are similar to the well-known polystyrene.

PLA

PLA1

PLA2

PLA3

PLA4

PLA5

0.39

0.11

0,21

0.43

0.17

0.11

19 ± 6

99 ± 28

8±3

38 ± 12 35 ± 11

37 ± 17

Figure 6: SEM images of modified PLA samples prepared in a batch foam process at 157 °C, 180 bar and a saturation time of 0.5 h

Contrary to expectations, PLA2 does not show much better properties than the other modifications although it shows good shear and elongational flow properties.

Furthermore, PLA2 showed smaller cells as well as bigger voids and a degree cell rupture.

Conclusion and future works The aim of generating bio-foams with standard and cost effective PLA was achieved by using appropriate modifiers. It was shown that the molecular weight could be increased by the use of the modifiers.

Furthermore, some of the investigated modifications (PLA1 and PLA2) showed an increased elongational viscosity. Strain hardening was noticed for all materials. It was noticed that most of the modified PLAs possess a reduced foam density but larger cells.

With the previously examined modifiers a first start was made but further studies will be conducted. The future work will focus on the foam extrusion process, on the addition of various nucleating agents to improve the cell morphology, and on the use of different standard PLA types with lower molecular weight, lower zero shear viscosity and more reactive end groups, probably leading to a higher reaction rate. www.ikt.uni-stuttgart.de www.polymer-engineering.de

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Basics

Plastics foaming

L

ightweight materials with improved cushioning, insulating, structural performances, and other characteristics are the reasons for an increasing demand for plastic foams [1]. Applications for foamed plastics include cushioning materials (e. g. as protection of electronic devices during transport), air filters, furniture, toys, thermal insulation, sponges, plastics boats, panels for buildings, even lightweight beams and much more [2].

Plastics foaming is a plastics processing technology that involves the uses of blowing agents, and sometimes other additives such as nucleating agents, to generate cellular structures in a polymer matrix [1].

Plastic foams and their processing Plastic foams possess cellular structures within the solid plastics matrices. The properties of the final foams are derived from the properties of the polymer matrix and the retained gas, as well as the foam morphology. Therefore, the choices of the base polymers, the blowing agents, and the controls of the cell structures will influence the applications of the foamed plastics. In general, foamed plastics can be classified in different ways: by stiffness as flexible, semi-flexible, and rigid foams, by density as low- and high-density foams and by structure as open- or closed-cell foams (fig. 1 and 2) [1].

Plastic foams can be produced by processes such as batch foaming, foam extrusion, and injection foam moulding. The cellular structure in plastics may be produced mechanically, chemically, or physically [3]. Regardless of the methods, the material to be foamed is in viscous state during the process. Mechanical foaming produces a cellular structure by mechanically whipping or frothing of gases into a polymeric melt, suspension, or solution. As the material solidifies, it encapsules gas bubbles in the polymer matrix, and thereby yields the cellular structure. In chemical foaming processes, the decomposition of a chemical blowing agent is used to produce gas within the viscous plastics and generate the cellular structure. For example, an organic nitrogen compound decomposes and liberates nitrogen gas to foam some types of PVC. The physical foaming process is another popular method to produce plastic foams. Here, the necessary gas is dissolved in the viscous melt and expanded by physical changes, i. e. by pressure reduction or expansion of a low-boiling liquid by further heat.

Fig. 1: Open cell foam: Good acoustic insulation [4]

By Michael Thielen

A special form of chemical foaming is the so called particle foam, best known from EPS (expanded Polystyrene; one of the brand names is Styropor®; fig. 3) In a first step, small Polystyrene beads take up a blowing agent by means of diffusion processes and get filled into a mould. By means of hot steam, the beads are getting softer and the reacting blowing agent expands them to bigger spheres. Due to the limited space in the mould, the expanding beads squeeze and weld together and form a rigid foam structure.

