N°12 - December by INFOPRO DIGITAL

www.formule-verte.com

N°

DECEMBER 2012

A GREEN CHRISTMAS

Biobased products on the table and under the tree BIOREFINERY A key tool for the development of the

bio-economy

Special report

BIOCOMPOSITES A much needed structuring

of the sector in France

BIODIVERSITY

L’Oréal

anticipates regulation BIOBASED PAINTS

An emerging

market

Editorial

synthetic biology

Is this the future of chemistry?

efore oil and the development of petrochemicals, all everyday products came from natural or renewable raw materials. Cosmetics and detergents already existed, and along with plant based medicine. And then came the petrochemical industry. Within the space of a century, it swept away three-quarters of

everyday products replacing them with fossil based versions. But because of our overuse of fossil fuels, we have ended up damaging our environment, and the legacy that we will bequeath to future generations is an increase of 2 to 6 ° C in the Earth’s average temperature by 2050, while oil and gas well will have almost dried up. This is why a return to a plant-based solution seems inevitable. Unlike the energy sector which draws energy from the sun, wind and tides, chemicals demand carbon which can only be obtained from re-used living sources. But this return to plants is not a step backwards by any means. Because, while the chemistry industry was perfecting its catalysts and reaction pathways, a new science has been born: synthetic biology. This discipline, which dates back thirty years, aims to create new biological objects (enzymes, DNA strands, and more). And if some sorcerer’s apprentices are seeking nothing less than recreating other forms of life by going as far as changing the constituent bases of DNA, others are advocating this technology for more down to earth aims, such as the production of chemicals from plant-based sugars. And these new start-ups

Sylvie Latieule Chief editor slatieule@etai.fr

* The UNAFIC threw the cat among the pigeons at a large dinner-debate.

are using their knowhow to modify the metabolism of microorganisms in order to make them produce compounds on a massive scale by feeding them sugars. Using this method, Global Bioenergies offers access to major intermediaries such as isobutene and perhaps propylene, while Metabolic Explorer is working on butane and propane. For the moment, not all substances are eligible for use via this technology; but the potential is there. Chemicals made from synthetic biology could

account for 50% of the chemical market by the end of the 21st century, according to Bernadette Bensaude-Vincent, philosopher of science, who spoke on the topic at the annual UNAFIC dinner*. And Bruno Jarry, a member of the Academy of Technology, explained that this approach is gaining ground on both the academic side as well as with biotech companies. “Now it’s a question of finding chemical manufacturers who want to use them; this is currently one of the major concerns of green chemistry,” he says. “Although new actors in production with sugar are interested in these fermentation processes, it will take them time to become DSM or BASF.” So if synthetic biology technology is become as important as the chemistry industry for making our major future products, then why are chemical manufacturers not investing heavily in the field? Some say that the technology is not mature, others raise ethical issues related to * Union Nationale des Associations Françaises d'Ingénieurs Chimistes French National Union of Associations of Chemical Engineers

the use of the living... In the meantime, synthetic biology is swelling its ranks. Will it sweep away fossil fuel based products fuel to impose its own new monopoly? FormuleVerte - N°12 - December 2012

Eco-designed skis ■ If the slopes are awaiting you, why not go eco-friendly skiing? Rossignol has developed a range of women’s ecodesigned skis and bindings. Their Attraxion 3S Echo skis and Attraxion 8 Echo, combine poplar wood from

controlled cultivation forests with flax fibre, which accounts for 10% of the fibres used. The manufacturer has reduced ink use by 50% and developed a ski sole made of 25% recycled material. For their Xelium Saphir 110S bindings, Rossignol won the

IPSO prize for best eco-designed product. The annual production of this system reduces CO2 emissions by 34% compared to traditional bindings, according to the manufacturer.

Christmas green Decorating the table with flax

■ For children who want to surprise

■ Flax has been invited into tableware.

Santa Claus, a flashlight is essential kit. Lexon has developed a flashlight based on polylactic acid (PLA) and bamboo. As part of a sustainable development strategy, this 3 LED lamp runs on solar energy. This range combines plastic based on starch corn and bamboo and also contains a rechargeable dynamo radio, a pen, a calculator, and a clock. PLA has won over Lexon, which has also developed another PLA based range.

For its nonwoven flax textile the design company Ecodeep received an eco-design prize during at the annual Sustainability and Businesses seminars in Lille in early October. From this textile Ecodeep has produced a range of tableware made up of rolled table cloths, table runners and napkins. The goal is to “replace non-woven plastic or wadding from Asia,

Bamboo and PLA light up the night

The Christmas tree isn’t the only the only touch of green this holiday season. Biobased products are appearing both on the table and under the tree.

FormuleVerte - N°12 - December 2012

Northern Europe and Canada.” In a move to reduce their carbon footprint Ecodeep has set up a local supply chain. The company also emphasises that these products do not contain glue and are compostable.

Green slippers under the tree

L’Occitane adopts PE from Braskem the 300 ml hand cream from the Bonne Mère range by L’Occitane. The care products manufacturer called upon Promens to manufacture bottles in green polyethylene from Braskem. The production by Promens at its site in Roche-sur-Foron (Haute-Savoie) of hand cream bottles and 600 ml Douceur de Douche shower gel is part of their Green Cube program established in 2009 by the plastic maker; this aims to reduce the environmental impact of its business and its products. With this approach, the bottle for “Douceur de Douche” was developed in a family format containing three times more than a normal 200ml shower gel, while requiring only twice the amount of plastic to manufacture the bottle. Both companies point out that the PE from Braskem is tough, protects formulas and is recyclable within normal polyethylene channels made from fossil resources.

A toast to maize ■ The company Vegware specialises in compostable food packaging, and markets wine glasses made of corn flour! According to the manufacturer, these 185 ml glasses offer an alternative to disposable plastic tableware derived from petroleum. They are composed of two parts which fit together. Vegware says that the carbon footprint of the wine glass is reduced by 77% compared to a similar products made of PET. And at the end of the meal, the glass accompanies vegetable waste to compost and degrades in less than 12 weeks.

