bioplastics MAGAZINE 05-2014

ISSN 1862-5258

September / October

05 | 2014

Highlights Fibers & Textiles | 12 Toys | 36

1 countries

... is read in 9

bioplastics

MAGAZINE

Vol. 9

Beach toys by ZoĂŤ b made from PHA, p. 44

Caring for nature!

To sary

celebrate

WWF

Playmobil

Keychain

Germany’s

has

created

designed

from

fifty-year a

bioplastics.

anniver-

unique

Panda

This

limited

edition toy has been produced using FKuR’s raw materials. Foam injection moulding (TSG) process was used to manufacture the Panda using FKuR’s Bio-Flex® F 6510 resin. Both partners chose this material as Bio-Flex® F 6510 mainly consists of renewable resource material.

In addition Bio-Flex® F 6510 is BPA-free which makes it particularly suitable for toys.

Panda Keychain made from Bio-Flex®

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

Editorial

dear readers Two topics have caught my attention recently, and both have been the subject of some controversial discussion. The first one is the question about the mass balance approach that I brought up in issue 03/2014, or perhaps, better, about Sustainability Certification as suggested by Michael Carus.

The second topic is the never-ending story about oxo-degradation. I’ve been waiting 8 years now for the suppliers of such additives (and I have asked them again and again) to provide scientifically backed evidence for publication in bioplastics MAGAZINE. Finally OWS and IKT are now starting a multi-client study to prove, once and for all, whether conventional plastics with these (much discussed) additives completely biodegrade or not. Please see p. 6 for details.

ISSN 1862-5258

One of two other highlighted topics in this issue is Fibres & Textiles, covering a lot of interesting details about fibres made from PLA, cellulose, different types of polyamides, the milk protein casein and more. And for the second highlight, Toys, we too received a pleasant number of articles. In many of the cases of applications for toys it is the search for natural alternatives, free of phthalates, Bisphenol A and other harmful ingredients, that toy companies, consumers and their families want.

September / October Highlights

05 | 2014

Fibers & Textiles | 12

Toys | 36

... is read in 91 countries

When you have this copy in your hands, you should have also received the fifth edition of our new bi-weekly newsletter. In addition to our daily news on our news site at http://news.bioplasticsmagazine.com (which has recently benefitted from a facelift) is a free newsletter bringing the latest news directly to your e-mail inbox. Of course the printed bioplastics MAGAZINE is still focused on more comprehensive and in depth extensive articles.

Vol. 9 bioplastics

Until then we hope you enjoy reading bioplastics MAGAZINE

Beach toys by ZoĂŤ b made from PHA, p. 44

MAGAZINE

On page 10 we introduce the five finalists of the 9th Global Bioplastics Award. The winner will again be publicly announced at the European Bioplastics Conference, on December 2nd in Brussels.

Sincerely yours Michael Thielen

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bioplastics MAGAZINE [05/14] Vol.9

3

Content Fibers & Textiles 12 Next-generation polyamide fiber 15 High tenacity fibres 16 Coloured PLA fibres 19 New biobased monofilaments 20 Casein-based polymers 22 Green high performance textiles 24 Rayon and more – Biobased chemical fibres

Toys 36 Application News (Toys) 37 Bioplastic baby products

From Science & Research

38 From packaging fillers to toys

28 Next generation chemical building blocks and bioplastics

41 Wood composites for toys

32 BREAD4PLA

42 How bioplastics and biocomposites are

Materials

changing the toy industry

44 Beach toys made from PHA

31 High barrier in-mould labelling

46 A waste-to-toys effort

05|2014

Politics / Markets 48 A bright future for bioplastics ?

Basics

September/October

50 Biobased Building Blocks

Opinion 52 Sustainability Certification

Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 - 08 Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Application News. . . . . . . . . . . . . . . . . . . . . . . . 34 - 36 Suppliers Guide. . . . . . . . . . . . . . . . . . . . . . . . . 54 - 56 Event Calendar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Cover: Zoë b

Cover

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

Envelopes

Editorial contributions are always welcome.

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

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

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

bioplastics MAGAZINE is read in 91 countries.

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bioplastics MAGAZINE

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Companies in this issue . . . . . . . . . . . . . . . . . . . . . 58

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News

New carbon fibre from plants Researchers at the University of North Texas have created a new carbon fibre from plants that can replace common fossil products in wide range of goods including parts for cars, aircraft, electronics and sports equipment. The patentpending carbon fibre also is stronger and lighter than similar products on the market.

The new carbon fibre is made from C-lignin, a linear polymer that was discovered by UNT Distinguished Research Professor Richard Dixon and Research Professor Fang Chen in 2012 and reported in the Proceedings of the National Academy of Sciences.

“Finding new uses for plant materials like C-lignin is a great step toward replacing common petroleum- and coalbased products with products made from natural materials,” Dixon said. Those products include carbon fibre; engineering plastics and thermoplastic elastomers, which can be stretched and formed to produce other products; synthetic

foams and membranes; and other fuels, products and chemicals currently sourced from petroleum.

The new carbon fibre was created in the laboratory of Nandika D’Souza, a joint professor in the departments of mechanical and energy engineering and materials science and engineering in UNT’s College of Engineering. D’Souza and engineering doctoral student Mangesh Nar engineer low carbon footprint products using bioresources through the National Science Foundation’s Partnerships for Innovation Program.

“Unlike carbon fibre made from other ligno-cellulose or lignin sources, C-lignin is ideal for creating naturallysourced carbon fibre because C-lignin fibres are linear, and can be easily processed into carbon fibre with the same equipment often used to produce fossil-fuel based carbon fibres,” D’Souza said. KL

Coca-Cola expands investment in bio-paraxylene development USA-based biochemical and biofuels company Virent recently announced that The Coca-Cola Company is making an additional investment in the company’s development and commercialization of its bio-based paraxylene, BioFormP. This investment will enable Virent to scale up separation and purification of BioFormPX material at their demonstration plant in Madison, Wisconsin, USA. “Over the course of our work together, Virent has continuously delivered on their commitments and advanced their technology.

That progress supports building additional capability for Virent and advances us on the path to a full-scale commercial solution for our 100% plant-based PET plastic packaging” said Scott Vitters, General Manager, PlantBottle Innovation Platform at The Coca-Cola Company.

Virent and The Coca-Cola Company have been working together since 2011, when they first announced their Joint Development Agreement and a Master Supply Agreement focused on the development of bio-based PX technology.

Paraxylene (Px), a chemical that is currently produced in a crude oil refinery, is the main raw material used to produce terephthalic acid (PTA), one of the two components of which PET the packaging material used by CocaCola - is made up of.

https://news.unt.edu

www.www.virent.com

“The Coca-Cola Company continues to be a valued partner for Virent. Their intention to use our BioFormPX material in the next generation of PlantBottle packaging is critical in attracting manufacturing partners from the PET supply chain. This – along with the progress we’ve made in our joint development work - moves us closer to seeing the first commercial 100% bio-based PET bottles on retail shelves made using Virent technology” said Lee Edwards, Virent CEO. virentIn the course of their work with The Coca-Cola Company, Virent has progressed their PX technology to commercial readiness, improved the process economics and produced bio-based PX which has been converted by The Coca-Cola Company into 100% bio-based PET bottles. This new investment will allow production of larger quantities of BioFormPX material.

Virent has run its demonstration system to fulfill a number of fuel and chemical orders since it started operation in 2010.

This added capability to produce larger quantities of purified PX will be combined with additional system enhancements to increase production capabilities, including larger volumes of bio-fuel and other bio-materials. KL

Photo: Virent

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News

Will the claims of oxo-degradable plastics stand up to scientific lab scrutiny?

That’s precisely what OWS (Organic Waste Systems nv, Ghent, Belgium) and IKT (Institute of Polymer Technology, University Stuttgart, Germany) intend to find out. They are setting up a multi-client study to provide a definitive answer to the question: do oxo-degradable plastics biodegrade or do they not?

After all, biodegradable plastics, whether oil-based, such as PBAT or PBS, or derived from biomass, such as PLA, PHA or TPS, all share one thing in common: they are certified as biodegradable. Simply put, these materials have been tested and proven to be capable of being “broken down especially into innocuous products by the action of living things, such as microorganisms.”

And this is the sticking point - the heart of the ongoing biodegradable – oxo-degradable controversy. Basically, scientifically based studies characterizing the microbial degradation of oxo-degradable plastics are lacking.

To remedy this situation, building on a desk research study conducted last year by OWS for Plastics Europe, a comprehensive laboratory-testing program is now planned, with the ultimate aim of delivering the necessary scientifically based proof of whether or not oxo-degradable products biodegrade.

What are oxo-degradable materials, anyway? They are simply conventional plastics, such as PE, PP, or PET, that are mixed with a small percentage of an additive, which subsequently accelerates free radical degradation of plastics.

Proponents of these materials argue that by breaking down the long carbon-hydrogen bonds and reducing the plastic‘s molecular weight, the molecules become ‘wettable‘ and able to sustain a biofilm on the surface supporting microorganisms, which then consume the molecules and reduce the plastic into water, carbon dioxide, and reusable biomass.

However, lacking proof from independent laboratories or certification bodies that this process actually occurs, critics of these materials doubt whether complete biodegradation takes place, and have dubbed these products oxo-fragmentable. Experts fear that these fragments will disperse into the environment, causing further problems with microplastic waste.

The fight is a fierce one. The controversy has already led the European Commission to consider a possible ban on oxodegradable carrier bags. And in France, a group of MPs in the French National Assembly have called for a similar ban.

Predictably, the oxo-degradable plastics industry has reacted furiously, calling this “a skillful lobbying attempt to take oxobiodegradable plastics off the French market and leave the field clear for bio-based plastics which are not competitive with oxo-bio and have very limited usefulness.“ Biodegradable materials offer advantages in certain functional biodegradation applications. These materials are particularly suitable for applications such as agricultural film, sod netting, and plant pots, or, closer to home, as bio-bags for organic household waste. Whether such biodegradable plastics are a solution against littering is a different discussion.

Oxo-degradable plastics, however, are specifically being marketed as the solution to worldwide plastics refuse. It’s a message that’s being heard around the globe. As countries increasingly adopt the widespread use of oxo-degradable plastics, the time has come to establish once and for all, what happens to oxo-degradable plastics at the end of life.

The multi-client project aims to put the issue to rest by investigating the claims and by attempting to verify these in the laboratory. “To make this study as objective and neutral as possible, we are aiming at a broad participation including government agencies, consumer goods producers, NGO’s, oxodegradable producers and the bioplastics industry,” said OWS. In a first phase a number of oxo-degradable plastic products available in the market will be abiotically treated. In a second phase, the fragmented parts will be used for further biodegradation testing according to internationally accepted ISO and ASTM standards.

Throughout the project, interim results will be provided on a regular basis. These intermediate results will be sent to all project partners, enabling them to keep track of the progress made. At the end of each phase, a report will be published and distributed amongst the project partners; a final report will appear at the end of the study .KL More information can be found in the official proposal: http://bit.ly/1qWJvV2 www.ows.be

Meanwhile manufacturers of oxo-degradable plastics object against this study in a statement that by its very vehemence raises incredulity. Shakespeare put it rather nicely when he wrote: “The lady doth protest too much, methinks.” KL Read the full commentary at plasticstoday.com (Sept 22) http://bit.ly/1B34FAW

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bioplastics MAGAZINE [04/14] Vol. 9

News

Improved performance of PLA-packaging The plastics processing industry has been faced with an ever growing number of demands from end consumers calling for responsible action to protect our environment. Added to these demands, are those of packaging materials producers whose concerns are not only environmental but are also focused on better and simpler processing of PLA-materials.

The GRAFE Group (Blankenhain, Germany) has expanded its product portfolio to include a new masterbatch under the name of Biocolen which is not only suitable for coloring PLA but also provides improved performance for packaging manufacturers.

The new material offers many advantages to processors, and new

application options to manufacturers of consumer goods.

The batch improves the temperature stability of PLA during the thermoforming process, by optimizing the material which must be stored cool and then reheated. One of the most important applications is for packaging microwave meals. The benefits available to the packaging manufacturers are clear.

The masterbatch improves the durability, achieving a higher flexibility and reducing the brittleness in the end product without impairing transparency. The packaging product is very easy to process and cut due to its material composition. www.grafe.com

New high-strength biocomposite

Processing of Bioplastics – what is feasible ?

In the automotive industry the increasing pressure to use sustainable or renewable thermoplastic materials has led to the use of polyolefins filled with short natural fibers for parts that are not mechanically demanding.

A wide range of marketable biobased engineering materials such as PLA, Bio-PE, PA, PHB, etc., has become available by now and there is growing demand from the industry. But what is the exact performance range of bioplastics and how involved are the necessary modifications to the materials and in the production process, before they can be used as desired?

To date, however, there have been no sustainable or 100% natural biocomposites for performance applications with high mechanical demand.

Now, (within the EU project Ecoplast), Biomer (Germany) and AIMPLAS (Spain) have developed a continuous production process for high strength renewable thermoplastic composites. These biocomposites are renewable, and have unexpected properties that enable the materials to be used for high-performance applications. The biocomposites show a modulus of over 6 GPa, a tensile strength of 70 MPa, and an impact strength of 40 kJ/m2.

The biocomposites can be thermoformed at 175°C. They can be used for structures in transport that need to withstand large temperature changes from –40°C to +60°C, or for stiff, shock absorbing arrangements.

For over 15 years, Biomer has focused on transforming PHB biopolyesters into high-performance durable bioplastics that are designed to be used in technical applications and last for years.