For processes like film blowing, thermoforming and foaming, the used polymers need a certain molecular structure, which allows an entanglement of the side chains for a so-called strain hardening. For this reason, foaming does not work with any plastics type on the market.

Bioplastic foams Just like conventional thermoplastics, some types of biopolymers can be foamed as well. For example there are blends on the market, based on thermoplastic starch (TPS), cellulose derivatives (cellulose acetate CA, cellulose acetobutyrate CAB, cellulose propionate CP) or Polylactidacid (PLA) with Polybutyleneadipateterephtalate (PBAT) which can be used for chemical or physical foaming. Particle foams are commercially available made from PLA (fig. 3), but also PHA and cellulose acetate can be converted into particle foams.

And last but not least, (partly) biobased polyurethanes have been commercially applied for example for car seats and cushions.

For more details on foamed bioplastics, please refer to the individual issues of bioplastics MAGAZINE (usually issue 01 of each year) [1] Leung, S.: Mechanisms of cell nucleation, growth, and coarsening in plastic foaming: theory, simulation, and experiment, PhD Thesis, Univ.Toronto, 2009 [2] http://www.britannica.com/technology/foamed-plastic [3] Nawaby, A. V. and Zhang, E., “Thermoplastic Foam Processing: Principles and Development,” Gendron, R. (Eds), CRC Press, Boca Raton, FL, pp. 1 – 42, 2004 (cited in [1]) [4] Bonten C.: Kunststofftechnik, Einführung und Grundlagen, Hanser, 2014

Fig. 3: PLA particle foam (Synbra)

Fig. 2: Closed cell foam: Good thermal insulation [4]

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Basics

Glossary 4.1

last update issue 04/2015

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 (bit.ly/OunBB0) bioplastics MAGAZINE is grateful to European Bioplastics for the permission to use parts of their Glossary.

Version 4.0 was revised using EuBP’s latest version (Jan 2015). [*: 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.

1 Generation feedstock | Carbohydrate rich plants such as corn or sugar cane that can also be used as food or animal feed are called food crops or 1st generation feedstock. Bred my mankind over centuries for highest energy efficiency, currently, 1st generation feedstock is the most efficient feedstock for the production of bioplastics as it requires the least amount of land to grow and produce the highest yields. [bM 04/09] st

2nd Generation feedstock | refers to feedstock not suitable for food or feed. It can be either non-food crops (e.g. cellulose) or waste materials from 1st generation feedstock (e.g. waste vegetable oil). [bM 06/11] 3rd Generation feedstock | This term currently relates to biomass from algae, which – having a higher growth yield than 1st and 2nd generation feedstock – were given their own category.

Aerobic digestion | Aerobic means in the presence of oxygen. In →composting, which is an aerobic process, →microorganisms access the present oxygen from the surrounding atmosphere. They metabolize the organic material to energy, CO2, water and cell biomass, whereby part of the energy of the organic material is released as heat. [bM 03/07, bM 02/09]

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Anaerobic digestion | In anaerobic digestion, organic matter is degraded by a microbial population in the absence of oxygen and producing methane and carbon dioxide (= →biogas) and a solid residue that can be composted in a subsequent step without practically releasing any heat. The biogas can be treated in a Combined Heat and Power Plant (CHP), producing electricity and heat, or can be upgraded to bio-methane [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 | 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 biobased carbon content is measured via the 14C method (radio carbon dating method) that adheres to the technical specifications as described in [1,4,5,6].

Biobased labels | The fact that (and to what percentage) a product or a material is →biobased can be indicated by respective labels. Ideally, meaningful labels should be based on harmonised standards and a corresponding certification process by independent third party institutions. For the property biobased such labels are in place by certifiers →DIN CERTCO and →Vinçotte who both base their certifications on the technical specification as described in [4,5] A certification and corresponding label depicting the biobased mass content was developed by the French Association Chimie du Végétal [ACDV].

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 has been developed and tested by the Association Chimie du Végétal (ACDV) [1] Biobased plastic | A plastic in which constitutional units are totally or partly 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]

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.