■ Before Christmas dinner, don’t forget to wash your hands with

A gift from Starck ■ How to impress at Christmas? With a biobased gift by Starck. The worldrenowned designer has designed an office trash bin for the company Elise, which specialises in paper recycling. The EliseByStarck trash bin is made from Gaïalene material by Roquette. Plant based plastics made from corn starch are behind this range of bins produced in various colours. This trash bin as well as the range by Roquette received an eco design award at the Sustainability and Businesses event in Lille in early October.

Z O O M

Vegetable oil for metal working

The company Molydal, a member of the IAR cluster, has launched an innovative range of vegetable oils for metal working and more specifically for the profiling of steel, stainless steel, heat exchangers, siding and more. Named Solester 77, this blend of esterified oils is 100% plant based and biodegradable and is designed without any environmental restrictions (free of harmful molecules, VOC free).

resin soles. The French brand is aiming to develop, manufacture and market original shoes using materials from local renewable resources. The company turned to the Advanced Green Tefabloc TPE range from CTS for the soles of these slippers. This material includes Gaïalene resins by Roquette. This range of thermoplastics combines flexibility, a comfortable feel and translucency, according to CTS. The compounder also emphasises its production without parboiling, which saves time and energy.

■ SWhile Souts slippers come in several colours, they are green thanks to their plant

Information selected by the site www.agrobiobase.com FormuleVerte - N°12 - December 2012

In light [DEBATE] ©

BIOREFINERY

A key tool for the development of the bio-economy For the IAR, the replacement of fossil carbon by green carbon necessitates the development of biorefineries which utilise the entire plant. To give every opportunity to this model, the cluster has consulted international experts.

A © Roquette

fter a century of dominance of fossil fuels, a return to a bio-economy seems inevitable in the coming years to deal with the major energy and environmental challenges of the world. But in a context where it will also have to cope with a significant increase in the global population, is it possible to use available plant resources for purposes other than that of food? Biorefinery probably brings a credible answer to this question. A firm supporter of this model, Professor Daniel Thomas, vice president of the IAR cluster,

FormuleVerte - N°12 - December 2012

along with Bruno Jarry, a member of the Academy of Technology, in November 2011 established a broad consensus on this issue within the framework of the first IAR meetings. These meetings were held in Chantilly, and brought together forty experts from around the world to discuss strategic issues on the development of biorefinery in Europe, and more particularly in France. Then, on the 21st of October 2012, these meetings resulted in a day of The Roquette biorefinery in Lestrem is considered the largest in Europe.

restitution in Reims, in the heart of the Pommery area. It was an opportunity for the IAR to disseminate key messages in order to give new biorefineries every chance of success. A set of recommendations was even drawn up, co-authored by Daniel Thomas and Bruno Jarry. At the forum on October the 21st in Reims, Daniel Thomas explained that, like a refinery which transforms all the various fractions of petroleum, a biorefinery is a facility that aims to transform biomass in order to collect both food and non-food. It can provide access to four families of products: food products, biomolecules, materials (biomaterials and biopolymers) and energy (biofuels and waste incineration). There are already industrial biorefineries where biomass comes from plant or forest sources. Soon, this biomass may be of marine origin, animal, or urban. For Daniel Thomas, the key word is flexibility, both in input (with the treatment of various types of biomass), as well as output with a mix of products that best meets market needs. In France, there are already several industrial biorefineries. For example, Roquette in Lestrem (59), is considered to be the largest important in Europe. It refines corn as well as wheat, for food as well as non-food utilisation. The Pomacle site (51), in the Champagne-Ardenne region, is another example of a biorefinery focussed around sugar (see inset). Sofiprotéol in Compiègne (60) operates a facility based on vegetable oils and fats. Tembec in Tartas (40) is an example of a forest biorefinery, but it does not work with food products. On a European level, there are 22 industrial

[DEBATE] In light POMACLE-BAZANCOURT: A GROWING BIOREFINERY

POMACLE-BAZANCOURT, AURÉLIE DUREUIL

The Bazancourt agro-industrial site has continued to grow since 1983.

biorefineries along with 26 pilot or demonstration projects, according to data from the European Star-Colibri project. Christophe Luguel, international manager for IAR, recalls that in the context of the FP7 and a special bid for tender for biorefineries, Star-Colibri allowed a European vision to be drawn up. In terms of the geographical location of

biorefineries, there are two different models, port biorefineries and field or territorial biorefineries. The first model aims to build small scale systems with a few thousand tons capacity, close to ports, in order to treat undifferentiated biomass from around the world. These already exist in Rotterdam (Netherlands) and Ghent (Belgium). In the second model, biorefine-

ries are located in rural areas. Every year they treat hundreds of thousands of tons of biomass which is produced locally. They are designed to create a harmonious relationship with farmers who are able to adapt their crops to the strategy of the biorefinery. It goes without saying that the IAR and the Picardy and Champagne-Ardenne regions advocate the development of territorial FormuleVerte - N°12 - December 2012

In light [DEBATE]

biorefineries. It is the only viable option for creating economic activity and employment in regional areas, while introducing the concept of industrial metabolism, with science and technology interacting with the agricultural world and the demands of society. To make this transition to a bioeconomy, heavy investment in R&D is needed, notably in the development of biomolecules which are designed to compete with certain molecules derived from petrochemicals. “They must be made in order to seek a balance between economic value and environmental impact,” the report says, citing two virtuous processes. The production method for methionine, developed by Roquette and Metabolic Explorer converts glucose via fermentation in a single step instead of the 5 steps for traditional chemical synthesis. Similarly, DuPont is able to produce more profitable propanediol via the fermentation of glucose. However, promoting the development of biotechnology with market forces alone will not suffice. Alfredo Aguilar, head of the biotechnologies unit at the general directorate of research at the European Commission, came to speak at Reims about European programs which are in place. The FP7 ends next year and the FP8 covering the period 2014-2020 is already being prepared. Two programs focussed on biotechnology and the bioeconomy will consider the theme of