The latest developments are fogging-free PHB thermoplasts that can be used in car interiors and that parallel PP or HD-PE in most mechanical properties. Biomer formulations are fully biodegradable in soil, sludge, rivers, ocean, or in garden composts at the end of life. KL

These and other questions are most vital for the processing industry and thus received great attention at the symposium held by IfBB – Institute for Bioplastics and Biocomposites, and SKZ, September 17-18, in Würzburg. Germany Basically, the participating practitioners were given a presentation of the first results from the collaborative project „Processing of Biobased Plastics and Establishment of a Competence Network within the FNR Biopolymer Network“, followed by contributions from the industry. The project is funded with a grant from the Federal Ministry of Nutrition and Agriculture (BMEL), administered by the Agency of Renewable Resources (FNR).

Visitors to the trade fair FAKUMA (October 14-18, Friedrichshafen, Germany) can visit IfBB at their booth (Hall 7 / 7508) and get more first hand info about the institute and the Biopolymer Network. MT www.ifbb-hannover.de

www.biomer.de

www.aimplas.es

www.ecoplastproject.com

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News

FKuR and Helian Polymers: tailor made PLA compounds for 3D printing The bioplastics specialist FKuR Kunststoff (Willich, Germany) and Helian Polymers (Venlo, The Netherlands), a leading provider of 3D printing filaments, are cooperating on the development of novel PLA blends for 3D printing. The initial results and applications of this collaboration will be shown at this year’s Composites Europe exhibition (booth A36, hall 8b). The highlight at the booth will be live 3D printing of natural fibre reinforced bioplastics.

Bioplastics such as PLA are particularly suitable for the FDM process (Fused Deposition Modeling). However, a significant disadvantage of unmodified PLA is its brittleness and low impact strength. As a consequence the quality of the finished product is adversely affected. With its new generation of PLA based filament formulations, the cooperation partners

www.fkur.com www.colorfabb.com

satisfy the requirement for an optimized material quality along with improved processing. With their unique and comprehensive product portfolio, both development partners will steadily expand the applications and markets for PLA in 3D printing.

Colorfabb are able to supply filaments in a wide variety of colors. Their product range includes the recently developed design materials reinforced with natural fibres namely woodFill Fine and BambooFill.

These two wood fibre reinforced grades enable the manufacture of components with a unique wood appearance and distinctive feel. Compared to conventional wood, there are virtually no limits to design freedom. This freedom of design enables designers and architects, as well as private users, to work with new creative options.

Biobased superabsorbent polymers BASF, Cargill and Novozymes have reached another milestone in their joint development of technologies to produce acrylic acid from renewable raw materials. The team has demonstrated the successful conversion of 3-hydroxypropionic acid (3-HP), to glacial acrylic acid and superabsorbent polymers. They have now also selected the process for further scale-up.

In August 2012, BASF, Cargill and Novozymes announced that they were joining forces to develop a process for the conversion of renewable raw materials into biobased acrylic acid. A short year later, in July 2013, the partners successfully demonstrated the production of 3-hydroxypropionic acid (3-HP), one possible precursor to acrylic acid, at pilot scale.

BASF initially plans to use the biobased acrylic acid to manufacture superabsorbent polymers. Currently, acrylic acid is produced by the oxidation of propylene derived mainly from the refining of crude oil. “After just 18 months we have selected the preferred process to convert 3-HP into glacial acrylic acid. Now we are working full force on the set-up of a small integrated pilot plant until the end of this year,” said Teressa Szelest, Senior Vice President Global Hygiene Business at BASF. Together with the pilot plant for 3-HP, operated by Cargill and supported by Novozymes, this will further support BASF’s plans for fast market entry of superabsorbent polymers derived from biobased acrylic acid.

“We are pleased to see the project progressing with high pace and commitment towards commercialization,” said Kristian Bjørneboe , Vice President Business Creation and Acquisition at Novozymes. “We are refining and pursuing options on how to move quickly towards commercial scale production of 3-HP to acrylic acid to meet market demands for consumer goods based on renewable raw materials.

Meanwhile, strain and fermentation optimization towards commercial scale requirements is progressing steadily.”

“Cargill came together with BASF and Novozymes to do what had not been done ever before. We have been working together for less than two years and we have made great progress toward our common goal,” said Jack Staloch Vice President of Research and Development at Cargill. ”It’s a great example of what can be accomplished when industry leaders with unique expertise in biotechnology and chemistry come together to create new innovations.”

Superabsorbent polymers and other products derived from biobased acrylic acid will be an innovative offer to the market and will meet consumer and industry demand for consumer goods based on renewable raw materials and sustainable supply chains. BASF is the world’s largest producer of acrylic acid, a high-volume chemical that feeds into a broad range of products, including superabsorbent polymers that can soak up large amounts of liquid, used primarily for diapers and other hygiene products. www.basf.com www.cargill.com www.novozymes.com

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bioplastics MAGAZINE [04/14] Vol. 9

bio PAC bio CAR biobased packaging

Biobased materials for automotive applications

conference

conference

12/13 may 2015

novotel amsterdam

fall 2015

» Packaging is necessary. » Packaging protects the precious goods during transport and storage. » Packaging conveys important messages to the consumer.

» The amount of plastics in modern cars is constantly increasing. » Plastics and composites help achieving light-weighting targets. » Plastics offer enormous design opportunities.

» Good packaging helps to increase the shelf life.

» Plastics are important for the touch-and-feel and the safety of cars.

BUT:

BUT:

Packaging does not necessarily need to be made from petroleum based plastics.

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

biobased packaging » is packaging made from mother nature‘s gifts. » is packaging made from renewable resources.

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

» is packaging made from biobased plastics, from plant residues such as palm leaves or bagasse. » offers incredible opportunities.

www.bio-pac.info

CALL FOR PAPERS NOW OPEN

in cooperation with

www. biobasedpackaging.nl

www.bio-car.info

Award

The Bioplastics Oskar Nominees for the 9th Global Bioplastics Award

F

or the fifth time now, bioplastics MAGAZINE is honoured to present the five finalists for the Bioplastics Award. Five judges from the academic world, the press and industry associations from America, Europa and Asia have again reviewed a number of really interesting proposals. On these two pages we present details of the five most promising submissions.

Bioplastics Award The 9th recognises innovation, success and achievements by manufacturers, processors, brand owners, or users of bioplastic materials. To be eligible for consideration in the awards scheme the proposed company, product, or service must have been developed or have been on the market during 2013 or 2014.

The following companies/products are shortlisted (without any ranking) and from these five finalists the winner will be announced during the 9th European Bioplastics Conference on December 2nd, 2014 in Brussels, Belgium.

Supla (SuQian) New Materials Co. (China)

Zandonella (Germany)

Durable bioplastics embrace personal mobile devices with advanced functions

Insulating ice-cream box made of BioFoam

Following the second prize at the 8th Bioplastics Award in 2013, Supla continued the development into a new grade of modified PLA, that not only fits the requirements of durability, ease of manufacture and assembly, plus shock resistance, but also has anti-bacterial properties.

With the lactide from Corbion, Supla polymerized PLLA and PDLA on a Sulzer PLA Unit. Based on these materials of high visual purity, Supla developed SUPLA™ 158 in 2014, answering a new market in the near future for mobile consumer electronics. Kuender, who is expert in injection moulding for electronics housings, has applied SUPLA™ 158 to kid’s cell phones for Dikon Information Technology (Shanghai) Co, Ltd., as well as a number of other innovative products.

Because hand-held devices have become the focus in the 3C market, Supla launched SUPLA™158 which meets all of the physical properties required for such applications. In addition, to answer the special need of this market, the material also has an anti-bacterial effect with the anti-bacterial ratio of coli and aureus respectively of 99.2% and 99.6%.

Supla (SuQian) New Materials Co. Ltd. will have a production capacity of 10,000 tonnes/annum of PLA polymerization and additional compounding lines by the end of 2014 at Suqian, China.

Supla’s eco-friendly high performance plastics can be processed on existing manufacturing machines without big changes. www.supla-bioplastics.cn

Sandro’s Bio Box is a 500 ml box made of BioFoam®, which contains the finest gourmet ice-cream.

As the first ice cream company, Zandonella GmbH, in spring 2014, launched its new trade mark Sandro’s Bio, in a box made of BioFoam®, the expanded PLA particle foam from Synbra. It looks similar in structure and has more or less the same properties as EPS. Even in a hot car this box keeps the ice cream frozen and well tempered for over an hour.

In addition, all other packaging components are made of renewable raw materials, AND all are appropriate for industrial composting. Further parts of the packaging concept are: paper wrap, shrink film (also for tamper evidence) made of PLA, label made of cellulose or PLA, PLA inlay, as well as coating film made of PLA. The packaging system bears the following certifications and/or labels: BioFoam® is the first biological foam packaging in the world to be Cradle to CradleCM certified, certified compostable (EN 13432), and has the German Ohne Gentechnik seal, confirming that the material of the Bio-Box has not been genetically modified and is renewable.

The idea is really new and sustainable!

Usually consumers are in a hurry and have to hurry to bring their ice creams to the freezer at home after their grocery shopping as soon as possible, before it melts. Not so with Sandro’s Bio Box. Thanks to the insulating effect, you can keep the ice cream frozen without cooling for over one hour. Additionally the product opens up new possibilities to the places where one can enjoy icecream. Why not take a box on the next picnic? www.sandros-bio.de

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bioplastics MAGAZINE [05/14] Vol. 9

Award

Swiss Coffee Company (Switzerland)

Rodenburg (The Netherlands)

UHU (Germany)

Beanarella: compostable coffee capsules

Biodegradable structure for habitat improvement

The first glue-stick with a plant-based container.

Working together with BASF the Swiss Coffee Company has succeeded in introducing a system that consists of a coffee capsule and an aromatight outer packaging. It fulfils the demanding requirements for protecting the product and brewing coffee in highpressure coffee machines, yet may still be composted. The system solution is predominantly based on renewable resources.

During the past year, Bureau Waardenburg together with Rodenburg Biopolymers and GEA 2H Water Technologies have developed a starchbased three dimensional biodegradable structure specifically for use in the improvement of dwellings. The potential uses for this starch-based three dimensional structure are almost endless. The companies are just starting to uncover the possibilities of the diverse range of applications.

With the UHU stic ReNATURE, paper gluing is becoming sustainable. The popular glue stick offers consumers a new and more environmentally friendly alternative to existing products – in an attractive design. The new UHU stic ReNATURE overcomes all challenges in the gluing of paper, carton, cardboard and styrofoam in the accustomed quality, showing that even a small product can make a substantial contribution to environmental protection and the saving of fossil resources.

Other than all existing conventional coffee-capsule producers the Swiss Coffee Company pursued a holistic approach, i.e. the company is paying attention from the first production step through to the end-of-life of the product.

This included extensive developments (capsule, high barrier film, non-woven filter medium, coffee machine etc.), certification (EN 13432, ASTM D6400 etc.) and practical tests in composting and AD ( anaerobic digestion) plants.

The coffee capsules themselves are made from ecovio IS1335 and are certified compostable (EN 13432). Also the barrier packaging (three functional layers) consists of biodegradable components. The outer paper-based carrier layer is followed by a thin barrier film as a middle layer and an inner sealing layer based on ecovio. All three single layers are certified according to EN 13432. The layers are bonded together by means of the compostable laminating adhesive Epotal® Eco from BASF. The packaging is designed to satisfy the demanding barrier requirements for coffee packaging with regard to moisture, oxygen and aroma. www.beanarella.ch

In a quest for artificial structures for use in the recovery of mussel beds, they have developed a biodegradable structure that can be used in restoration and improvements of their habitats. In contrast to many other bio-plastics, it undergoes complete breakdown without the need for composting agents.

Already there appears to be a wide range of potential applications for this product. Its original application was as a structure for the recovery of mussel beds and oyster beds. In addition, several other applications in the area of water purification, sewerage treatment, aquaculture, soil aeration, reclamation and the protection of coasts and sandbanks have become apparent.

One application example is a method to improve water quality using zebra mussels as a biological filter. This method is being tested in the south of the Netherlands on behalf of Waterschap Brabantse Delta.

Zebra mussels (Dreissena spp.) filter water in order to feed. They remove algae and small particles, which are deposited in excretion. In sufficient numbers they can prevent algal blooms and reduce turbidity. This improves the growing conditions for aquatic plants and the ecological water quality. www.biopolymers.nl

58% of the UHU stic ReNATURE’s container consists of renewable raw materials, namely sugar cane based bioPE. Some other parts of the container still have to be made from conventional plastics, such as, for example, the practical screw cap, to ensure a tight seal. The cap prevents the glue from drying out and makes it last longer.

As well as being fully recyclable, the new UHU stic ReNATURE is solvent-free and 70% of the glue formula is naturalbased. Another ecological as well as economic advantage is that the UHU stic ReNATURE is far more efficient in its application and more economical than comparable products. With the medium-sized UHU stic ReNATURE, users can glue approximately 200 sheets of A4 paper more than would be possible with its main competitor.

UHU stic ReNATURE is the result of several years of intensive development and testing to achieve an innovative, sustainable, safe and high quality product. UHU stic ReNATURE – the UHU initiative for a more sustainable world – is available in the shops as 21g and 8.2g variants since January 2014 and a new size (40g) will be launched from December 2014. www.uhu.de

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Fibers & Textiles

Nextgeneration fibre Terryl, an innovative, cost-competitive, biobased polyamide for textiles

C

athay Industrial Biotech (Shanghai, China) has recently introduced Terryl®, a new biobased polyamide 56. Many recent biobased chemicals projects have unfortunately encountered challenges competing with existing petrochemical routes in the market. Commercialization of Terryl, a costcompetitive fibre with excellent textile performance and a significantly sizeable market, may bring back some investor confidence to the industry.

Wallace Carothers invented the world’s first commercial synthetic fibre, polyamide 66 (PA66), in the 1930s. The polyamide structure was a synthetic analogue for the natural amide bonds in silk protein, replacing amino acids in silk with hexamethylenediamine (HMDA) and adipic acid produced by butadiene from naptha cracking. During World War II, PA66 served as a substitute for silk in parachutes and ropes, and its material properties and comfortable feel made it a preferred choice for women’s stockings. Polyamide 6 (PA6) was commercialized shortly after PA66, with a current combined global market over 6 million tons per annum.