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]

Biogas | → Anaerobic digestion 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] Biorefinery | the co-production of a spectrum of bio-based products (food, feed, materials, chemicals including monomers or building blocks for bioplastics) and energy (fuels, power, heat) from biomass.[bM 02/13] 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 [1,2,15]

Basics Carbon neutral, CO2 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] Cascade use | of →renewable resources means to first use the →biomass to produce biobased industrial products and afterwards – due to their favourable energy balance – use them for energy generation (e.g. from a biobased plastic product to →biogas production). The feedstock is used efficiently and value generation increases decisively.

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]. Cellulose 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 (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) Certification | is a process in which materials/products undergo a string of (laboratory) tests in order to verify that the fulfil certain requirements. Sound certification systems should be based on (ideally harmonised) European standards or technical specifications (e.g. by →CEN, USDA, ASTM, etc.) and be performed by independent third party laboratories. Successful certification guarantees a high product safety - also on this basis interconnected labels can be awarded that help the consumer to make an informed decision.

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 timeframe. 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 | is the controlled →aerobic, or oxygen-requiring, decomposition of organic materials by →microorganisms, under controlled conditions. It reduces the volume and mass of the raw materials while transforming them into CO2, water and a valuable soil conditioner – compost.

When talking about composting of bioplastics, foremost →industrial composting in a managed composting facility is meant (criteria defined in EN 13432).

The main difference between industrial and home composting is, that in industrial composting facilities temperatures are much higher and kept stable, whereas in the composting pile temperatures are usually lower, and less constant as depending on factors such as weather conditions. Home composting is a way slower-paced process than industrial composting. Also a comparatively smaller volume of waste is involved. [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

e.g. sugar cane) or partly biobased PET; the monoethylene glykol made from bio-ethanol (from e.g. sugar cane). Developments to make terephthalic acid from renewable resources are under way. Other examples are polyamides (partly biobased e.g. PA 4.10 or PA 6.10 or fully biobased like PA 5.10 or PA10.10) 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) Environmental claim | A statement, symbol or graphic that indicates one or more environmental aspect(s) of a product, a component, packaging or a service. [16] Enzymes | proteins that catalyze chemical reactions Enzyme-mediated plastics | are no →bioplastics. Instead, a conventional non-biodegradable plastic (e.g. fossil-based PE) is enriched with small amounts of an organic additive.

Microorganisms are supposed to consume these additives and the degradation process should then expand to the non-biodegradable PE and thus make the material degrade. After some time the plastic is supposed to visually disappear and to be completely converted to carbon dioxide and water. This is a theoretical concept which has not been backed up by any verifiable proof so far. Producers promote enzyme-mediated plastics as a solution to littering. As no proof for the degradation process has been provided, environmental beneficial effects are highly questionable.

Ethylene | colour- and odourless gas, made e.g. from, Naphtha (petroleum) by cracking or from bio-ethanol by dehydration, 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 about 50 member companies throughout the European Union and worldwide. 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.

DIN | Deutsches Institut für Normung (German organisation for standardization)

FDCA | 2,5-furandicarboxylic acid, an intermediate chemical produced from 5-HMF. The dicarboxylic acid can be used to make → PEF = polyethylene furanoate, a polyester that could be a 100% biobased alternative to PET.

DIN-CERTCO | independant certifying organisation for the assessment on the conformity of bioplastics

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

Dispersing | fine distribution of non-miscible liquids into a homogeneous, stable mixture

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.

Density | Quotient from mass and volume of a material, also referred to as specific weight

Drop-In bioplastics | chemically indentical to conventional petroleum based plastics, but made from renewable resources. Examples are bio-PE made from bio-ethanol (from

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Basics 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]. If GM crops are used in bioplastics production, the multiple-stage processing and the high heat used to create the polymer removes all traces of genetic material. This means that the final bioplastics product contains no genetic traces. The resulting bioplastics is therefore well suited to use in food packaging as it contains no genetically modified material and cannot interact with the contents.