10 FormuleVerte - N°12 - Décembre 2012

The Tembec biorefinery in Tartas is based around utilising wood.

biorefineries. Mr. Aguilar also mentioned the probable creation in 2014 of “biobased PPP for growth.” This involves setting up public-private partnerships within a European strategy developed alongside governments. There is discussion on funding of some 2 billion euros between now and 2020 in order to advance the bioeconomy. All of these efforts can only succeed with improvements in plants and research into new terrains. “In Europe, the discourse on the decline in agricultural production over the last 25 years has doubtlessly led to a reduction in research budgets in the area of plant improvement. But today, this discourse is changing and this new paradigm should allow organisations such as the INRA to resume research on plants in general and in particular roots,” says the report. All available technologies, including GMOs, will then have to be examined. The fundamental theme resources will be focussed on in future IAR meetings planned for 2013, said Dominique Dutartre, President of the IAR cluster. .

Competing uses

Given that existing biorefineries produce both from food and from non-food from food crops, the debate on the competition of these two uses was of course discussed at Chantilly and elements of this discussion were highlighted. Firstly, the conclusion can be drawn that this competition has always existed. Before the industrial revolution,

farms used an average of 30% of cultivated land for non-food applications: feeding transport animals, dyes (madder), fabric (flax), and rope (hemp) amongst others. It was also pointed out that if first generation fuels, which have been so condemned, had not existed, there would have been no second generation! Olivier de Bohan, president of Cristal Union, noted that these first generation biofuels have had positive consequences in terms of investment and the creation of economic activity in our country. And Daniel Thomas said that the debate was already outdated with the advent of the second generation. He recalled that a plant is a combination of reserve molecules (starches, oils, proteins) and structural polymers (lignocellulose and lignin). Reserve molecules, which by definition are easily accessible, have naturally found applications both in power as well as industrial uses. By contrast, structural polymers have been selected during development for their strength properties. Hence the difficulty of the so-called second generation, which aims to convert these polymers both into biofuels, as well as new molecules in order not to divert molecules reserved for food purposes. In France, the horizon is set at around 2016-2018 for the production of second generation biofuels. Second generation biobased chemicals will probably appear in the next decade.. ■ REIMS, SYLVIE LATIEULE

In light [STRATEGY] Teams from the materials department of the Department of Defence are carrying out active monitoring, in order to assist in the development of plant based technologies and materials for use in by army as well as by civilians. An interview with Pierre-François Louvigné, combatant system and materials innovation architect at the Directorate General of Armaments.

BIOBASED MATERIALS

The DGA, proactive in materials substitution

How is the DGA organised the REACH framework in in terms of research into order to replace all paints new materials? and solvents with paint Pierre-François Louvigné: systems that are more enviThe DGA has three ronmentally friendly. This missions: preparing future work was important defence systems, equipping because our paints have the armed forces, and functional properties such promoting exports. In 2011, as infrared low-visibility. the DGA spent 724 million Over the last four years we euros on research and techhave begun to implement nology. In order to prepare more specific actions in for the future, five actions terms of bio-based matehave been identified: defirials. Today, the field which ning future systems with seems most relevant to us is the armed forces, detecting plastics; we are going to look emerging technologies, at what we can replace with directing the investment biobased and biodegradaeffort into research, identible resins. fying key technological and industrial capabilities, and What are the types developing cooperation. of materials Within this context, we have Since 2011, Vegeplast’s biodegradable self-locking collars have been fitted on you are researching? a materials department combatant parachute kits (EPCs). P.-F. L.: We distinguish working on all materials between man-made matewhich will be used in the defence fields rials and those which are biosourced. Since greenhouse gas emissions, energy effiand a department specifically concerned 2007, the use of bio-based materials has ciency and renewable energy.. with environmental issues. We have devebeen included in our guidelines. Therefore loped a strong relationship between these there is a very strong motivation to replace What actions have been implemented two departments. Since 2007, the Departman-made materials with biobased since 2007? ment of Defence has been publishing its products. We are not seeking new properP.-F. L.: Firstly, we placed a priority on reduenvironmental action plan with general ties but rather obtaining materials with cing the environmental impact of weapons environmental objectives in terms of specific properties for our purposes; today, programs. We also worked on paints within

12 FormuleVerte - N°12 - December 2012

[STRATEGY] In light we are proactive on this issue. We will not wait for things to happen in order to seize opportunities. We want to support these technologies and help them grow. Several funding mechanisms exist for this purpose, including RAPID and ASTRID (see inset).. The support mechanisms essentially concern SMEs. Why this interest in these companies? P.-F. L.: Our motivation is innovation, and this can be found particularly in SMEs. We certainly don’t want to neglect the potential that exists in them; that is why we want to them to know about the financing available to us. Resin from the company Vegeplast is an example of these projects; this solution has been validated and qualified by the Department. They have developed biodegradable self-locking collars for combatant parachute kits (EPCs). These products have been used on EPCs since 2011 as a replacement for polyamine links. However, production volumes are still too low to compete with polyamine collars. For projects which we support, potential applications should as far as possible involve the civil domain

SUPPORT MECHANISMS FOR RESEARCH

where volumes are greater. Production volumes are in some ways a key to success.. What is your analysis of the supply of bio-based materials? P.-F. L. : Currently what is on offer is clearly not mature; there is an emerging and unstructured supply, but we have all the necessary skills in France to structure it.