Industrial biotech companies have attempted to commercialize production of biobased materials such as PLA, PHA, 1,3-PDO, BDO/PBS, and PTT. All of these examples are polyesters. The only commercialized biobased polyamides have involved longer chain monomers for the specialty long chain polyamide markets.

Amongst those, Cathay Biotech has taken over half the world’s dodecanedioic acid market within a decade, a rare example of a bioprocess successfully replacing the chemical process for an industrial chemical.

To address the much larger shorter chain nylon market, Cathay Biotech has developed proprietary technology to commercially produce biobased pentamethylenediamine (DN5), a novel five carbon platform chemical. The DN5 has been polymerized with adipic acid to make Terryl, a biobased polyamide alternative to PA6 and PA66 (collectively referred to as nylon for the rest of this article).

Terryl Molecular Structure PA66 is a high end textile fibre due to its many advantages such as strength, wear resistance, moisture absorbance, comfort, dyeability, and antistatic and flame retardant properties.

Nevertheless, there is still room for improvement. For example, PA66 spinning costs are significant on top of the resin cost, mainly due to gel formation during spinning and qualification issues for dyed fibre. Despite the fact that PA66 dyes more readily than polyester, variability in dyeing reduces qualification rate for the highest AA textile grade, which increases costs in the forms of product downgrade, additional processing, or wastage.

This variability is due to the structure of PA66, where chains line up with all internal amide hydrogen and oxygen moieties involved in hydrogen bonding (cf. Fig. 2). Because the internal hydrogen bonding sites in PA66 are all occupied, dyeing relies on the terminal ends of the polymer chains. These ends represent a small portion of the polymer and can be either amines or acids, making it a significant challenge to control end ratios for consistent dyeability.

PA66 can theoretically be modified on a structural level to improve performance properties while maintaining the advantageous mechanical properties by partially offsetting a portion of the internal hydrogen bonding without completely disrupting the chain alignments. This can be done by changing

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bioplastics MAGAZINE [05/14] Vol. 9

Fibers & Textiles O

H N

N H

O

Nylon 66 O

Terryl®

O

X N H

O N H

H N

N H

N H

H N O

O O

H N

O

O

H N

N H

O

O

O

O

H N

N H

H N

N H

O

O

H N

O

H N

H N

X O

O

O

X

N H

N H

Fig. 2: PA 66 and Terryl Molecular Structure. Nylon 66 internal H and O sites are all involved in hydrogen bonding, so dyeing relies on amine ends of the polymer. Terryl has unbound intemal H and O sites (represented by green X’s), providing better dyeability, moisture absorbance, and wicking.

the even carbon number diamine-even carbon number diacid nylon chemistry to an odd-even chemistry, e.g. replacing HMDA with DN5 (cf. Fig. 2). This would partially offset the internal hydrogen bonds, increasing the number of potential interaction sites for dye or water by over two orders of magnitude. This was predicted to improve dyeability, fluidity, moisture absorbance, wicking and by extension comfort while reducing gel formation and dyeing variability. The mechanical advantages such as strength and wear resistance of PA66 were expected to be preserved.

Based on the molecular structure, Terryl was expected to have superior performance properties and reduced fibre spinning costs compared to PA66.

Terryl Performance Properties Test data and customer feedback based on Terryl produced from Cathay Biotech’s initial 1000 tonnes per annum continuous production line confirmed the theoretical predictions. Terryl and nylon have comparable physical properties such as strength, density, and wear resistance.

Using existing PA6 equipment, Terryl was successfully spun at high speed into common specifications for tricot swimwear fabric (44decitex/12 filaments per centimeter, Fully Drawn Yarn) and knitted pantyhose (33decitex/12filaments per centimeter, Draw Textured Yarn). As expected, Terryl’s fluidity also made direct polymerization melt-spinning possible for significant fibre cost savings. Compared with PA66, Terryl fabric had superior elastic recovery, moisture absorbance and wicking (∆MR), comfort, and dyeability.

Terryl carpet fibres dyed as deeply at room temperature as PA66 fibre at high temperature. Under the same dyeing conditions, Terryl carpet, hosiery and seamless underwear dyed deeper and more color fast than nylon. By saving energy, chemical dye, and off-grade wastage, using Terryl improves both environmental footprint and fibre cost.

Unexpectedly, Terryl also had significantly improved antistatic and flame retardant properties. In fact, Terryl was found to be self-extinguishing.

PET

PTT

PA6

PA66

Terryl

density

1.40

1.33

1.14

1.14

1.14

Textile fiber strenght (cN/dtex)

3.8

3.0

4.2

4.5

4.3 - 4.4

Melting point (°C)

256

228

222

262

254

Wicking (ΔMR)

poor

poor

1.5 - 2.0 %

1.5 - 2.0 %

> 3.0 %

Fig. 3: Terryl Properties Comparison: Terryl is lightweight and strong like nylon, with superior wicking

%

Equilibrium Moisture Absorbance

9.0 — 8.0 — 7.0 — 6.0 — 5.0 — 4.0 — 3.0 — 2.0 — 1.0 — 0.0 —

Polyester

Nylon

Terryl

Cotton

Fig4: Terryl moisture absorbance closer to cotton than nylon, softer hand

20 — 30 — 40 — 50 — 60 — 70 — 80 — 90 — 100 — Temp (°C) Terryl

PA66

Fig. 5: Side by side dyeing trials for carpet fibre from Terryl’s and PA66. Terryl dyes at room temperature while PA66 requires high temperature

bioplastics MAGAZINE [05/14] Vol. 9

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Fibers & Textiles %

Limiting oxygen index

40 —

Nylon has been used in carpet for its superior dyeability and wear resistance. Polyester PTT from biobased 1,3-PDO has recently gained some traction amongst carpet manufacturers for its renewability. Terryl wear resistant and lightweight like nylon and contains higher renewable content than renewable PTT. According to biobased carbon content as determined per ASTM D6866, Terryl is 45% biobased carbon, compared to 27% for PTT made from biobased 1,3-propanediol.

35 — 30 — 25 — 20 — 15 — 10 — 5— 0—

Cotton

Polyester

Nylon

Terryl

Figure 6: Terryl is more flame retardant

% Renewable Carbon Content (ASTM D6866) 50 — 45 — 40 — 35 — 30 — 25 — 20 — 15 — 10 — 5— 0—

Nylon

PTT

Terryl

Figure 7: Terryl renewable carbon content compared to PTT from biobased 1,3-PDO and existing nylon.

Terryl’s elasticity, moisture wicking, comfort, antistatic, dyeability and flame retardant properties give it a potential performance advantage in numerous textile applications including carpet, hosiery, seamless underwear, and performance sportswear.

Future Prospects Based on these promising initial results, Cathay Biotech has begun expansion of Terryl production. Purely focused on Industrial Biotechnology with a successful commercialization track record and an international R&D team dedicated to the industry for over ten years, Cathay Biotech is the world’s first and to date only commercial scale producer of DN5. Terryl will be the first new broad-use polyamide since the invention of nylon 66 (PA66) and nylon 6 (PA6) in the 1930s. To promote Terryl, the China Chemical Fibre Association formally announced the inauguration of the Biobased Polyamide Fibre Material Technology Innovation Industry Alliance in March 2014. Led by Cathay Biotech, the industry alliance includes academic and industry leaders and will focus on research and development of Terryl applications.

Competitively viable today, Cathay Biotech’s DN5 technology still has much room for future optimization and improvement, whereas the mature chemical process for HMDA is close to theoretical yield leaving little runway for future improvement.

Biobased raw materials are also expected to be more sustainable both environmentally and economically than butadiene from petroleum in the long run. Large-scale commercialization of Terryl will hopefully highlight the importance of industrial biotechnology for the chemicals industry. www.cathaybiotech.com

By: Charlie Liu Vice President Cathay Industrial Biotech Shanghai, China

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Fibers & Textiles

A

pplications of biopolymers for technical fibres are a niche in the world of biopolymers. Nevertheless, we see an increasing request for the development of special yarns based on biopolymers. Key issue is to develop yarns with an attractive combination of (mechanical) properties and price.

Biobased polyamides In many applications PET or PA multifilament yarns are used for reinforcement. These yarns have a high tenacity (> 800 mN/tex) and a high melting point (above 200°C). For different applications it is preferred to replace these yarns by biobased analogues. Best known example is of course a yarn produced from PLA. But for several applications the thermal and chemical stability of a PLA yarn is not sufficient. In those cases biobased polyamides can be an attractive alternative.

Yarns from PA11 are already known in the market.

The API Institute also successfully developed a PA11 yarn, but after all practical application was hampered by the price of the polymer. For this reason biobased polyamides that are cheaper and can be converted in to technical yarns have been looked for. At the moment the best option seems to be PA10.10. Thermal and chemical properties are excellent and a tenacity of 400 mN/tex can be achieved. This is not yet the same level as for PET or PA yarns, but for many applications still sufficient.

High tenacity fibres www.api-institute.com

By: Bas Krins Director R&D API - Applied Polymer Innovations B.V. Emmem, The Netherlands

High tenacity PLA yarns Fig. 1 800 700 Tenacitiy (mN/tex)

Based on availability and price, PLA is the most investigated biopolymer. For technical application it is important to improve the tenacity. Compared to e.g.

PET the price is higher and the tenacity lower. This makes replacement of PET yarns by PLA difficult. So there is a continuous drive to reach higher tenacities. In order to achieve this the team at API Institute focussed on the polymer quality and spinning conditions as they both play an important role.

Improved polymer c

500

regular spinning grade

400 300 200

Anonther result is that spinning conditions play an important role. By optimization of the spinning conditions in combination with the polymer quality, production of high tenacity yarns on an industrial scale should be possible. The author is looking for opportunities to continue these developments.

Fig. 2

At the moment tests are running in a greenhouse to investigate the long term behavior at real conditions.

100 0 5 10 15 20 25 30 35 Elongation (%)

Creep (%)

PLA yarns show a significant creep behaviour, especially in wet environments and at increased temperatures. This limits the possibilities to use PLA yarns in e.g. greenhouses. By investigating the structural background of this phenomenon it was possible to improve the properties considerably. The results of a time-to-failure test at extreme conditions is shown in Fig 2.

Improved polymer b

600

As an illustration the graph in Fig 1 shows the difference with respect to the yarn properties of a regular spinning grade PLA multifilament yarn and grades with a reduced D-isomercontent. The data shown is obtained from small scale proof-of-principle trials.

Low creep PLA

Improved polymer a

75 Wet creep (10N/1000 dtex) at 41°C 70 65 60 PLA multifilament 55 50 45 Commercial 40 product based 35 on PLA tape 30 PLA multifilament special process 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Time (hour)

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Fibers & Textiles

Coloured PLA fibres The manufacture and dyeing of staple fibers made from PLA

A

n article in bioplastics MAGAZINE (06/13) described in detail the behaviour of IRT (infrared transparent) biodegradable plastic mulch films.

To summarize briefly the results: When exposed to strong sunlight or radiation, dark and black plastics heat up as a function of the radiation intensity. This effect is caused by the carbon black on the surface which absorbs radiation above 750 nm (nanometer). It also absorbs the UV (200-400 nm) and the visible radiation (VIS) in the range of 400-750 nm.

The term Cool Black describes the effect that dark/black surfaces do not heat up but rather feel cooler to the touch due to reduced heat absorption.

To reduce heat absorption there are three methods that differ based on the underlying principles of physics:

a) Reflection This involves using fillers to reflect radiation. These may include titanium oxide (to whiten), zinc sulfide, talc, chalk, barium sulfate, etc. Aluminum and silver (as a coating) may also be used.

This method is most popular due to the lower material costs and technical feasibility.

b) Interference This involves using mica-based materials. Mica (often referred to as glimmer) is a sheet silicate and consists of four separate layers or sheets. Incoming radiation is refracted and dispersed as it enters every individual layer or sheet. This results in reduced heat absorption and lower temperatures.

c) Thermal transmission IRT (infrared transparent) colouring refers to pigment mixtures which prevent or inhibit the complete absorption of energy (light) from the UV and the visible (VIS) range while at the same time allowing the energy from the near infrared (NIR) range to pass through to the greatest extent possible.

The material does not absorb the heat but only allows it to pass through.

Polymer Granart

PET

POY rund 48 f POY rund 80 f FDY rund 48 f FDY rund 80 f

single fibre yarn count

total yarn count

6-15 dpf 6-15 dpf 3-07 dpf 3-07 dpf

290-720 dtex 480-1200 dtex 140-340 dtex 240-560 dtex

PA

CF/BCF rund 48 f CF/BCF rund 80 CF/BCF trilobal 48 f CF/BCF trilobal 80 f CF/BCF trilobal 46 f

14-25 dpf 14-25 dpf 14-25 dpf 14-25 dpf 14-25 dpf

670-1200 dtex 1120-2000 dtex 670-1200 dtex 1120-2000 dtex 900-1600 dtex

PP

CF/BCF rund 48 f CF/BCF rund 80 CF/BCF trilobal 48 f CF/BCF trilobal 80 f CF/BCF trilobal 46 f

9-15 dpf 9-15 dpf 9-15 dpf 9-15 dpf 9-15 dpf

430-720 dtex 720-1200 dtex 430-720 dtex 720-1200 dtex 580-960 dtex

Fig. 3: Spinning machine Busschaert Eng. Spin Boy I (top) and corresponding technical titer parameters. (Source: Grafe)

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Both effects (transmission and reflection) result in lower temperatures for dark / black coloured surfaces. In both cases, the UV and VIS range should block all radiation (light, heat). Both organic and inorganic pigments may be used, however carbon black is no longer allowed. The formulations for transmission differ than those for reflection. Which mixture is chosen also depends on the carrier polymer, e.g. amorphous, crystalline or semi-crystalline.