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.

HMF (5-HMF) | 5-hydroxymethylfurfural is an organic compound derived from sugar dehydration. It is a platform chemical, a building block for 20 performance polymers and over 175 different chemical substances. The molecule consists of a furan ring which contains both aldehyde and alcohol functional groups.

5-HMF has applications in many different industries such as bioplastics, packaging, pharmaceuticals, adhesives and chemicals.

One of the most promising routes is 2,5 furandicarboxylic acid (FDCA), produced as an intermediate when 5-HMF is oxidised. FDCA is used to produce PEF, which can substitute terephthalic acid in polyester, especially polyethylene terephthalate (PET). [bM 03/14] Home composting | →composting [bM 06/08] 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.

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).

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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).

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, 02/09] ISO | International Organization for Standardization JBPA | Japan Bioplastics Association Land use | The surface required to grow sufficient feedstock (land use) for today’s bioplastic production is less than 0.01 percent of the global agricultural area of 5 billion hectares.

It is not yet foreseeable to what extent an increased use of food residues, non-food crops or cellulosic biomass (see also →1st/2nd/3rd generation feedstock) in bioplastics production might lead to an even further reduced land use in the future [bM 04/09, 01/14] LCA | is the compilation and evaluation of the input, output and the potential environmental impact of a product system throughout its life cycle [17]. It is sometimes also referred to as life cycle analysis, ecobalance or cradle-tograve analysis. [bM 01/09] Littering | is the (illegal) act of leaving waste such as cigarette butts, paper, tins, bottles, cups, plates, cutlery or bags lying in an open or public place.

Marine litter | Following the European Commission’s definition, “marine litter consists of items that have been deliberately discarded, unintentionally lost, or transported by winds and rivers, into the sea and on beaches. It mainly consists of plastics, wood, metals, glass, rubber, clothing and paper”. Marine debris originates from a variety of sources.

Shipping and fishing activities are the predominant sea-based, ineffectively managed landfills as well as public littering the main land-based sources. Marine litter can pose a threat to living organisms, especially due to ingestion or entanglement.

Currently, there is no international standard available, which appropriately describes the biodegradation of plastics in the marine environment. However, a number of standardisation projects are in progress at ISO and ASTM level. Furthermore, the European project OPEN BIO addresses the marine biodegradation of biobased products.

Mass balance | describes the relationship between input and output of a specific substance within a system in which the output from the system cannot exceed the input into the system.

First attempts were made by plastic raw material producers to claim their products renewable (plastics) based on a certain input of biomass in a huge and complex chemical plant, then mathematically allocating this biomass input to the produced plastic.

These approaches are at least controversially disputed [bM 04/14, 05/14, 01/15]

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 Organic recycling | means the treatment of separately collected organic waste by anaerobic digestion and/or composting.

Oxo-degradable / Oxo-fragmentable | materials and products that do not biodegrade!

The underlying technology of oxo-degradability or oxo-fragmentation is based on special additives, which, if incorporated into standard resins, are purported to accelerate the fragmentation of products made thereof. Oxodegradable or oxo-fragmentable materials do not meet accepted industry standards on compostability such as EN 13432. [bM 01/09, 05/09] 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 and not degradable, 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] PEF | polyethylene furanoate, a polyester made from monoethylene glycol (MEG) and →FDCA (2,5-furandicarboxylic acid , an intermediate chemical produced from 5-HMF). It can be a 100% biobased alternative for PET. PEF also has improved product characteristics, such as better structural strength and improved barrier behaviour, which will allow for the use of PEF bottles in additional applications. [bM 03/11, 04/12] PET | Polyethylenterephthalate, transparent polyester used for bottles and film. The polyester is made from monoethylene glycol (MEG), that can be renewably sourced from bio-ethanol (sugar cane) and (until now fossil) terephthalic acid [bM 04/14] 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 (PHA) or the polyhydroxy fatty acids, are a family of biodegradable polyesters. As in many mammals, including humans, that hold energy reserves in the form of body fat there are also bacteria that hold intracellular reserves in for of of polyhydroxy alkanoates. Here the microorganisms store a particularly high level of