The manufacturers with whom we work know what they are doing; when we have a technical discussion, they know we respond. I’m rather confident; there really is potential in France. Today resins need more work; the development of this sector seems obvious, and we are here to support this innovation.. ■ INTERVIEW BY AURÉLIE DUREUIL

réal R&I ©M atte o L’O

In light [INTERVIEW] BIODIVERSITY

L’Oréal anticipates regulation

How is L’Oréal involved in the World Summit on biodiversity? Rachel Barré: This biannual conference is the governing body of the United Nations Convention for Biodiversity. Its mission is to advance the implementation of international targets for biodiversity conservation through political decisions made between signatory countries. Some major protocols have been adopted; in 2010, it was the Nagoya Protocol in Japan. This aims to improve access to genetic resources and to allow a more equitable sharing of benefits coming from the utilisation of these resources by users. This framework will inevitably have an impact on access conditions to certain plant-based raw materials and thus on the manner of innovating from biodiversity. This is why we participated in a roundtable on the topic, held in conjunction with the Summit. We provided testimony on private innovation challenges related to the implementation of this protocol. What are the impacts of the implementation of the Nagoya Protocol on sourcing at L’Oréal? R. B.: The Nagoya Protocol establishes broad rules. Firstly, each signatory country becomes the “owner” of its genetic resources and their associated traditional knowledge. Therefore, countries have to put in place mechanisms for accessing resources and developing fair and equita-

14 FormuleVerte - N°12 - December 2012

The 11th World Summit on biodiversity was held in Hyderabad, India, from the 8th to the 19th of October. Rachel Barré, from the environmental research and sustainable development department at the research and innovation division of L’Oréal, was present. She describes the implications for innovation and sourcing of renewable raw materials

ble models for the sharing of the benefits of their utilisation. The first point means that all users must request access to a given resource from the country. This access will be granted on the basis of contracts for sharing, drawn up for specific applications. The concept of benefit sharing aims for equitable distribution of value and ideally should contribute to preserving biodiversity. Negotiations for access to certain raw materials will therefore focus on financial or non-financial compensation. This step will complement our current practices of sustainable sourcing. In order to continue to innovate from biodiversity, it is necessary that such rules do not block access but rather promote sustainable sourcing. Where countries up to in terms of the ratification of the Nagoya Protocol? R. B.: The work is at a more or less advanced stage, depending on each country. Since the adoption of the Biodiversity Convention in 1992, a number of countries have established rules. Some of these states are in the reviewing process in order to make updates according to the 2010 protocol. Others have more work to do. Currently, less than a dozen countries have ratified the protocol but all of them are preparing for ratification by 2015. Europe and its members have not yet ratified it, but a draft regulation was proposed in October. And today, what is your group’s policy in terms of supply of plant based raw materials?

R. B.: In 2005, in terms of supplies of renewable raw materials, L’Oréal committed to anticipating the overall rules of the Nagoya Protocol. These commitments do, of course, comply with the regulations of the countries which have adopted them, but more broadly to establish supply chains which offer a fair return to all countries. In parallel, L’Oréal is committed to increasing our use of renewable resources, for example by applying the principles of green chemistry or developing biotechnology. For all plant based materials, we ensure that ingredients are completely sustainable and responsibly produced. To implement this, we use a “life cycle” approach which we supplement with biodiversity analyses on both ecological and social aspects; the studies cover the entire supply chain. What is the proportion plant based raw materials in L’Oréal’s sourcing? R. B.: Since 2005, the group has been committed to increasing the proportion of plant based raw materials in our portfolio. In 2011, 55% of new raw materials used by the group were of plant origin. Specifically for polymers, 70% of new products were plant based in 2011. Certain polysaccharides are, for example, replacing some conventional polymers. And for packaging, we are also studying the possibility of using bioplastics but there hasn’t been any substitution yet. ■ INTERVIEW BY AURÉLIE DUREUIL

[REPORT] In light SOLID STATE FERMENTATION

New R&D equipment for Soufflet The agro-industrial group has opened 3400 m2 of R&D facilities. They will help support innovation in the field of solid state fermentation and develop products for different application areas.

is participating in. Among them is the Becoming a key player in covers 1,400 m2 with four floors, each Osiris program, which is seeking to develop innovation; it is in this dedicated to a specific activity. The first innovative products in four different applicontext that the agro-indusfloor is for the SSF and has 7 types of 10 kg cation areas: crop protection, animal feed, trial group Soufflet opened size fermenters. The second level of the health and biofuels. In the field of plant brand new research facilities at its Nogentbuilding accommodates activities focussed protection, the aim of Soufflet is to develop sur-Seine site (Aube). At a cost of 112 around liquid fermentation, and is responnatural plant protections, in accordance million euros, they consist of a research sible for testing biocatalysts produced via with the 2018 Ecophyto plan. Soufflet is laboratory and a technology hall, which SSD. For this it is equipped with eight focusing in particular on the fight against employ about 70 researchers. “These two fermenters with capacities of 1.5 to 13 l. The Fusarium wilt, a fungal disease affecting third floor houses the physico-chemical tools provide a unique combination in the cereal crops. In terms of animal feed, the laboratory, whose mission is to analyse world of research in the field of solid state group is working on the enhancement of samples and activity (enzymatic, physifermentation,” says Jean-Michel Boot, CEO grain co-products and improving the assical, chemical, etc.) of selected strains, as well of the Soufflet group. Solid state fermentamilation of feed by animals. In the area of as conducting applicative testing. The last tion allows the production of rich enzyme health, the Osiris program is seeking to floor is assigned to the screening of strains. complexes via the culture of micro-orgacreate ingredients with beneficial properComprising a culture collection, a microfluinisms. “SSF uses microorganisms capable of ties for nutrition. Finally, the project aims to dic laboratory and a mutagenesis laboraproducing many more types of enzymes, increase the efficiency of bioethanol tory, this floor is notably responsible for permitting better fermenting of biomass production, limiting the use of cereals, screening microorganisms in solid medium through improved hydrolysis of difficult subsnotably through the use of biocatalysts. with the aid of advanced technologies such trates,” explains Jérôme Souppe, director of As well as the Osiris program, the agroas microfluidics and micro-compartmentabiotechnology research at Soufflet. He adds: industrial group is involved in four regional lisation. “The challenge for Soufflet is to master this biotechnology research programs. Amongst These facilities will be used to support of promising technology.” Soufflet’s objective is others, they are aiming to develop solutions numerous R&D projects which the group to develop fermented raw materials suited in the field of soil biofertito targeted applications, lisation (the Optisol according to the 3S principroject) the production of ple corresponding to the bioemulsifying agents (the different research axes: Catalip program), improstrains, substrates and ved performance in lactic systems (processes). production (Novopoly) as The 2000m2 Technology well as the development Research Hall (HTR) has a of cereal products contaisporulation room and a ning probiotics (Panitaste). fermentation room. The With all of these research latter features mixing and programs there is no raw materials pre-procesdoubt that the group’s sing equipment, two pilot R&D teams will be fermenters with capacimaking good use of the ties of 300kg and 1.2 tons, recently opened new facias well as a packaging line. lities. ■ And as for the Soufflet centre for research and The newly inaugurated R&D facilities will help Soufflet master the technology of À NOGENT-SUR-SEINE, innovation (CRIS), this solid state fermentation. DINHILL ON FormuleVerte - N°12 - Décember 2012