The application of these effects on PLA-based staple fibers is an ongoing subject of internal tests.

The following section describes the technical equipment for the production of staple fibers in the lab. This equipment was used for tests on the spin and colouring behaviours of PLA materials and on the application of IRT formulations on PA6 at first.

The spinning results depend on the chemical, rheological and physical parameters of the PLA used. Due to technical reasons (adjustment of parameters) the facility was always

IMAGINE – If there was an easy way to identify your polymer. started up with PE. The following types were used: Natureworks PLA Biopolymer 2051D, PLA Ingeo 3052 and PLA Revode 190.

The same yarn type was used for all variations: BDF/CF, titer: 1300 dtex/ 16 dpf, with plates for 2 x 40 holes without texturing.

The pull-off speed of the winder was 1000 meter/min. The temperature program varied between 160 (Zone 1) and 200°C (Zone 5).

With the Ingeo material, the spinning process went very well, even with the use of spinning oil. The wind-up process onto the coil went smoothly.

The Revode material flowed well from the nozzle. It could be sucked up and wound around the godets very well. However, as soon as spinning oil was used, problems developed with the winding. If spinning oil was not used, the individual filaments would separate on the godets. In general, the stretching was too low and not ideal. It was not possible to draw the yarn on to the coil.

The Natureworks 3251D material was used as the masterbatch carrier for colouring the PLA yarns. The colours yellow and brown were tested.

The following observations were made: Without spinning oil, the take-up on the godet was very good but the multifilaments still stuck a bit. The yarn bobbins had a lot of lint and were more difficult to wind and unwind. Unfortunately, the spinning oil was necessary in order to prevent static charges and is therefore recommended.

The task was to develop a spinnable formulation for the production of IRT (infrared-transparent) staple fibers. From the 3 synthetic polymers for staple fibers (PP, PA and PET), PA6 was chosen as the reference polymer. The titer settings were 1067 dtex / 13 dpf. Further tests will use the basic formulation, but with PLA as the carrier material.

Socks and knitted stockings were knit from the yarn rolls providing a thermal simulation test. PA6.6 socks, coloured with carbon black, were used for comparison.

We made it possible.

The new DSC 214 Polyma.

More than a DSC. Your Solution.

The socks were then radiated for approximately 5 minutes with 4 x 1000-watt infrared lamps. The surface temperature of the socks was measured following radiation. The results are shown in the figure below. 

Granulate Extruder

Spinning pump

ore: 221 ut m o d /n22 Fin .com h c s .netz www

Spinnerets Filter

Cooling duct

Stretching

Texturing

Winder

Fig. 1: Melt-spinning set-up (Source: Grafe)

NETZSCH-Gerätebau GmbH Wittelsbacherstraße 42 95100 Selb Germany Tel.: +49 9287 881-0 Fax: +49 9287 881 505 at@netzsch.com bioplastics MAGAZINE [05/14] Vol. 9

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Hopper

Spinning head

Extruder

Zone 1

Zone 2

Temp (°C)

[U/min]

Speed m/min

Speed

Godet 4

Potentiometer

Zone 3

Temp (°C)

m/min

Zone 4

Rear

Spinning pump

Front

[U/min]

Die plate

Zone 5

Temp (°C)

[°C]

Temp (°C)

Godet 3

Potentiometer

Cooling duct

Extruder Speed

Temp [°C]

Potentiometer

Temp(°C)

Cooling air speed Speed

Texturing

Godet 2

m/min

Cooling-air Temp (°C)

Potentiometer Potentiometer Temp(°C)

Speed m/min

Winder

Potentiometer

Cooling-air

Chill roll

Stand by button

Godet 1

Temp (°C)

Potentiometer

ok Programming

Spinningoil

Temp(°C)

Potentiometer

Spinning pump

Temp

Extruder

on

Temp

Spinnp.

on

off

Speed Spinning pump

Extruder

off

The first three curves (from top to bottom) show the thermal absorption behaviour of the carbon-black coloured PA6 yarn. The varying absorption behaviour is due to the varying concentrations of carbon black. The carbon-black coloured yarns heat up faster than the IRT coloured yarns within the same time period. A uniform end temperature (approx. 40-55°C) is attained after approximately 100 seconds.

Spinning pressure control (bar)

Potentiometer

Fig. 2: Flow diagram of spinning machine (Source: Grafe)

www.grafe.com

By: Carlos Caro Project leader GRAFE Advanced Polymers GmbH Blankenhain, Germany

PA6 heats up faster than PA66.

The degree of (IRT) thermal transmission (lower curves) depends on whether there is enough colourant and whether the UV and VIS ranges are completely or partially absorbed. The heat-up speed in the same time period is much lower, the uniform end temperature of maximum 40°C is attained only after 4 minutes (in comparison to 100 seconds for the carbon-black coloured yarn).

The results show that the temperature differences between IRT yarns and carbon-black coloured yarns are between 10 and 15°K. One must, of course, consider the concentrations of carbon black and of IRT active colourants in the yarn.

Further work is needed, e.g. formulations as compounds (dosing 100%) or as masterbatch (dosing 7-10%), optimization of measuring methods to determine thermal absorption under conditions of use and finally using the formulation for PLA applications.

Generally speaking, the cooling down effect is good.

However, this new process places very special technical demands on the formulation, fiber spinnability and measuring methods. 

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60 50 40 30 20

PA6 PA6 PA6.6 Cool-1 Cool-2

10 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Time in sec (*10)

Fig. 4: Increase in temperature as a function of time (Data source: Nylstar Spain)

Fibres & Textiles

New biobased monofilaments T

echnical textile market is very traditional and very high demanding, in terms of performances, quality level, prices and compliances. The traditionally used polymers, at least for what is related to the monofilament extrusion and spinning, are all coming from oil (Polypropylene, Polyesters, Polyamides are the main ones).

In 2009 Sider Arc (Cornaredo, Italy) research and development team started working on new polymeric materials for monofilament spinning, looking towards the direction of bio or green.

The aim of this activity was to select new materials (coming from renewable resources) and try to get monofilaments with the same performances of the standard oil derived materials.

The first polymer Sider Arc started working with was PLA or polylactic acid. The reason for this choice can be found in its chemical nature: the material is coming from renewable resources but it’s a thermoplastic biopolymer (therefore available on the market and amendable by additives). The hydrolytic degradation leads to products that can be easily assimilated by fungi or bacteria, making the difference in specific end-uses.

PLLA polymer (coming from the L-lactide isomer) is the one that Sider Arc started to process, due to the higher cristallinity (about 37%) and to the slow degradation process.

In terms of polymer processing, the critical point for PLA extrusion is directly related to the materials sensitivity to hydrolysis: drying must be accurate and water content has to go down to ppm level, otherwise the molecular weight will be too low, and the melt viscosity won’t be enough for the spinning.

Rheological behaviour can be considered comparable with polyolefins, with a little bit lower melt elasticity.

Crystallization rate, temperature control in the stretching phase and thermo fixation are, together with the selection of the right monofilament spin finish, are the most important issues for extrusion and polymer processing into yarns.

2.500,00

Biolene monofilaments, made with 100% PLA polymer, are part of Sider Arc’s range of products since end of 2009, the actual diameter range is from 50 to 200 µm, mainly developed for the medical market, for applications such as tissue engineering /recovering of healing tissues, where the advantage of a material which is radio transparent and not toxic is required.

Further applications for these monofilaments are in the spacer fabrics market (3D fabrics), due to the properties of stiffness and elastic recovery, or in hot liquid filtration and tea bags (finest counts) and in the 3D printers technology (coarser counts).

In the last two years Sider Arc started evaluating also new sources for the polymeric materials.

Green HDPE (made from sugar cane based bio-ethanol): The idea behind is to have monofilaments with the same performances of the yarns coming from oil-based polyethylene, but obtained with ecological processes.

The development work done by Sider Arc R&D staff in this case is with the suppliers (polymer producers) to have the right grade for monofilament extrusion, and on the spinning – stretching process to get the same mechanical parameters and dimensional stability that can be achieved with the standard grades.

Applications for these monofilaments can be found in shading and protective nets, coated nets for pipes (protection against corrosion), ropes, clothes labelling.

The described developments (as well as other developments with e.g. recycled PET) are starting from tradition, but they’re running in the direction of green, with the aim to grant to the technical textile market the highest possible quality and the best possible performances, but with sustainable monofilaments. MT www.siderarc.com

tensile stress [cN]

Comparison between HDPE monofilaments coming from oil derived grades and from green sources. Tensile test on 0.25mm diameter monofilaments.

Fossil based HDPE chips 2.000,00

1.000,00

Green HDPE chips

500,00 0,00

Elongation [%]

1.500,00

0 10 20 30 40 50 60 70 80

bioplastics MAGAZINE [05/14] Vol. 9

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Fibers & Textiles

Raw materials supply level

Extrusion / processing level

Fibre exit and fibre post processing

Casein-based polymers Qmilk on the road to success

A

bout a year ago, bioplastics MAGAZINE reported about Qmilk®, who have developed an innovative and unique technology for the production of textile fibres made from the milk protein, casein. The development includes textile fibres for various applications including clothing, home textiles, industrial applications, medical equipment and automotive equipment. In addition the company is working on different grades for non-fibre applications. bioplastics MAGAZINE visited Qmilk in Hanover, Germany.

How it started

The raw materials

The initial idea was to use casein from raw milk that is no Ionger suitable for sale and, under the current legislation cannot be used as food. ln Germany alone every year 1.9 million tonnes of milk must be disposed of. Globally more than 100 million tonnes of milk are wasted every year. This so-called non-food milk is the base raw material for Qmilk.

“Currently we are getting non-food powdered milk from the dairy companies,” explains Anke Domaske founder and CEO of Qmilk. “But the in the long term we will collect the milk directly from the farmers. A special company Qmilk collect is already founded and preparing its start of operations. “We plan to start up our own casein plant in 2016,” says Anke Domaske.

After their first approaches with fibres made at the Fibre Institute Bremen (Germany) Qmilk collected some investors money and started to set up a production in a 3000 m2 building in Hanover. This includes offices and laboratories and a small Tech Center where besides some injection moulding machines a small Leistritz corotating twin screw extruder is installed to develop and improve recipes.

Basically when milk gets contaminated or else no longer usable for food, it is collected in special tanks, either still on the farm or at the dairy company. Then the milk turns sour and the two phases of the sour milk: whey and curd are separated.

In further steps the curd is being processed to powdered milk, containing the casein which is later being used to make the biopolymer.

The pilot unit

And what about the fat and the milk sugar? Also this will be used. “We strive to find the maximum utilisation of every part of the waste stream,” explains Ines Klinger, project manager at Qmilk.

Brand new and quite impressive is the huge pilot processing unit (see photograph). This three stories high unit includes

20

all to produce up to 1000 tonnes per year of either fibres or granules for other applications. The process starts on the third level with the in-feed boxes for the milk powder, and dosing of other ingredients. One level down a 30mm Leistritz twin screw mixes and kneads the recipe which is then extruded either into the spinning dies or a granulator. On the ground floor the spun fibre-filaments are finally collected to strings and stretched via a number of heated rollers.

bioplastics MAGAZINE [05/14] Vol. 9

Fibers & Textiles The fibres The pilot plant is being used to further develop and optimize the recipes and to develop new grades. For the fibres currently counts of 3.3 and 6.1 dtex are the standard.

“But we also succeeded in making 1.7 dtex,” Anke tells us proudly. Qmilk will mainly produce staple fibres and continuous filaments. The conversion of the staple fibres into yarns will then be performed by the customers.

Dyeing of the fibres is absolutely no problem. “On the contrary,” says Ines Klinger, “casein it a substance that is very good miscible with pigments.” That is why casein is also commercially used in the paint industry for example.

Qmilk is strongly working on getting the plant to higher outputs, as the company is currently handling more than 300 requests from textile customers that are waiting in line to buy the casein based fibres and yarns. About half of the projects are interested in using 100% Qmilk fibres, the other 50% will use it in blended fabrics.

Milk powder infeed

And clothing is by far not the only field of applications.

Besides home textiles and technical textiles even applications such as reinforcing cords in tires are within the scope of investigation.

The plastic But the Qmilk-polymer can not only be used for the spinning of fibres. The pilot plant allows moving the spinning dies aside and installing a granulator instead.

Depending on the recipe and the processing parameters a wide variety of plastic grades, with different property spectrums can be produced. Certainly this is a wide field for investigation and development.

Both fibres and plastics have in common their very special properties of being made from a biobased waste stream (milk) showing antibacterial behaviour inherent flame retardancy good chemical resistance a (comparably) low density of 1.127 g/cm3 a low melting point (energy advantages when melting and cooling, and thus in short cycle times)

Outlook Anke Domaske and the growing team are enthusiastic and work hard on the progress. They are planning to have the pilot plant on full production (1000 tonnes/a) by early next year. The continuous development of new recipes and the optimization of the processes is another big target. “And we are always striving to make Qmilk even more sustainable,” as Anke points out. The use of the milk’s own water, which is currently still wasted, as process water for Qmilk, is just one example.

Anke Domaske at her twin screw extruder

By: Michael Thielen www.qmilk.eu

bioplastics MAGAZINE [05/14] Vol. 9

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Fibers & Textiles

Green high performance textiles

W

ith its long-standing experience of more than 60 years, Arkema is the world leader in castor oil chemistry. Based on this chemistry, the company produces Rilsan® polyamide 11 (PA11), the only high performance polyamide entirely derived from a 100% renewable and ecological raw material. Arkema developed a large range of PA11 grades, adapted to specific, high demanding applications, such as automotive industry, oil production and sports, but also, textile applications.