Basics energy reserves (up to 80% of their own body weight) for when their sources of nutrition become scarce. By farming this type of bacteria, and feeding them on sugar or starch (mostly from maize), or at times on plant oils or other nutrients rich in carbonates, it is possible to obtain PHA‘s on an industrial scale [11]. The most common types of PHA are PHB (Polyhydroxybutyrate, PHBV and PHBH. Depending on the bacteria and their food, PHAs with different mechanical properties, from rubbery soft trough stiff and hard as ABS, can be produced. Some PHSs are even biodegradable in soil or in a marine environment 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.

Modified PLA types can be produced by the use of the right additives or by certain combinations of L- and D- lactides (stereocomplexing), which then have the required rigidity for use at higher temperatures [13] [bM 01/09, 01/12] 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] PTT | Polytrimethylterephthalate (PTT), partially biobased polyester, is similarly to PET produced using terephthalic acid or dimethyl terephthalate and a diol. In this case it is a biobased 1,3 propanediol, also known as bioPDO [bM 01/13] Renewable Resources | agricultural raw materials, which are not used as food or feed, but as raw material for industrial products or to generate energy. The use of renewable resources by industry saves fossil resources and reduces the amount of → greenhouse gas emissions. Biobased plastics are predominantly made of annual crops such as corn, cereals and sugar beets or perennial cultures such as cassava and sugar cane.

Resource efficiency | Use of limited natural resources in a sustainable way while minimising impacts on the environment. A resource efficient economy creates more output or value with lesser input.

Seedling Logo | The compostability label or logo Seedling is connected to the standard EN 13432/EN 14995 and a certification process managed by the independent institutions →DIN CERTCO and → Vinçotte. Bioplastics products carrying the Seedling fulfil the criteria laid down in the EN 13432 regarding industrial compostability. [bM 01/06, 02/10] Saccharins or carbohydrates | Saccharins or carbohydrates are name for the sugar-family.

Saccharins are monomer or polymer sugar units. For example, there are known mono-, di- and polysaccharose. → 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.

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.

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]

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

Starch derivatives | Starch derivatives 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 connected with an 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 famous definition of sustainability is the one created by the Brundtland Commission, led by the former Norwegian Prime Minister G. H. 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 nonhuman environment).

Sustainable sourcing | of renewable feedstock for biobased plastics is a prerequisite for more sustainable products. Impacts such as the deforestation of protected habitats or social and environmental damage arising from poor agricultural practices must be avoided. Corresponding certification schemes, such as ISCC PLUS, WLC or BonSucro, are an appropriate tool to ensure the sustainable sourcing of biomass for all applications around the globe.

Sustainability | as defined by European Bioplastics, 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

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 [15] ISO 14067 onb Corbon Footprint of Products [16] ISO 14021 on Self-declared Environmental claims [17] ISO 14044 on Life Cycle Assessment

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Suppliers Guide 1. Raw Materials

AGRANA Starch Thermoplastics Conrathstrasse 7 A-3950 Gmuend, Austria Tel: +43 676 8926 19374 lukas.raschbauer@agrana.com www.agrana.com

Simply contact:

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

suppguide@bioplasticsmagazine.com

1.1 bio based monomers

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

Tel.: +49 2161 6884467 Stay permanently listed in the Suppliers Guide with your company logo and contact information.