Special report BIOCOMPOSITES

A much needed structuring of the sector in France

With 169,000 tonnes of flax and hemp grown each year, France has advantages in the field of biocomposites. Fibre producers, processors and application companies, industry players are moving towards developing a structured offer.

Today, natural materials represent about 1% of the volume of fibres used in composites,» says Frédéric Reux, managing editor of JEC Composites during a seminar on biocomposites held in Paris in early October. Prospects are also encouraging; in 2020, the level should reach 22%. “All sectors are concerned,” says Frédéric Reux. The day was organised jointly by JEC Composites and the European Confederation of Flax and Hemp (CELC) and was an opportunity to showcase several examples of the use of biocomposites, notably in the automotive industry. According to Frédéric

16 FormuleVerte - N°12 - Décembre 2012

Reux, the development of biocomposites is part of the trend which should drive the composites market in the coming years. Already, the composites market is doing well. “The more developed countries are, the higher composites consumption per capita is.” While the transportation, aerospace and construction industries accounted for 60% of consumers, “projections for 2015 indicate that volume growth will come from Asia,” says Frédéric Reux. It is a geographic area which currently accounts for 31% of sales (24 billion €) and 43% of volume sales (3.7 Mt). North America leads with 36% of sales (27 billion €) ahead of Europe (26 billion €,

ALONG WITH FLAX, HEMP CAN REPLACE FIBREGLASS AND CARBON FIBRE.

[BIOCOMPOSITES] Special

France produces 80% of European fibres Today, the industry of biocomposites, flax and hemp are doing well. And in this field, France has strengths to play on. “Europe is the second biggest source of plant fibre in the world and France produces 80% of European fibre, with 169,000 tons of flax and hemp. This is the equivalent to around two-thirds of the production of fibreglass,” says Pierre Bono, CEO of Fibres Research and Development (FRD). The company, which was founded in 2007, brings together eleven shareholders, fibre producers and major players in the utilisation of agricultural resources, “which invest together in order to utilise their plant material. They produce 15% of all natural fibres in France from flax, linseed, hemp, miscanthus and wood,” says Pierre Peter Bono, who adds that the materials sector mainly uses flax and hemp. These plants, cultivated in France, have accounted for, respectively, 75,000 and 8,000 hectares per year over the last 10 years. Based around this production, players are moving towards agricultural diversification and opportunities and address the composites market. An example is Chanvrière

RESOURCE AVAILABILITY: AN OUTDATED QUESTION! Fibres Recherche et Développement (Fibre Research and Development - FRD) produced, along with the ADEME, an evaluation of the availability and accessibility of plant fibres for materials use in France, published in 2011. “At the time, we felt the need to respond to a number of preconceptions. The issue of resource availability was a recurring issue when we created FRD in 2007; today, the question no longer arises in terms of volume availa-

de l’Aube (LCDA). “We are an agricultural cooperative specialising in the production and processing of hemp, established in 1974. Our first activity was, and remains, the provision of fibre for the specialty papers market. Our constant concern is to utilise all the components of plants whilst expanding our production and adapting our industrial tool to market needs,” explains Benoît Savourat, president of LCDA. A cooperative representing nearly 330 producers and a third of European production of hemp, it has moved towards diversifying its markets. Firstly, it offers the “woody” component, chènevotte, which represents 50% of the plant, for building (hempcrete), animal litter and mulch for soil production. “Fibre, that represents approximately 30% of the plant, has seen our largest investment in R&D. We had to adapt our fibre production in order to allow for use in insulation and composites,” says Benoît Savourat. LCDA was also behind the establishment of FRD in order to “pool resources in order to have an R&D unit which is relevant and sustainable,” and Agro-Fibre Technology and Plastics (AFT Plasturgie), which develops and produces reinforced compounds with natural fibres. This development on a portion of the value chain is part of a willingness to move towards a structuring of the composites industry.

Actors in the value chain working together on a project

ble because the resources are there. The issue now is the stability and reproducibility of resources available for day to day supplies for application companies.” It is a trend confirmed by Benoît Savourat, president of LCDA. “Increasing production area and industrial investment will pose no problem. If we have visibility on markets and the opportunities, we can produce” he says.

“Create a structuring tool with a nationwide scope allowing each link in the value chain to detail its own needs and expectations.” (IAR cluster).