From the popular fibre to the era of green chemistry PA 11 was first synthesized in 1942 and patented in 1947.

Its initial applications were right in the textile industry, which used Rilsan fibres to make bathing suits, socks and stockings that “will last for ever”, as well as permanently pressed shirts and undergarments. Until the 1970s, the product was as popular as nylon, its main competitor. Then, the product gradually disappeared from the textile market place to serve industrial applications requiring high resistance.

But to target new markets in which ecological challenges and the quest for technical performance have become a genuine concern and a differentiating factor, Arkema has recently re-marketed a special grade of Rilsan to be spun into high performance fibres. These technical fibres combine a unique bunch of advantages: light weight, soft touch, dimensional stability, bacteriostatic properties (no need for a specific treatment), abrasion and chemical resistance, non-iron - or even lower sweat with its low water uptake.

Rapidly, consumer products manufactured with innovative textiles based on Rilsan fibres combining both the environmental and the technical benefits, appeared on the market.

As an example the French company MONNET, the famous sports and outdoor socks brand, has developed ultra tough sports socks made of Risan fibres, designed jointly with SOFILA, the French nylon yarn spinning specialist. These ski socks are typically very soft to the touch, lightweight, comfortable and offer natural bacteriostatic and thermo-regulating properties. Tested by a large number of manufacturers within the textile sector, Rilsan PA11 fibres from SOFILA were soon to be used in many other hosiery brands.

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In another sector, UNITIKA, a Japanese company specializing in technical fibres for the manufacture of garments and luggage, have contributed to the design of a new luggage range entirely manufactured from PA11 fibre.

Thanks to Rilsan, the outstanding characteristics of these bags include superior sturdiness and wear resistance.

Pebax® Rnew : a bio-sourced elastomer for non woven textiles Another innovation based on Arkema’s polyamide 11 expertise is Pebax Rnew, a polyether block amide, partially bio-sourced. With this new elastomer containing between 20 and 90% renewable raw materials, Arkema promises to open up revolutionary opportunities for the design of durable elastomer nonwovens for superior performance, lighter weight, and ease of assembly.

The high elongation and high energy recovery of Pebax Rnew nonwoven material is produced with the meltblown process. As a meltblown web, Pebax Rnew can be used to make roll goods with a large width which are then cut into narrow widths. These nonwovens are suitable replacements for many narrow elastic and spandex-containing woven or knitted textiles. In a waistband for example, 200 g/m² Pebax Rnew webs afford total recovery when stretched 100% repeatedly, and elongation at break of up of 600%. They also have excellent hot-wash and dry cleaning resistance.

Melt spinning of nonwovens is a rapidly growing process, and is a simple and inexpensive approach to converting polymer directly into roll goods.

“Greener” materials in terms of resources and energy consumption In addition to their renewable source, Rilsan and Pebax Rnew production are characterized by 15%, (on average) lower fossil energy requirements than for petroleum-based polyamides. The CO2 emissions related to the production of Rilsan and Pebax Rnew are on average 75% lower.

This environmental footprint argument is seriously considered by more and more players that assess the environmental impact of their manufactured products. www.arkema.com

Fibres & Textiles

Rayon and more – Biobased chemical fibres

By: André Lehmann, Johannes Ganster, Hans-Peter Fink Fraunhofer Institute for Applied Polymer Research IAP Potsdam, Germany

T

he first chemical fibres manufactured on an industrial scale were in fact biobased and date back to 1905 when Courtaulds Fibres in the UK started the production of viscose fibres. They were wet-spun from chemically modified high purity wood pulp with subsequent regeneration of the pure cellulose in fibre form. Even today, they are the most important family of biobased chemical or man-made fibres.

With the introduction of nylon (polyamide) fabric at the 1939 New York World’s Fair, oil-based fibres set out to conquer the world markets being produced by the much more effective melt spinning technology. Today, with the increasing number and availability of biobased or at least partially biobased thermoplastics, new opportunities for melt-spun biobased fibres arise, notably with poly(lactic acid) and, again, with polyamides.

Even more on the high-tech side, the possibilities to produce less expensive carbon fibres from biobased feedstock, namely lignin-containing precursor systems, are being explored in the US and Europe. Both melt and solvent processes are followed for precursor spinning.

Cellulose man-made fibres Viscose fibres have an ever increasing market share with over 5 million tonnes p.a. today and are used mainly for textile applications. An alternative method to manufacture cellulose man-made fibres is the Lyocell technology introduced in the 1990s. Today the main producer of Lyocell fibres is Lenzing AG (Austria) with an annual output of 222 kt for textile applications. Cellulose acetate fibres, dry spun from acetone solution are mainly used for cigarette filters.

Technical viscose fibres, often called rayon, amount to some 100 kt mainly used for rubber good reinforcement, in particular fast running and run-flat tyres. For these

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so called Super 3 tyre cord yarns typical (single filament) tensile strengths are around 850 MPa with moduli in the range of 20 GPa. With a density of 1.5 g/cm³, light weight construction potential in composite manufacture is offered by this kind of biobased fibres. The suitability of these fibres for reinforcing both petro- and biobased thermoplastics has been demonstrated in [1]. Benefits versus glass fibre reinforcement are found mainly in improved impact behaviour, reduced weight, less abrasion and better recycling.

Using various alternative methods it has been demonstrated that cellulose technical fibres can be manufactured with drastically improved tensile properties.

None of these methods, however, is currently in production but there shall be named a few. On a pilot plant scale, fibres with 1.3 GPa strength and 45 GPa modulus were developed

by Acordis (NL) at the beginning of this century spun from an anisotropic super phosphoric acid solution [2]. Less critical solvents can be used in the combination of the Lyocellmethod with the cellulose carbamate derivative leading to liquid crystalline solutions to be dry-jet wet spun into fibres with strengths up to almost 1 GPa and moduli in the range of 50 GPa [3]. Most recently, in the group of Prof. Sixta (Aalto University, Espoo Finland) ionic liquids have been employed to spin the so-called IonCell fibre with properties in between Lyocell and Bocell [4].

Melt-spun fibres Melt spun fibres are by far the most dominating in the world market. The annual output of polyester (polyethylene terephthalate – PET) fibres alone amounts to more than 41 million tonnes, while the figures for nylon (polyamide - PA) and polypropylene (PP) fibres are 3.9 and 2.8 million tonnes, respectively [5]. One of the main reasons for that is doubtlessly

Fibres & Textiles the high efficiency of the manufacturing process. Today, spinning speeds of over 8000 m/min are reached which is at least 40 times faster than what is attainable with solution spinning. Moreover, no solvent must be recycled and from the spinning dope (in this case molten thermoplastic) 100 % fibre product is obtained. However, solution spun cellulose fibres (viscose) have unique properties, e.g. in terms of moisture regulation and wear comfort which warranties their (increasing) share in the world fibre market.

Traditionally, all melt spun fibres are based on fossil feedstock. However, with the progress made in synthesizing biobased and partially biobased thermoplastics, as well as their increasing availability on the market, corresponding fibres can be melt-spun in principle. Of course, many requirements have to be met, e.g. in terms of molecular weight distribution, processing additives, stabilisers etc. in order to produce a so-called spin-type polymer. Efforts have been and are being made to provide such types depending on the market demand.

Fig. 1 View on the 3k wet-spinning line at Fraunhofer IAP

Pioneers in this direction are, in the PLA-sector, NatureWorks who offer spin-types which can be used for textiles, for carpets (BCF-yarn) or even for meltblownnonwovens. Advantages to be mentioned are, depending on the specific application, low moisture absorption and high resistance to ultra violet light and biodegradability.

Mechanical properties are typically in the range of 400 MPa strength and 6 GPa modulus. Moreover, PLA and PLA-copolymer fibres are used in surgical applications as suture materials taking advantage of their bio-compatibility and metabolisability in the body.

Polyamide fibres, mainly from PA6 and PA6.6, play an important role in the textile sector for apparel, carpets, and other mostly woven fabrics. In the technical field, monofilaments for brushes, fishing lines etc. are produced.

The polyamide family provides a good example for the introduction of biobased raw material. For decades, PA11 has been produced on the basis of castor oil. More recently, partially biobased PA6.10, PA10.10, and PA4.10 have been on the market. Their application in fibre form is still somewhat limited. PA11 is used for eyelash brushes while PA6.10 is found in carpet applications. Properties of the fibres depend of course on spinning conditions and polymer recipes, molecular mass etc., but also on the position of the specific polyamide in the polyamide family. For example, due to its more aliphatic character, PA11 has a significantly lower moisture absorption and a better chemical resistance than PA6 or PA6.6. The possibility of spinning micro-fibres from PA11 with diameters less than 10 Âľm has been demonstrated at Fraunhofer IAP (Fig. 2).

Fig. 2 SEM-photograph of melt-spun PA11 micro-fibre prepared at Fraunhofer IAP

Fig. 3 Carbonization oven at Fraunhofer IAP

In the class of aromatic polyesters, poly(trimethylene terephthalate) (PTT) should be mentioned with 37 % biobased content from the 1,3-propanediol unit. The commercial product SoronaŽ by DuPont™ gives fibres with good softness, comfort stretch and recovery as well as moisture management which find applications in carpets, apparel and automotive flooring.

While PLA is a sort of new polymer type, and PA6.10 etc. resemble their petro-based relatives, the third category in this series are so-called drop-ins. They are chemically identical to completely petro-based polymers but their feedstock is completely or partially biobased. To this category belong biobased PE (Braskem) produced with bio-ethanol

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Fibres & Textiles from sugar cane, and Bio-PET used by CocaCola for their Plant Bottle, where only the 30 % ethylene glycol component is made from bio-ethanol. Although to our knowledge commercial fibre applications are not yet reported, the potential is obvious e.g. for commingled or co-woven fibre composites (PE) or traditional fibre applications for PET.

Carbon fibre precursors No other material provides better material properties for lightweight constructions (automotive industry - especially electro cars, wind turbine fan blades, sporting goods etc.) than carbon fibres. By a slow heat treatment of an organic precursor fibre up to temperatures of 2500 °C (in some cases 3000 °C) a special arrangement of stacks of hexagonal carbon layers oriented along the fibre direction is formed.

One of the first precursors were rayon fibres. However, low carbon yield (20 %), high carbonization temperatures and the need of high temperature stretch graphitization reduced their market share to less than 11 %.

Nowadays, more than 85 % of the carbon fibres are based on polyacrylonitrile (PAN) from fossil feedstock. Thus, the price of the PAN directly depends on oil and gas prices.

Several studies underline the enormous growth of the carbon fibre market which is expected to double within five years.

To establish carbon fibres in the mass market, the current price of least 15 €/kg has to be significantly reduced. One possibility could be the use of lignin [6].

fibres. As a side product of the wood pulping process lignincontaining liquors are separated on a million tonnes scale per year. The challenge is to shape the extracted lignin into fibres of appropriate fineness as well as morphology (no voids) and provide mechanical properties, which at least allow the further continuous stabilization and carbonization.

Brittleness is crucial point here. So far, reported properties of the ex-lignin carbon fibres are in the range of glass fibre values [6] yet with density advantages of 30 %.

10 €/kg for a mid-tech carbon fibre is considered by many OEMs as a break through value for mass applications in the automotive industry. With this or similar scenarios in mind, several alliances between research organizations, carbon fibre manufactures, automotive industry as well as pulp producers have been formed demonstrating the huge interest in developing a cost optimized lignin based carbon fibre filling the gap between glass and carbon fibres.

Conclusions The use of biobased chemical fibres started over 100 years ago with viscose (rayon) and continues to grow in this field of regenerated cellulose (viscose, Tencel). Apart from cellulose, more and more biobased building blocks and thermoplastics, notably PLA, other polyesters (e.g. PTT) and polyamides enter the market which can be melt-spun into fibers with interesting properties. Even for high-tech products like carbon fibres, the use of biobased feedstock, here lignin, is intensively pursued, yet on the research and development level. p C

The existence of cyclic structures combined with a high carbon yield, which is comparable to PAN, offers the potential of lignin as a precursor material for carbon

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References

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[1] Erdmann, J., Ganster, J., Fink, H.-P., PLA meets Rayon – Tough PLA compounds reinforced with cellulose rayon for injection moulding. Bioplastics MAGAZINE [03/12] Vol 7, 22-25.

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[2] Northolt, M.G., Boerstoel, H., Maatman, H., Huisman, R., Veurink, J., Elzerman, H., The structure and properties of cellulose fibres spun from an anisotropic phosphoric acid solution. Polymer 42(2001), 8249-8264.

[3] Fink, H.-P., Ebeling, H., Rihm, R., Fibre Formation from Liquid Crystalline Solutions of Cellulose Carbamate in N-Methylmorpholine-N-Oxide. Proceedings of the 7th Int. Symp. “Alternative Cellulose- Manufacturing, Forming, Properties”, 2006, Rudolstadt, p. 13-23 [4] Sixta, H., Progress in Regenerated Cellulose Fiber Production. Workshop on Cellulose Dissolution and regeneration, Göteborg, December 3rd, 2013 [5] Man-made Fiber Year Book 2013, Deutscher Fachverlag, October 2013, 4 [6] Fink, H.-P., Lehmann, A., Ganster, J., Bio-based carbon fibers – efforts and prospects. Technical Fibers International, Man-made Fiber Year Book 2013, Deutscher Fachverlag, October 2013, 44 www.iap.fraunhofer.de

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From Science & Research

Next generation chemical building blocks and bioplastics

T

EU projects SYNPOL & BioConSepT – Two approaches, one goal!