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

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39 mm

Evonik Industries AG Paul Baumann Straße 1 45772 Marl, Germany Tel +49 2365 49-4717 evonik-hp@evonik.com www.vestamid-terra.com www.evonik.com

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

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PTT MCC Biochem Co., Ltd. A JV of PTT and Mitsubishi Chemical Corporation Bangkok, Thailand Tel: +66(0) 2 140-3563 info@pttmcc.com www.pttmcc.com

Corbion Purac Arkelsedijk 46, P.O. Box 21 4200 AA Gorinchem The Netherlands Tel.: +31 (0)183 695 695 Fax: +31 (0)183 695 604 www.corbion.com/bioplastics bioplastics@corbion.com

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 62 136 Lestrem, France plastics@dupont.com Tel.: + 33 (0) 3 21 63 36 00 www.renewable.dupont.com www.roquette-performance-plastics.com www.plastics.dupont.com

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.

Tel: +86 351-8689356 Fax: +86 351-8689718 www.ecoworld.jinhuigroup.com ecoworldsales@jinhuigroup.com

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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 1.3 PLA

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

6 issues x 234,00 EUR = 1,404.00 €

www.issuu.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

1.2 compounds

Sample Charge for one year:

www.facebook.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!

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

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

Suppliers Guide 2. Additives/Secondary raw materials

BIOTEC Biologische Naturverpackungen Werner-Heisenberg-Strasse 32 46446 Emmerich/Germany Tel.: +49 (0) 2822 – 92510 info@biotec.de www.biotec.de

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

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

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

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

9. Services

3. Semi finished products 3.1 films

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 1.5 PHA

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

Metabolix, Inc. Bio-based and biodegradable resins and performance additives 21 Erie Street Cambridge, MA 02139, USA US +1-617-583-1700 DE +49 (0) 221 / 88 88 94 00 www.metabolix.com info@metabolix.com 1.6 masterbatches

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

Infiana Germany GmbH & Co. KG Zweibrückenstraße 15-25 91301 Forchheim Tel. +49-9191 81-0 Fax +49-9191 81-212 www.infiana.com

Taghleef Industries SpA, Italy Via E. Fermi, 46 33058 San Giorgio di Nogaro (UD) Contact Emanuela Bardi Tel. +39 0431 627264 Mobile +39 342 6565309 emanuela.bardi@ti-films.com www.ti-films.com

6. Equipment 6.1 Machinery & Molds

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

Natur-Tec® - Northern Technologies 4201 Woodland Road Circle Pines, MN 55014 USA Tel. +1 763.404.8700 Fax +1 763.225.6645 info@natur-tec.com www.natur-tec.com

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

6.2 Laboratory Equipment

4. Bioplastics products

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

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

MODA: Biodegradability Analyzer SAIDA FDS INC. 143-10 Isshiki, Yaizu, Shizuoka,Japan Tel:+81-54-624-6260 Info2@moda.vg www.saidagroup.jp

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

7. Plant engineering

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

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

UL International TTC GmbH Rheinuferstrasse 7-9, Geb. R33 47829 Krefeld-Uerdingen, Germany Tel.: +49 (0) 2151 5370-333 Fax: +49 (0) 2151 5370-334 ttc@ul.com www.ulttc.com

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Suppliers Guide 10. Institutions

10.2 Universities

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10.3 Other Institutions

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10.1 Associations

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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

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

Biobased Packaging Innovations Caroli Buitenhuis IJburglaan 836 1087 EM Amsterdam The Netherlands Tel.: +31 6-24216733 http://www.biobasedpackaging.nl

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

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

39 mm

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/

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

Sample Charge for one year: 6 issues x 234,00 EUR = 1,404.00 € The entry in our Suppliers Guide is bookable for one year (6 issues) and extends automatically if it’s not canceled three month before expiry.