33%). In volume, Europe is lagging, with 2 Mt (22%), behind Asia and North America (3 Mt, 35%). Frédéric Reux stresses that European players have “their role to play with high added value products.” The main trends which will drive the composites market by 2015 are the development of thermoplastics, injection processes, the development of wind power, and the development of biocomposites. These developments are based on the use of plant fibres. “There are 4000 plant fibres in the world,” says Christophe Baley, professor at the Brittany Engineering Laboratory of Materials (LIMATB). However, not all are used for biocomposites. The researcher points out that flax fibres are very regularly dispersed, which has an interest for the composites industry, unlike cotton for example.

report

These companies are also involved in a project named Sinfoni. This structu-

CONSISTENT QUALITY OF FIBRES IS REQUIRED IN BIOCOMPOSITE APPLICATIONS. FormuleVerte - N°12 - Décembre 2012

Special report [BIOCOMPOSITES]

ring project for clusters (within the framework of Investment for the Future) is accredited by Industry and AgroResources (IAR), Fibres, Up-Tex and Techtera. Presented on the 22nd of November, it brings together upstream players - Chanvrière de l’Aube (hemp) and Calira (flax fibre), primary transformation players which form fibres, such as AFT Plasturgie, EcoTechnilin and Eyraud, application companies – Lafarge, Soprema, Faurecia and Bombardier, as well as technical centres. “This project aims to set up a sector of excellence supplying plant based flax and hemp technical fibres. Just like a symphony, it is a questioning of harmonising different complementary actors in the value chain,” says Pierre Bono, CEO of FRD and the project leader. “There was an urgent need to create a structuring tool with a nationwide scope allowing each link in the value chain to detail its own needs and expectations. This is essential for the emergence and sustainability of this industry,” says Guillaume Jolly, head of training and biomaterials at IAR. When fibre producers require contractual orders in order to anticipate their production costs and provide stable material costs, indus-

18 FormuleVerte - N°12 - December 2012

trial users can detail their expectations in terms of quality supplies, for example, and processors can position themselves on the adaptation of fibre pre-forms according to application specifications. Fibre production must be anticipated according to production runs. “As of June 2012, we have made commitments to producers for materials which will be produced in 2013 and placed on the market in January 2014,” says the president of LCDA. While the supply issue does not arise in terms of quantity (see inset), quality issues are the subject of numerous discussions. Industrial users cannot afford to produce parts with varying qualities depending on the fibre used. “The problem of variability has existed since flax fibre was first used by man. For composites, such as textiles, it has to be a homogeneous product. Producers in the flax sector have long solved the problem via mixed cultures and harvests,” says François Vanfleteren, director of Lineo. It is a question of storing harvests and then transforming batches which come from different producers and different years, thus obtaining homogeneous pre-forms (semi-finished products comprising the fibre matrix combined

FIBRES ARE WOVEN ACCORDING TO FINAL APPLICATIONS.

with resin and ready to be shaped by application companies), from year to year. In terms of price, while the hemp industry relies on contracting in order to avoid fluctuations, the flax industry has not always done so. As noted by Karim Behlouli, CEO of EcoTechnilin: “The Sinfoni project aims to create conditions for large-scale use of these materials and this has to happen by structuring volumes and prices. Until now, the hemp industry has not experienced significant fluctuation thanks to 5-year contracts. We are trying to apply this to the entire chain of natural fibres in France in order to properly calibrate the average price. The goal is not to negatively affect anyone. Today, some flax producers have realised this and are positioned for the long term.” It is essential work as the number of downstream industrial projects increases. “When applications for large production runs such as automobiles reach production, changes in the costs of raw materials have to be taken into account in order to establish sustainable industrial strategies. Increasing quantities should also lead to lower industrial costs and, therefore, lower prices. This will make flax more competitive with fibreglass. Today, we are closer to carbon fibre,” explains François Vanfleteren.

[BIOCOMPOSITES] Special

ADVANTAGES AND DISADVANTAGES OF PLANT FIBRES

BIOCOMPOSITES ARE ALREADY USED IN SPORT AND RECREATION.

military equipment. Nevertheless, flax and hemp are not perfect and some of their characteristics remain problematic in technical applications techniques. Work notably needs to be done on absorption of moisture and fire resistance. And some knowledge is still missing. “We need to improve our knowledge of high performance biocomposites in railway contexts. This includes fatigue response of structural parts,” says Véronique Andries, senior expert on eco-design at the Alstom group. © Molydal

The replacement of fibre and carbon fibre by plant fibre does not just respond to initiatives on corporate sustainability. Plant fibres from flax and hemp can lighten composite parts. “A plant fibre can lessen weight by 10 to 25% on a finished part,” says Pierre Bono of FRD. It is a lightening which is much appreciated by the transport industry in particular. These fibres also have mechanical vibration damping, thermal and sound insulation qualities. Pierre-François Louvigné of the DGA also cites transparency to waves used in

In terms of transformers, firms are positioning themselves by developing preforms tailored to the needs of end users; a good example is Lineo. Founded in October 2006, the company aims to develop new markets for preimpregnated flax pre-forms. “We are committed to developing products that can be used by composites producers without compromising their manufacturing process,” says François Vanfleteren, head of Lineo. The company has worked with Decathlon on the introduction of flax fibre into the sporting goods industry. “In the field of sports and recreation, it takes an average of 3 years lead time to go into production,” said the director of Lineo, which participated in the development of Artengo tennis rackets. The company is currently involved in several projects with automotive and aerospace companies and has obtained the support of the DGA and DGCIS to work on developments for the purposes of civil and military applications. These sectors seem to be very active in this field. For example, PSA-Peugeot Citroën is increasing the number of development projects, notably for lighter vehicles, with the introduction of flax fibres for ever more technical parts. The Flaxpreg project involving Faurecia aims to reduce the weight of a car trunk floor by 50%