Building block succinic acid succinic acid succinic acid succinic acid succinic acid succinic acid succinic acid succinic acid succinic acid n-butanol maleic acid isobutanol farnesene 3-hydroxypropionic acid 3-hydroxypropionic acid butanediol butanediol

he Bioeconomy Strategy published by the European Commission in 2012 promotes the use of renewable resources from land and sea for a post-petroleum economy to build an innovative, more resource-efficient and competitive society that aims to optimize the trade-off between food security, the sustainable industrial use of renewable resources and environmental protection. This strategy promotes the production of renewable biological resources and conversion of these resources and their waste streams into value added products, such as chemical building block compounds and bioplastics.

European research is helping to gather the fundamental knowhow required to develop reliable processes for development and processing of feedstocks from disparate and novel sources.

To some extend this is done through two EU-funded projects, BioConSepT and SYNPOL, due to conclude in 2015 and 2016, respectively.

Companies BASF, Corbion DSM, Roquette Bioamber, Mitsubishi, Mitsui, Faurecia Bioamber, PTT-MCC Biochem Bioamber, Lanxess Myriant, PTT chemical Myriant, Uhde Bioamber, Cargill Bioamber, Dupont, Evonik Granvio, Solvay Novozymes, ADM Gevo, Lanxess Amryis, Kuraray Novozymes, BASF, Cargill OPXBIO, Dow Novamont, Genomatica BASF, Genomatica, Toray

Non-food competing feedstock materials The need for alternative resources, because of the finite sources of fossil reserves is generally accepted. In order to become a competitive alternative on the market, the price of e.g. bioplastics for a certain application must be in the same range as the competing petroleum-based plastics, which currently, despite of the volatile oil prices, is not the case.

The most promising approach to make bioplastics and chemical building block compounds economically more competitive is the use of waste streams as a source, such as household waste or sewage sludge loadings from water treatment plants that now end up in landfills.

The two European Union KBBE projects SYNPOL and BioConSepT aim to integrate production (fermentation) and

Table 1: Industrial Alliances and Partnerships for the Production of Bio-based Building Block Chemicals

Bio or chemical conversion plus (integrated) separation & purification

+ Robust micro-organisms and enzymes

© TNO

2nd generation feedstock

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Fig. 1: Integration of bioconversion and separation technology for the production and application of platform chemicals from 2nd generation biomass (BioConSepT) Demonstration at industrial scale

© TNO

Applications

From Science & Research

Recycling

Degradation

Waste feedstocks

CO2 + H2

Reactor design New biopolymers

Syngas production

Degradation

Biopolymers synthesis

Strain design

PHA downstream process

Pilot plant

Fig. 2: The SYNPOL platform

separation technologies for the cost-effective commercial synthesis of high added-value chemical building blocks and bioplastics. While SYNPOL uses (bio)waste to produce syngas, which is then fermented, BioConSepT focuses on the use of so-called second generation feedstocks like wood (lignocellulose) and non-edible oils and fats.

The BioConSepT project: From Plants to Plastics BioConSepT (Bio-Conversion and Separation Technology) aims to demonstrate the technical and economic feasibility of white biotechnology processes where 2nd generation biomass will be converted into chemical building blocks. For producing bioplastics two types of biomass, which are not competing with the food chain, are being evaluated: lingocellulosic biomasses, and non-edible fractions of fats and oils.

The main achievements expected for BioConSepT are to develop the robust enzymes and microorganisms suited for recalcitrant 2nd generation feedstocks, to reduce equipment costs and the number of process steps by the integration of bio- and chemical conversion and highly selective separation technologies; and by proving the suitability of the produced platform chemicals for industrial application by demonstrating integrated production chains from 2nd generation feedstocks to platform chemicals at industrially relevant scale.

BioConSepT will bring novel technologies from lab to pilot scale by high-level applied research. The large industrial parties and SMEs expect new products, processes, and services with a potential value of hundreds of million Euros.

Integration Along the Value Chain BioConSepT was established in line with the newly developing concept within the chemical industry of emerging partnerships and alliances. In this vision, individual

partners focus on their own strengths but benefit from their collaborations along the business chain from the source to the consumer. Compared to the food industries, where most chains are owned by single companies/industries, this situation is clearly a new development and is specific for the chemical industry. Table 1 presents some of these partnerships and alliances - including biotechnology startups and large industries - for a few common chemical building blocks. BioConSepT aims to demonstrate the feasibility of an integrated chain approach, which is regarded as the basis for the next generation of industrial biotechnology processes.

Note: websites of each Alliance or Partnership can be found at www.bioplasticsmagazine.de/201405 The technological objectives of BioConSepT focus on all individual aspects along the production chain, from plant biomass to pilot plant (Fig. 1). BioConSept focusses on dicarboxylic acids like itaconic acid and furan-dicarboxylic acid for use in bioplastics.

The SYNPOL project: Introduction of novel technologies and biotech approaches in Europe Complex organic waste raw materials - such as municipal and industrial waste - which are pyrolyzed, gasified and then fermented by microorganisms, are the starting point of the SYNPOL (Biopolymers from syngas fermentation) project, which aims at producing 100% biodegradable bioplastics (PHA) and chemical building block compounds such as butanediol, succinic acid, hydroxybutyric acid and crotonic acid.

Pyrolysis and gasification are widely regarded as the main viable large-scale options for (bio)waste disposal.

Gasification, combined with biosynthesis processing systems such as fermentations, has become a promising industrial

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From Science & Research Fig. 3: The SYNPOL roadmap

procedure. Research related to fermentative production of chemicals from CO/CO2 has greatly increased in recent years The fermentation of synthesis gas (syngas) has become an attractive technology for the production of biofuels for which processes are already available from companies in the USA, New Zealand and Canada, but not in Europe. Therefore, SYNPOL´s technology (Fig. 2) aims to open a new window for the rational design of an innovative European process to convert complex wastes into new biopolymers also using novel processing technologies such as microwave-supported pyrolysis. To this end, SYNPOL will establish an integrated platform for biopolymers production. Reduced energy input and optimised purification of waste streams will contribute to the economic viability of end products.

According to the objectives roadmap of the project (Fig. 3), bacteria will fermentatively produce bioplastic basic compounds, the so-called polyhydroxyalkanoates (PHA), out of the C1 carbon fractions of the syngas. Different prototypes of biopolymers and their blends will be prepared from SYNPOL. Finally, PHA, plasticizers and nanoclays will be further assessed for their physical and mechanical properties, for their appropriate end use in different sectors of the bioplastics industry.

The PHA material has wide applications as it can then be formed and moulded into almost any given design.

Two projects with big expectations From the perspective of both projects, important progress will be achieved in terms of combining the environmental benefit of future-oriented biopolymers and chemical building blocks with the economic viability of their production. This should finally facilitate the decision of responsible policy makers from agriculture, the waste-generating industrial sectors and from the polymer industry to break new ground in sustainable production. In the future, production of bioplastics and chemical building blocks from different biomass streams applying gasification and/or separation technology should be integrated into existing process lines of biotechnological bioplastic companies, where the feedstock material directly accrues. By taking profit of synergistic effects, this can be considered a viable strategy to minimize production costs and leads to realize the project´s vision of taking organic biomass (waste) streams and turning them into commercially useful products that generate both an environmental and economic benefit. The two projects therefore offer timely strategic actions that will enable the EU to lead modern and futuredriven technologies for organic waste revalorization and sustainable biopolymer production on a global level. www.bioconsept.eu www.synpol.org

SYNPOL aims to convert complex waste into new costefficient biopolymers in three major steps: Pyrolysis of different waste streams to produce synthesis gas (syngas); Fermentation of the carbon fractions of the gas (CO and CO2) by using different natural and recombinant autotrophic bacteria to produce chemical building blocks and PHAs; Synthesis of biobased plastic prototypes (blends) with well-defined structures and improved properties for wide commercial use, through chemical and enzymatic catalysis by utilizing the monomers and polymers produced during syngas fermentation.

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By: Oliver Drzyzga, Auxiliadora Prieto, José Luis García CIB-CSIC, Madrid, Spain (for SYNPOL) Peter J. Punt, Ernst Geutjes, Dirk Verdoes TNO, Zeist/Delft, The Netherlands Ellen Fethke RTD Services, Vienna, Austria (for BioConSepT)

Materials

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High barrier in-mould labelling

iko Pac (Turnhout, Belgium) is a packaging expert in injection molding of plastics for food packaging. Their slogan is “thinking out of the box”, and this is exactly what they did when they took part in this joint development project – a joint development that involved BASF with its Ecovio® biopolymer, Druckhaus Rahning (Bünde, Germany) for the manufacturing of the IML labels, and Taghleef Industries’ for the supply of NATIVIA™ PLA film.

The working group used existing and well established technologies, designed for use with standard oil-based plastics, to produce a biobased and compostable injection molded thin-wall and in-mold decorated pot for food packaging. The major step ahead was using the new, biodegradable and bio-based Ecovio IS for injection molding, and the bio-based and compostable metallised Nativia PLA film for the barrier label.

Ecovio and Nativia are widely used in packaging applications.

However, a known characteristic of both materials is their poor barrier against moisture and gases, which does not allow their use for shelf stable food products. As a consequence, the team decided to use a vacuum metallised Nativia film for labelling the 0.6mm pot’s bottom and surrounding wall to provide barrier. Druckhaus Rahninig, a leading printing house specializing in the manufacturing of labels, used their know-how to print the labels, by using a 5-color + lacquer reel-fed UV printer to produce both the wrap around and bottom labels.

The measurement of O2 permeation at 25°C and 40% relative humidity, according ASTM F1927–07, revealed that by adding the metallised PLA label, the O2 permeation was lowered to about 25% of the original Ecovio O2 permeation value, and 10 times lower than standard PP tubs.

Ecovio consists of Ecoflex®, a compostable co-polyster (PBAT) and PLA, which is derived from plant-based starch. The main areas of use for Ecovio are plastic films such as organic waste bags, dual-use bags (first for shopping, then for organic waste), agricultural films, as well as paper-coating, shrink films, foam packaging and injection molded products. Products made of Ecovio is for injection molding benefit from an optimum balance of rigidity and toughness. Flow behavior is easily adjusted according to the application – from medium to high flow requirements.

Nativia biaxially oriented, bio-based and compostable PLA films are widely used in various food packaging applications, thanks to their high clarity, gloss, seal-ability and compatibility with existing packaging machines. To date, they had never been tested for manufacturing labels for injection molding. MT

www.ti-films.com www.mikopac.com www.rahning.de www.basf.com

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From Science & Research

BREAD4PLA D Biodegradable packaging for the bakery industry made from bakery waste

By: Rosa Gonzalez Leyba Extrusion Department AIMPLAS (Plastics Technology Centre) Paterna/Valencia, Spain www.aimplas.es

eveloping a totally biodegradable new package, made of waste from the bakery industry. This has been the aim of BREAD4PLA, a European project since in 2011 (cf. bM 04/2012) and which finished in September 2014.

“We searched for a biodegradable polymer, made from sliced bread crusts and sponge cake, that could be later used in the conservation of these products in order to end with a full cycle”, says Rosa González, main researcher of the project at AIMPLAS, Technological Institute of Plastics (based in Paterna/Valencia, Spain).

That was the original idea of this project, which is funded by the European Union Program LIFE+, and in which researchers from the Centro Tecnológico de Cereales-CETECE (the Spanish Technological Centre for Cereals), the Leibniz Institute for Agricultural Engineering Potsdam-Bornim e.V. (ATB, Germany), the Biocomposites Centre of the Bangor University (United Kingdom) and the Instituto Tecnológico del Plástico-AIMPLAS (the Spanish Technological Centre for Plastics) have all been involved.

With the collaboration of all of the above organisations, and with the support of Spanish industrial companies such as Panrico and Grupo Siro, lactic acid and polylactic acid (PLA) have been obtained by way of the enzymatic fermentation of sliced bread crusts and sponge cake provided by the bakery industry. The lactic acid has been polymerized into PLA to produce plastic packaging. The result is a new compostable PLA film with which various types of bags and packages have been produced to package several food products.

The fermentation of waste bread allows the production of 0.35 kg lactic acid per kilogram of bread, which is same range as for other feedstocks. Regarding the production of PLA, yields at this small pilot plant have been around 50%. From the same lactic acid, the yield in industrial process will be at least 77% based on data from pilot trials. So, depending on the scale, one kilogram of bread can be converted to 0.175 and up to 0.25 kg of PLA. However, in both processes, lactic and PLA production, some points have been detected to be improved and the yield increased, being more feasible to make improvements on a large scale, mainly based on purification processes.

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“We have validated the new PLA package for different bakery products by analyzing its lifespan, conservation and organoleptic quality. Although initially we observed that the lifespan is reduced with sliced bread and biscuits, unlike the ones which are on the market, the behaviour of home-made butter-cakes and pastries was regarded perfectâ€?, explains Ana GarcinuĂąo, who is responsible for R&D at CETECE. As is known for commercial PLA packages on the market, the PLA that has been developed is less permeable to oxygen and more permeable to water vapour compared with traditional polypropylene (PP) and polyethylene (PE) packaging, and so initially it could be inconvenient for biscuits and cakes since they become much too soft as they take in moisture. The opposite problem applies to sliced bread which becomes too hard as it loses humidity. However, the low permeability to oxygen retards mould formation. These barrier properties are in fact an advantage for pastries and homemade butter-cakes. In this case, the film produced has the same performance as traditional packages made from fossil fuel sources, such as PP, leading to the same product shelf-life, thus becoming a much more sustainable alternative compared with the current solution. Moreover, it has other advantages which make it more attractive, such as the reduction of rancidity of the packaged food with this material (rancidity is the property that determines the extent to which the product is oxidized/degraded by the formation of peroxides).

In addition, compostable tests performed using the packages developed, according to specific standards (such as EN 13432) for plastic packaging, confirmed the biodegradability and compostability properties, meaning that the product will be able to manage well under industrial composting conditions.