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Cure time reduction ETU replacement accelerator

Fachmagazin für die Polymerindustrie

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Companies in this issue Company

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Acconia

Advert

Company

14

Editorial

EPEA Intl. Umweltforschung

Agrana Starch Thermoplastics

24

Erema Plastic Recycling Systems

46 14,22

47

Espaçoplas

22

Aljuan

22

European Bioplastics

6,7

Almuplas

22

Evonik

Alpar Architectural Products

10

FKuR

6

19,20

Ford Motor Company

8

14

Fraunhofer UMSICHT

14,36

AIMPLAS

Alpla Amorim Cork Composites API

46

Grabio Greentech

Arkema

8

Grafe

Arkema

24

Green Building Council

Avantium

1,16

Advert

Company

Editorial

Advert

Novamont

7

47,52

Novo-Tech

12

Omikron

14

13,48

OMV/Polytype

19

46,51

Organic Waste Systems

22

2,46

PolyOne

8

President Packaging

47

47

PTT/MCC

47

Qingdao Guosen Machinery

12

Renolit Gor

13

Röchling

8 7

46,47 10

Hallink

47

Roquette

47

Saida

35,46

8

Infiana Germany

BASF

7

Innovia

Bcomp

8

Inpro

10

Bergamo Technologie

14

Institut for bioplastics & biocomposites

8

Institut für Verbundwerkstoffe

8

SICC

14

Biobased Packaging Innovations

48

Sharp

28

SHENZHEN ESUN INDUSTRIAL 48

46

Showa Denko

46

Bio-Fed

30

Institute of Textile Technology, Aachen

8

Solegear

30

BioPro Baden Württemberg

8

IVL

14

Solvay Epicerol

8

Biotec

7

Bison Werke Bähre & Greten

12

47

Jinhui Zhalolong

15,46

Kingfa

46

Taghleef Industries

47

Tecnaro

8,14

Bösel Plastic Management

37

KU Leuven

5

Thünen Inst. F. Holzforschung

BPI

48

Lanxess

8

TianAn Biopolymer

8

TransFurans Chemicals

Braskem

7

Leibniz-Inst. for Agr. Eng.

Carlsberg

24

Limagrain Céréales Ingrédients

CellMat technologies

32

Lineo

22 7,19,20

CNR Coca-Cola

36 47 8

Uhde Inventa-Fischer

47

8

UL International TTC

47

Liquid Light

7

UN Studio

M+N Textiles

11

Univ. Bayreuth

46

14 38

Collanti Concorde

14

Metabolix

47

Univ. Stuttgart (IKT)

Columbia Plastics

30

Michigan State University

48

Velibre

47

Vinmar

5

Visesa

14

Vizeplas

22

VLB

22

VTT

14 20

29

Minima Technology

8,38

Composites Europe

8 8

Conecor

14

Corbion

7

Danone

19

Natur-Tec

DIN Certco

8

Nespresso

30

WWF

DSM

8

NetComposites

14

Zhejiang Hangzhou Xinfu Pharmaceutical

Newlight Technologies

5

Mitsubishi Chemical narocon

DuPont

47 7,10

NatureWorks

46 14

Enar

8,28

47

8,12

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05 Oct 15

04 Sep 15

Fiber / Textile / Nonwoven

Barrier Materials

Land use (update)

06/2015

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07 Dec 15

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Films / Flexibles / Bags

Consumer & Office Electronics

Plastics from CO2 (Update)

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Composites Evolution

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ional rofess ast • P ate • F -d o -t Up

46

Green up your flooring High performance naturally

Biobased polyamides for carpeted floors can improve the overall environmental sustainability of building interiors. Used for floorings, VESTAMIDÂŽ Terra withstands typical mechanical and physical loads in office and public buildings, and durably retains the attractive surface of the floorings.

Evonik offers a variety of technical longchain polyamides suchs as PA610, PA1010 and PA1012. They all share a similar to improved technical performance compared to conventional engineering polyamides while also having a significantly lower carbon footprint. www.vestamid-terra.com

A real sign of sustainable development.

There is such a thing as genuinely sustainable development.

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

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

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

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

284

The “OK Compost” certificate guarantees conformity with the NF EN 13432 standard (biodegradable and compostable packaging) 5_2014