report

whilst maintaining performance. “The cycle time and the cost of raw materials have to be in line with the constraints of mass automobile manufacture,” says Arnaud Duval, head of the innovation acoustics and soft trim division at the research and innovation department at Faurecia. “We do a lot of research via consortiums”, says Frédéric Rousseau, head of innovation at the direction of research and advanced engineering at PSA-Peugeot Citroën. “We will bring together several consortiums with whom we work.” While the automotive industry seems to be making good progress through various projects, the aviation industry is also looking at the question. François Vanfleteren of Lineo says that they are working on a project funded by Europe for the implementation of industrial production of sandwich panels for Boeing. In the railway industry, Véronique Andries, senior eco-design expert at Alstom stresses that despite “the culture of metal,” the group has nevertheless become interested in biocomposites “in recent times”. Alstom is involved in several projects and studies into possible applications. Little by little, biocomposites are conquering new areas of potential applications. As R&D projects gradually reach fruition, plant based fibres move into the industrial production of biocomposites. The structuring of the sector will have to be completed in order to answer concerns about issues of quantities, quality and costs. ■ AURÉLIE DUREUIL FormuleVerte - N°12 - December 2012

Sponsored article Five years of initiatives, projects and achievements: we look back over a success story with its founder members. Five must be a magic number, since the project also began with five members: two industrial groups, Roquette and Rhodia (now part of the Solvay Group), and three institutions, USIPA, IAR and UIC, one of the pillars of the project.

Happy birthday! The ACDV is five years old: how time flies…

20 FormuleVerte - N°12 - December 2012

one of them could have imagined at the outset the results they have achieved together. The ACDV is an adventure story of men and women who have come together, on a voluntary basis, to pursue a single course that is now bearing fruit. "In 2006/2007, we felt a great need to work together on building an association to promote plant-based chemistry. Even if there is still a long way to go, one thing we can say is that the unity of our group is already a real success," claims Jean-Luc Pelletier, Executive Officer of the USIPA federation. A success that would not have been possible without collective mobilisation and readiness to listen to others. "This is a human adventure, a space for dialogue, that has enabled us to come together regularly and construct a real message setting out the virtues and potential of biosourced products," adds Thierry Stadler, Managing Director of the Industries and Agri-resources Competitiveness Cluster. It has to be said that the process of bringing two very different industrial cultures together in a single association was by no means self-evident and yet "we have learned to work together, despite being from very different sectors," comments Guy-Noël Sauvion, Head of Economic and Environmental Evaluation at Solvay. The facts and figures speak for themselves: close on 50 members from all the key stakeholders in the sector – agro-industrialists, chemical firms, users, customers – a crosscutting organisation no other country can equal, working groups with a total of close on 70 members. All this, plus the organisation in Paris of the first biobased chemistry conference that generated its own statistics: 450 participants, 30% of them from outside France. "Not to mention reaching financial maturity," stresses Jean-Luc Pelletier. One of the association's initial aims was to prove to the authorities its capacity for rapidly achieving financial breakeven. Mission accomplished, as far as the everyday running of the association is concerned. Another source of pride is the success that major groups have had in welcoming and including SMEs to create a shared dynamic.

"We are very happy to see the extent to which SMEs are participating actively, even acting as the driving force, in our working groups," enthuses Guy-Noël Sauvion. The ACDV's dynamic energy is now recognised well beyond the borders of France: "when will Europe be getting its own ACDV?" is a question often put to Christophe Rupp-Dahlem, ACDV Chairman and Director of the Biobased Chemistry Programme with Roquette. This question alone demonstrates the demand and the scope for an association of this type. Over and above the personal involvement and the results achieved so far, says Daniel Marini, Director of Economic and International Affairs at chemical industry federation UIC, it is important to note "that we have been able not only to bring together two links in the value chain, but also to identify clearly the challenges that biobased chemistry might represent within the chemical field as a whole". And that is undoubtedly one of the ACDV's greatest successes to date. The ACDV is now recognised as an unquestionable reference. This status it owes in part to the involvement, from the outset, of firms like Rhodia, Roquette and also to the initiatives it has successfully conducted:

among them, the creation of the first biomass content indicator (supplementing the biobased carbon content indicator), with a European pilot of the indicator tested and validated for robustness and reliability by SGS. Another initiative has involved participating in numerous studies conducted by French environment and energy management agency ADEME, in particular on life cycle analysis (LCA) and the potential applications for biobased chemistry. The list goes on… But what about tomorrow? "In the near future, we must focus our efforts on everything that can be done to accelerate support from the authorities," explains Christophe Rupp-Dahlem. "There is indeed a missing link," admits Jean-Luc Pelletier, "between the pilot demonstration project and the first commercial unit".

Another challenge: setting the example In just a few years, the association has become a reliable and credible contact for ADEME, funding agency Oséo and the relevant ministries, but this is still not enough, adds Daniel Marini: "plant-based chemistry must serve as an example, it must apply the 12 principles of sustainable chemistry.

PLANT BASED SUMMIT 2013

THE EVENT DEDICATED TO BIOBASED CHEMISTRY IN 2013

Having access to green carbon is good, but not enough in itself; the whole life cycle has to be taken into consideration". The objective is to develop sustainable plant-based chemistry that incorporates environmental and economic criteria. And this is where indicators and statistics are needed. If it is to establish its credibility beyond question, the ACDV cannot afford not to produce indisputable quantified economic and environmental data. Government support is channelled through Institutes of Excellence for carbon-free Energy (called IEED in french), including PIVERT, IFMAS, Greenstars and IDEEL. Another major challenge for the association is promoting the start-up of the first innovative industrial units in France, with all the knock-on benefits they may bring in terms of jobs. This is the stance adopted by Thierry Stadler, who points out that France has a considerable lead in encouraging businesses with strong regional roots. "Biorefining is a perfect illustration of the positive role that strong local connections can play in revitalising industry in the regions," he explains. "In short, the ACDV is a natural extension of all the innovation work that goes on within the competitiveness cluster. Which is why," he continues, "our efforts should now be focused at the European level and on promoting the installation of the first industrial units in France." Regional biorefining in France certainly offers an alternative local model to portbased refining, but the plant resources involved are central to a much wider debate: that of global resources. "The ACDV has sufficient credibility to rise above an approach that can sometimes still be too France-centric," is the view of Guy-Noël Sauvion; "the issues are most definitely global and, after all, why not envisage expor-