DRIVING A RESOURCE EFFICIENT EUROPE

In this way waste from the bakery industry takes on a commercial value, since it has not been used so far, and biodegradable and environmentally friendly packages are obtained - and used once again in the same industry.

The BREAD4PLA project has been a demonstrative project performed on a pilot plant scale. Industrialization would be the next step. It will be necessary to consider the logistic aspects, such as the collection of adequate quantities of bakery waste and its transportation to the lactic acid production plant. The project partners are now working on this step to make it possible.

Register now!

2/ 3 December 2014 The Square Meeting Centre Brussels More information is available at: conference@european-bioplastics.org Phone: +49 (0)30 28 48 23 50

www.conference.european-bioplastics.org

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Application News

Lightweight sports canoe Composites Evolution‘s Biotex Flax materials have been used successfully by German-based canoe designer Lake Constance in its Felicity freestyle canoe.

Composites Evolution (Bridgeway, Chesterfield, UK) explains that the Biotex materials range of natural reinforcements provide a sustainable alternative to high-performance materials such as glass fibre. Its Biotex materials are designed by composites experts specifically for composites processes and are suitable for a wide range of applications such as automotive, sports and consumer products.

Fruit packs for Italian schools The EU program Frutta nelle Scuole (Fruit at School) was first introduced in 2009, involving 870,000 children in 5,000 schools in Italy, and resulted with an increased consumption of fruits and vegetables among children. One of the supported initiatives consisted of distributing packs of ready-toeat fruits and vegetables in primary schools to children between the ages of 6 and 11 years.

Fruit packs are designed to be easily consumed on the go by pupils, and NATIVIA™ bio-based and compostable PLA films have been chosen for the pillow packs of fresh cut apples and pears, thanks to their performance and environmental benefits.

Other varieties include oranges, kiwis, carrots, cherry tomatoes and fennels. MT www.fruttanellescuole.gov.it www.ti-films.com

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For its Felicity canoe, Lake Constance was looking for materials with excellent mechanical properties which could still maintain a natural look and feel to the final product.

According to Composites Evolution, with proven mechanical properties and easy processing, Biotex Flax helped Lake Constance stay true to the unique look and feel needed for its product.

The Felicity is described as a precise and agile solo Freestyle/ touring canoe. Lake Constance builds its canoes in-house, in a vacuum infused all-natural-fibre laminate.

Sebastian Stetter of Lake Constance Canoes commented „Using Biotex Flax meant we took a huge step forward towards fulfilling our mission - building canoes which are as sustainable as possible. Working with it was such a pleasure that we want to use it everywhere. Once we made the switch to flax, we never looked back.“ MT www.lakeconstance.de www.compositesevolution.com

Applications Figure 2: Bionic design of ZIEHL-ABEGG fan blade with optimised geometry for reducing drive power and noise (photo credit: ZIEHL-ABEGG).

Biobased PA 6.10 helps bionics

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pecialising in innovative, application-orientated plastic compounds for over 25 years, AKRO-PLASTIC (Niederzissen, Germany) has partnered ZIEHL-ABEGG (Künzelsau, Germany) to develop a polyamide 6.10-based AKROMID® S compound for the bionic bio-fan.

Akromid S from Akro-Plastic, satisfies the common definition of a bioplastic, with a biogenic carbon content of up to 70%. Castor oil forms the basis of sebacic acid, which in turn serves as the main building block for the polymer‘s renewable raw material portion. PA 6.10 is not bio-degradable. In engineering plastics applications, this property is completely undesirable, as such applications require a long service life of the end product and an equally high material resistance, which cannot be fulfilled by a degradable plastic.

Ziehl-Abegg recognised the advantages of bionics early on in the area of ventilation technology and has consistently applied the acquired knowledge in the design of their new generation of fans, whose blade geometry is based on an owlwing pattern, resulting in a reduction in fan noise.

Bionics, which utilises design solutions based on examples found in nature, ensures constant improvement in the development of solutions for technical design work. Alongside lightweight construction due to material reductions, high mechanical strengths through the use of struts in the necessary places and a reduction in notching effects due to special notching geometries, various other solutions have been developed based on the knowledge gleaned. The latestgeneration axial fan from Ziehl-Abegg, made from AkroPlastic polyamide 6.10, was developed in this way.

CO2 savings of up to 60% with respect to the percentage of polyamide The mechanical properties of AKROMID S, reinforced with 30% glass fibre, ensure safe operation of the fan even at higher speeds. Excellent surface quality is also achieved with this glass-fibre content. Not least, this is the result of the process technology used in the manufacturing method. The twin-screw extruder from the sister company Feddem in Sinzig (Germany), which has no kneading block, ensures careful dispersion. The incorporated glass fibres are not reduced as drastically in length with this gentle compounding method, allowing greater values to be achieved in tensile strength and impact strength.

The new bionic fans will soon be used in refrigeration technology (cold chain to the supermarket), heaters and heat pumps, and for electronics cooling (computing centres and switchgear-cabinet and inverter cooling). In these areas, the fans ensure that noise emissions are greatly reduced, in addition to making efficient usxe of resources in terms of materials. The environmentally friendly bionic concept from Ziehl-Abegg has received honours and awards in a number of competitions. MT www.akro-plastic.com

www.ziehl-abegg.com

Top view of bionic fan (photo credit: ZIEHL-ABEGG).

Whereas knowledge of mechanical strength ensures a design‘s longevity, further knowledge of fluid mechanics is necessary for fan blades.

Compared with standard polyamides (such as PA 6 and PA 6.6) PA 6.10 has advantages in terms of less water absorption, better chemical resistance and lower density.

The use of this material in Ziehl Abegg fans provides the following advantages: up to 6% lower component weight less effect of moisture on the mechanical properties greater dimensional consistency

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Application News (Toys)

Disney – It’s A Small World™ Meal Sets

Good News in the last minute

In 1964, Walt Disney debuted the ride It’s a Small World at the World’s Fair in New York. It was so successful, that in 1966 it was re-opened at Disneyland. Walt Disney commissioned the talented and inspired illustrator Mary Blair to It’s a Small World. Blair is a legend within the design community and her simplicity and whimsical style were the perfect choice for these iconic characters.

It has been a long tradition, not only in England or in Germany to model rail transport systems at a reduced scale.

The first good news was that German model railway accessories manufacturer Vollmer started to make miniature buildings from PLA a few years ago. The website read: “Due to limited resources on our planet and also due to gigantic oil catastrophes in the past months, the Vollmer Company has committed itself to find alternatives to fossil fuel based plastic materials. The result is a plastic material with a minimum of 80 % recyclable raw materials. And additional to that: the BIO-material is fully degradable.”

Whitbread Wilkinson (w2 products Ltd) have revisited these stunning archive artworks to recreate a new collection in the spirit of Mary’s original designs. As a result the London (UK) based company now introduced eight cup, bowl & plate sets, made from a heat resistant grade of PLA. The material, developed in China in cooperation with the Chinese Academy of Sciences is 100% recylable and biodegradable. It can be used safely in a microwave and dishwasher, “something old-fashioned melamine is not,” as Jackie Piper, Director of Whitbread Wilkinson says.

The classic cups, bowls and plates have been transformed and cleverly crafted to form mini-people in a stacked set. “We are launching with eight charming characters; each wrapped in the colourful archive graphics from It’s a Small World,” Jackie adds.

Packaged in eye-catching standup packs-these characters are ready to add some real personality to any childs mealtime. Most probably the real fun will start when you start to mix and match bodies and heads... A small world just got bigger! MT www.designedinlondon.com/category/6/children

Then, a few weeks ago, when the preparation to this toysissue started, Vollmer announced that they just went out of business. This was not due to any bankruptcy or the like, but the company explained that the overall market situation for model railway accessories had become difficult.

Now, the latest good news: The business of Vollmer is being continued since September by Viessmann Modellspielwaren GmbH from Hatzfeld, Germany. We just received a confirmation that Viessmann wil also continue the ecological approach and offer miniature model buildings and accessories made from PLA based bioplastics. “One reason is that PLA can be laser-cut, which is not possible with the traditional polystyrene materials, as a spokesperson of Viessmann pointed out. MT www.vollmer-online.de

Nova Nature teethers, soothers and trumpet Nova Nature(Vancouver, Canada and Blaine, Washington, USA) specializes in high quality natural toys and gifts. As a company, they are growing out of the desire to provide toys that are safe, natural, eco-friendly, and sustainable.

PlantBaby® teethes and rattles are made from plant-based natural plastic, Ingeo™ PLA from NatureWorks. There are some eight styles of enviro-friendly PlantBaby rattles and teethers. The tee-

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ther design is inviting for babies with soothing colours, gentle rattling sound, and an easy to grasp, hold and shake handle.

Safe, flexible and soft parts which are made of silicone are perfect for chewing. Babies will enjoy playing the musical mouthpiece called Plant Rattle Trumpet and exploring the beads on the handle.

All toys conform to the North American ASTM Toy Safety Standard, F-963, and there are no age restrictions for use.

www.novanatureworld.com

Toys

Bioplastic baby products Safe for babies and better for the environment.

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or decades our children were exposed to toys that contain harmful chemicals, some causing adverse and long-term health problems. BPA, PVC, Phthalates, Styrenes and Heavy Metals are well-known health offenders associated with many oil-based plastics. These materials, in whole or used as additives, may be present in items used everyday including toys. Some of these substances can act as hormone disruptors linked to possible reproductive problems and birth defects, some are potent carcinogens that accumulate in animals and in humans, some are known neurotoxins with other negative health effects. To add insult to the injury, those toys can cause long lasting environmental problems such as pollution and deforestation, to say the least.

Bioserie (Hong Kong) bioplastic baby products are an excellent alternative for addressing parents’ need of using safe baby products which do not contain any potentially harmful chemicals. Bioserie’s products also provide an alternative to consumers who are looking for environmentally responsible products.

www.bioserie.com

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Bioserie bioplastic baby products are made using Ingeo™ PLA by NatureWorks and a proprietary blend of biobased components. They are tested and certified by USDA to be 100% biobased. They contain absolutely no oil based plastics and no oil based chemicals, thereby they protect babies and the environment from both known and yet-to-be known harmful effects of oil based chemicals and plastics.

EN 71 and ASTM F963 toys safety tests for the US and the EU markets are already concluded for the first product, bioplastic teether for babies. There were absolutely no oil based chemicals and heavy metals detected in those tests.

• International Trade in Raw Materials, Machinery & Products Free of Charge • Daily News from the Industrial Sector and the Plastics Markets

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M

• Current Market Prices for Plastics.

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CM

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

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Bioserie utilizes its own twice award-nominated (in 2013, in Germany and the USA) innovative bioplastics manufacturing technology to produce heat resistant, 100% biobased injection moulded products. Their own manufacturing technology is key for our claim to being completely free of oil-based chemicals. “After developing our bioplastics manufacturing technology to a level suitable for mainstream durable consumer product applications, we identified a consumer product category that can benefit the most from our technology”, says Kaya Kaplancali, Founder & CEO at Bioserie. “We cooperated with NatureWorks LLC and PolyOne Corp during the R&D phase.” MT CY

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

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Toys

From packaging fillers to toys

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ince 1994 the Loick group has been involved in the field of development and production of new types of products using sustainable resources as a replacement for the present application of plastics for these items.

Alongside the production of bio-degradable products such as, for instance, packaging materials Farmfill®, catering accessories and consumables Greenway and toys PlayMais® the group also installs and operates bio-gas plants and solar farms all over Germany.

The roots of the Loick group lie in the efforts of the farmer and land-owner Hubert Loick, to find new ways of increasing the value of his land and products he was growing - all within an ecological method for production, and also for disposal of agricultural waste. Today there are three primary areas with which the company is involved: 1. The original agricultural business covering around 800 hectares of own and leased agricultural land for the production of all kind of biomass and trade of fertilizers, 2. the production of biologically viable materials (packaging and bioplastics) from renewable resources (including maize starch) and …

3. the logical next step, the production of bioenergy by the use of biomass and biomass residue.

With these three areas the company created a closed loop which contributes to maintaining and preservation of natural resources and avoids the use of nature’s resources for primary energy needs/usage and also avoids overloading the environment with even more scrap and waste material. The overall activities of the Loick group thus are oriented towards this closed loop concept based on a sustainable closed loop business. Setting up new loops and value added chains is the basic day-to-day activity of the group with the objective of extracting a maximum from the raw materials supplied and to producing the highest environmental return.

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It all started with Farmfill Farmfill products first appeared in the mid-1990s, based on maize and water. The ground used to grow maize etc was economically and ecologically suitable for this purpose but could not be used for the production of food or animal feeds (due to EU regulation on set-aside land).

The foaming process of the packaging material is achieved by the release of water vapour in a twin-screw extruder without the use of any foaming agent. The production process thus offers clear advantages over the use of expanded polystyrene. The high environmental sustainability level of the Farmfill production process shows itself not only in the ease and simplicity of product disposal but also in the energy usage throughout the whole product life-cycle. So, in comparison with packaging chips based on the use of mineral oils, only about one quarter of the energy is required. With regard to the use of maize chips the whole corn is used which means that there is no call for costly energy usage to extract the starch. From culture through to waste disposal the focus is on

Toys

sustainable production. The amount produced is disposed of in the form of biologically degradable waste via the company’s own biogas installations which produce electric current, heat and cooling as environmentally friendly plants.

possible. A vacuum conveyor is used to fill the granulate into an extruder and is there foamed up using water vapour. It is also possible to produce different shapes at this stage, such as cylinders or others.

Any remnants from the biogas production plant form the basis of the fertiliser for the next maize harvest. In this way the whole production process is part of a closed loop. Raw materials and energy sources are cared for, and nature enjoys the benefits. The maize is grown and used exclusively for industrial purposes and so none is able to find its way into the human food chain or animal feed.

First, German Telekom – and then PlayMais

The biological packaging chips can basically be used several times. But in comparison with conventional plastic chips they also have clear advantages when it comes to disposal.