contact@chimieduvegetal.com

ting this concept of biorefinery?" Once again, the ACDV is expected to take on another dimension; it certainly has the resources to do so. Lastly, Jean-Luc Pelletier and Guy-Noël Sauvion mention another new step: this would involve forging much closer ties with the downstream industry and seeking to bring the ACDV's contribution to the attention of a general public increasingly aware of the issues at stake. In short, creating a strong link to the general public where no such link yet exists. Watch this space. The birthday celebrations would not be complete without a unanimous tribute to the work of Valérie Lucas, CEO of the ACDV, and Aurore Friès, in charge of Member Relations. Five years of keeping the association running smoothly, coordinating people, topics, Board and other meetings, and analysing opportunities of every kind. Five years working in every area of communi-

cation, ensuring the overall consistency of all the messages and events for an association that has never ceased to grow. The proof? the 19/20th November 2013, the ACDV changes up a gear: in the wake of the success of its first conference in September 2011, it is now organising the Plant-Based Summit in Paris , an international event that will provide visitors with answers to all their questions thanks to all the biobased solutions and sector stakeholders that will be present. Not so much a new challenge as one more major initiative on behalf of the biobased chemistry industry and of its fifty members. Although the number of members will undoubtedly have grown by then, of that you can be sure! ■

Join us!

www.chimieduvegetal.com FormuleVerte - N°12 - December 2012

c.hu

Focus [PRODUCT] BIOBASED PAINTS

An emerging market On November the 16th, the Axelera cluster brought together forty members to discuss the interest of switching the paint industry to plant based sourcing.

ver the last fifteen years, the paint sector has undergone significant changes. First they were driven by regulatory changes such as the VOC Directive, coming from the 1997 Kyoto Protocol. A war has been waged against organic solvents with a switch to water or powder based products. And then REACH arrived, with the objective of verifying the safety of all chemicals on the market. Today we are entering a new phase with the inevitable depletion of oil resources and reducing the carbon footprint of products with a view to stage 4. This step promotes substituting petrochemical ingredients with biobased versions in all areas, notably including paints. In order to discuss this issue, on November 16th, the Axelera cluster held a workshop on bio-based paints and varnishes. Various suppliers of ingredients and paints had the opportunity to testify that there is already a range of partially or totally bio-based paints, even if their market share is still very low. Alain Lemor, a scientific delegate with Novance, said that among all categories of resins used in paints, alkyd resins are already partially bio-based (50 to 60%). The challenge is to offer a version which is 100% bio-based. Thus Novance has launched VG Tech Hydro aimed at the decoration and varnishes markets. Alain Lemor said that in terms of other major families of resins (acrylic, polyurethane, vinyl, and polyester) opportunities are emerging with the development of new monomers (diacids, diamines, and diols). Olivier Choulet, president and CEO of the young company Ecoat, also addressed the

22 FormuleVerte - N°12 - December 2012

challenge of alkyd resins, firstly putting forward alkyd emulsions in water. “Alkyd resin is a big loser with the passage of water, unlike acrylic,” he said. Meanwhile, the company has developed a range of Secoia resins, based on oilseeds such as soya or sunflower and tall oil. It is now available in a 100% bio-based version, with improved colour and brightness, which remains one of the weaknesses of biobased ranges. Founder of Neoformula Consulting & Development, Claude Stock felt that a formulator can find certain ingredients in a biosourced version: binders, pigments, dispersants, wetting agents, defoamers, thickeners amongst others, as well as the Vegerust corrosion inhibitors from the company Labema. “However, coalescing agents are not very efficient and there are no biocides,” says Claude Stock. Similarly, agrosolvents have a disadvantage in their low volatility, slowing drying. For its part, the family SME Derivery came to present their range of 100% mineral or plant-based paints, marketed since 2006 by Laboratoires Natura. These products are based around a patent for oil-based emulsions. This move towards biosourcing can also be seen in photocrosslinkable paints and varnishes. Philippe Cicero from Sartomer (Arkema) came to talk about the Sarbio project which aims to develop biobased ingredient of these resins which use acrylate and methacrylate chemistry. Biobased is also emerging in the field of coil coating. Murielle Moneron, development and innovation manager at the Beckers group, talked about the beginnings of a partnership with a major client. But it is

their only project; “Our problem is that there are not many biobased products available”. A need for labels Biobased products also have the reputation of being more expensive by a factor of 20 to 50%. Hence the importance of using labels in order to avoid greenwashing. Francis Viez stressed the growing confusion between natural and biobased, given the use of mineral fillers. But while Ecolabel or the NF environmental norm do not make a distinction, paint industry player players now have the Pure label. Certified by Ecocert, it provides information on the percentage of renewable raw materials used in the formulation. Participants also agreed on the importance of LCA, a tool which needs some improvement in order to help decision making. And in terms of carbon 14 measurement, a method used in the United States, it can measure the percentage of renewable carbon. But the Plant-based Chemistry Association (ACDV) wanted to go further by proposing an indicator on the biobased content of products taking into account carbon as well as other elements of biomass (oxygen, sulphur, nitrogen etc.). This label is becoming the standard in Europe. Finally there was the contribution by Philippe Brunet, technical and regulatory head at Fipec. He lamented that plant based chemistry as it is understood today by total biomass deconstruction, is reproducing the petrochemical model. “We have to change our thinking. Nature provides us with ready-to-use products, extractible by physical processes. There are billions of molecules; it’s a question of finding the ones that interest us.” ■ LYON,, SYLVIE LATIEULE