The packaging chips are made from natural raw materials and are fully bio-degradable and, when thermally recycled (incinerated), they are CO2 neutral.

They can be equally well disposed of in bio-bins (as industrial compost), or disposed of in domestic rubbish – under no circumstances do they belong in the yellow bin system! FARMfill packaging chips are DIN 13432 certified by DIN CERTCO. The packaging material is shipped in bags (500 l/bag), or loose by the truckload. The Loick group recognised early on the problem of cost-intensive transport of large volumes, and appropriate research was carried out, often with the help of the research teams at the Fraunhofer UMSICHT (Oberhausen, Munich), and new types of innovative transport were developed.

At the end of the 1990s the first customers (for instance Deutsche Telekom), expressed the desire for specially coloured packaging material. This was the start of a move towards colouring the normally white chips, using food colourings.

Now almost any colour can be supplied.

It was clearly happening - a very simple product was emerging to offer a totally new creative concept. If the packaging chips are slightly moistured they will stick together because of the starch content. And if they are made too wet they will simply dissolve.

This effect was the birth of PlayMais (Play-Maize), the creative construction toy based on maize starch from the Loick group. A banal idea – the packaging chip – something completely new had been created.

PlayMais - A box full of creativity!

PlayMais, like the packaging material, is made from maize starch and coloured with food colourings. The maize used for PlayMais however, will be grown on land not used for foodstuff and animal fodder. PlayMais is 100% bio-degradable and toxicologically perfectly safe. It is particularly suitable for children from three years of age and was promoted for the first time at the Nuremberg international toy exhibition in

In 2010, for example, a special granulate for packaging filler production was developed which ultimately was the basis for the finished foam product.

In simple terms, this product comes from a break in its production process immediately before the foaming stage.

The last step can be carried out in a simplified process right at the client’s plant and the finished product can then be blown into the warehouse or store.

The foaming factor is around 35. This means that one truck loaded with the compound (25 tonnes) could save 34 truck runs. This would overcome natural hurdles, such as additional transport to countries outside of Germany. With such help the business today is already taking the exports outside of European borders. The granulate is shipped to the customer in big bags, and shipment in sea-containers is also

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2001. Since that time PlayMais has enjoyed terrific success which began in the children’s playroom and today is exported worldwide. Whether they are in Europe, America, Australia or the Far East, they all play with the creative toy Made in Germany.

PlayMais is simply great fun because: PlayMais only sticks together when it is moistured with water PlayMais pieces can be easily shaped with the fingers.

PlayMais promotes motor skills PlayMais promotes creativity PlayMais promotes children’s development PlayMais has a high learning value PlayMais is a natural product and cares for the environment Despite the trends in international trade PlayMais is developed and made in Germany. This is not obvious when one looks closely at the toy market. PlayMais is a well-rounded affair in the cycle of nature. In addition the environmental aspect of PlayMais is not just theory, but is setting new standards in the intelligent use of the earth’s resources.

PlayMais can be shaped, pressed, cut and lots more. It sticks together when moistured with water, and sticks to

lots of other surfaces such as paper and card, where it can be used to embellish pictures, or on glass to make window decoration, and even on flower pots. In addition PlayMais can be combined with wooden sticks or string and thus used to make, for example, toy motor car axles. Thanks to its ease of play and modelling PlayMais gives all children a quickly achieved sense of success. Thanks to its unending shaping and moulding possibilities there are no limits to the fun and pleasure it offers.

PlayMais promotes creativity and helps little fingers to shape fantastic things. Glue is not needed. A bit of water and one’s fantasy are all that is needed.

Unlimited creative shapes and forms. From simple 2-dimensional shapes that younger children will stick onto a card, up to difficult 3-dimensional models for older children.

PlayMais knows no limits.

In other words, PlayMais stands for naturalness and creativity, it teaches in a special way, trains the child’s motor skills and promotes social behaviour in all age groups. www.playmais.com

By: Benedikt Schürholz Head of Sales Loick Biowertstoff GmbH Dorsten, Germany

3 rd y.eu

mistr www.co2-che

CO2 as chemical feedstock – a challenge for sustainable chemistry 2 – 3 December 2014, Essen (Germany) 1st Day, 2 December 2014: Policy & visions + CO2 capture & purification + H2 generation: prerequisite for CO2 economy

2nd Day, 3 December 2014: CO2 based fuels + Chemicals & building blocks + Polymers & materials

Early Bird until End of September:

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For the 3rd year in a row, the nova-Institute will organize the conference “CO2 as chemical feedstock – a challenge for sustainable chemistry” on 2 – 3 December 2014 in the “Haus der Technik” in Essen, Germany.

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, 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 largest event on Carbon Capture and Utilization (CCU) in 2014. Our goal is to connect more than 300 participants from the leading industrial and academic players in CO2 utilization that are expected to attend the conference and to share their recent success stories, as well as new ideas and products in implementation. We hope also you will be part of this opportunity to get in touch with this innovative and active network.

Dominik Vogt

nova-Institut

+49 (0) 22 33 / 48 14 - 49 dominik.vogt@ nova-institut.de

for Ecology and Innovation GmbH Chemiepark Knapsack, Industriestraße 300 50354 Huerth, Germany

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Toys

By: Hannes Frech University of Natural Resources and Life Sciences, Vienna, Austria Department for Agrobiotechnology, IFA-Tulln Institute for Natural Materials Technology

www.Fasal.at www.ifa-tulln.ac.at www.hapetoys.com www.rotor-design.de

Wood composites for toys

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ince almost exactly 20 years the Institute for Natural Materials Technology (IFA Tulln in Austria) has been working on wood composites (FASAL®) to help establish a place for them in the injection moulding and profile extrusion markets. In a joint research project with the company FASAL WOOD KG, Vienna, Austria, lasting several years, new blends have been compounded and tested.

Depending on the customer requirement the Fasal wood composites can be based on renewables based on biodegradables, or based on conventional WPC materials The easy-flowing type Fasal Bio 337 (based on wood and PP) in particular has been able to convince some toy-makers of its extraordinary possibilities in design and function. Fasal‘s general manager, Ing. Kresimir Hagljan, works closely with his customers right from the preparation of product drawings through tool making to manufacture of finished parts.

Toy designer Markus Hirche (rotordesign, Stuttgart, Germany) recognized the advantages of Fasal and developed the wooden Meine kleine Welt (My little world) multi-play system for the company Hape toys (headquartered in Luzern, Switzerland).

The possibility of injection moulding the Fasal material allows the attractive design of three-dimensional characters and play elements for the target group, and includes functional elements, such as the head of a figure turning with a stop.

Positions can be integrated in the mould. With ultrasonic welding technology the solid wood elements and the halfshell elements made from Fasal are joined together.

The colouring of the base material in the production process can avoid additional painting work. Runners can be 100% recycled in the production process. The material from PEFC (Programme for the Endorsement of Forest Certification) certified wood flour from solid wood production was also modified to offer the possibility of it being imprinted with standard print colours.

Fasal materials conform to the strict guidelines of the toy industry, such as EN 71 and ASTM, especially with regard to the mechanical requirements of the prefabricated elements.

The combination of solid wood and Fasal allows a complete redesign of game characters and opens up a new dimension in the wooden play-world.

Meine kleine Welt – A role-playing game for toddlers from ages 18 months to 4 years.

Spare parts and accessories can merge a modern design language with a combination of a simple production process of injection moulding with Fasal, and solid wood production.

Toddlers from the age of 18 months start to observe and explore the world around them.

The perception of the natural material, the warmness and the character of the wooden play world has been achieved and implemented with this material combination. The use of a sustainable and recyclable material is visible and sensible - also in terms of the future generations.

The Meine kleine Welt wooden multi-play system supports the sensitive capturing and understanding of materials by playing with this new combination of solid wood, plywood and the Fasal fibre compound.

Simply the relation to animal or human figures is very important during the role-playing game for the children.

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To offer children from 18 months onwards ergonomic, natural, but also functional characters and game-play elements, a wood-based material combination with the WPC Fasal Bio 337 was selected.

bioplastics MAGAZINE [05/14] Vol. 9

Meine kleine Welt with an attractive material combination, is a modern, future-oriented wooden multi-play system with many possibilities and excellent play value. 

Toys

How bioplastics and biocomposites are changing the toy industry

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onsumers are becoming more mindful of how and where products are made. A recent study by Euromonitor International’s Consumers Editor, Daphne Kasriel, noted, “consumers are increasingly looking to connect with brands, business models and products that do not associate with negative environmental and social impacts.” Thus also toy companies are responding to rising concerns about toxins, an increasing desire for sustainable materials and, a greater awareness of how and where products are made.

BeginAgain, a Fort Collins (Colorado, USA) -based toymaker focused on thoughtful product design and imaginative storytelling, was looking for a safe, sustainable, soft plastic material free of phthalates, BPA etc, for several new products.

They were introduced to Terratek® Flex, a new compostable elastomeric bioplastic developed and manufactured by Kansas-based bioplastics manufacturer, Green Dot. “Green Dot’s corn starch bioresin is the most innovative ecomaterial we’ve ever had our hands on – it’s the new rubber,” said BeginAgain co-founder Chris Clemmer. “It’s safe, soft and can be naturally scented. It’s even dishwasher safe, yet transforms into compost at the end of its useful life.” In fact Terratek Flex, a proprietary patent pending starch-based compostable elastomer has been verified by SGS Fresenius Laboratories to meet ASTM D6400 and EN 13432 standards for biodegradability in an industrial composting facility and has been found to biodegrade in a backyard-composting environment as well.

BeginAgain is Green Dot’s exclusive toy design partner.

The companies collaborated to create several new toys that

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combine BeginAgain’s playful designs with Green Dot’s innovative new bioplastic. The Green Ring teether is made from a 3-inch loop of smooth maple wood encircled by Terratek Flex soft compostable bioplastic. BeginAgain’s Green Keys are also made with Terratek Flex and are perfect for teething and developing grasping skills. The soft non-toxic plastic was tested by NSF Laboratories and verified to be free from phthalates, BPA, lead and cadmium, and can be easily removed and sanitized in the dishwasher. BeginAgain’s imaginative ice cream play set called Scented Scoops features scoops made from Green Dot’s bioplastic and scented with chocolate, vanilla and strawberry flavors that smell good enough to eat. The starch-based bioplastic is superior for scenting and retains scents longer than petroleum-based plastics.

Consumers value these BeginAgain products not only because they are non-toxic and made with more sustainable materials, but also because both the materials and products are produced regionally in the United States.

“Using recycled plastic is a great first step, but we have to do more to reduce our impact on the Earth,” says David Bowen, BeginAgain co-founder. “We must fundamentally change the way we make and consume products. Renewable, plant-based materials like bio-resins, sustainably harvested wood and natural rubber are a big part of the solution.”

Green Dot is also working with toymakers using the company’s Terratek WC wood and Terratek SC starch composites. The materials combine by-products from lumber manufacturers and food ingredient companies with virgin, reclaimed, or recycled plastics to produce small uniform

Toys

By: Kevin Ireland Communications Manager Green Dot Holdings LLC Cottonwood Falls, Kansas, USA

pellets optimized for injection molding or extrusion. Toymakers find that Terratek WC is not only more sustainable, but also more durable than either plastic or wood alone, particularly for toys that may be used and left outside. The toy parts can be colored in the molding process to alleviate concerns about toxins in peeling or chipping paint. Offering similar benefits as the WC material but with the clean, finished look of unfilled plastic, Terratek SC provides an option for toy makers that want a more sustainable material but without the aesthetics of wood.

Green Dot’s biocomposites and bioplastics offer toy manufacturers a cost competitive material that is more

sustainable and more durable, for safer toys that will last for years. Green Dot CEO Mark Remmert explained, “Bioplastics are a natural fit for toymakers. Companies large and small recognize that their customers are seeking toys that are safe and earth friendly. Green Dot stands ready to meet this need with a full line of biobased, compostable and biocomposite materials. We’re looking forward to continuing to help these companies make toys that are safer, more sustainable, perform better, last longer and, of course, are just plain fun. www.greendotpure.com

INTAREMA® The new system generation from EREMA.

Self-service. Redefined.

Reaching perfect pellet quality at the press of a button: the new INTAREMA® features the intelligent Smart Start operating concept, bringing together production efficiency and remarkably straightforward operation. This is all about usability. Including an ergonomic touchscreen, practical recipe management and automated standby mode.

CHOOSE THE NUMBER ONE.

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Cover Story

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alerie Lecoeur, a mother of three young children who was born and raised in France and now lives in North Carolina, founded Zoë b in 2011 because: “I believe parents deserve options that are both safer for their children and healthier for our planet”, as she says.

Beach toys made from PHA

Take beach toys for an example: It all started when Valerie was walking on the beach with her kids in Amagansett, New York. They were doing one of their Trash And Treasure Hunts— but sadly, the kids were finding mostly trash. Frustrated by all the plastic debris that had washed up on the beach, Valerie had a thought: Why not take one thing every family brings to the beach and make it biodegradable, so it’ll disappear in a couple of years if it gets accidentally left behind and washed out to sea? And since nothing comparable was available Valerie simply founded the company and started production.

“Somebody had to do it“, she said to bioplastics MAGAZINE, and I want to have it produced here and not imported from a faraway country.” That’s how the world’s first biodegradable beach toys were born (cf. bM 02/2011). Before that, when Valerie was initially introduced to bioplastics after reading books like Cradle to Cradle, she had done some experiments with bioplastics based on potato starch in order to make babybibs. However that was not successful, so she continued her efforts into beach toys.

The five-piece beach kit includes a bucket, sifter (which doubles as the lid), shovel, and cups made from Mirel™ PHA

by Metabolix, a bioplastic that completely biodegrades when exposed to microbial activity in the soil or sea.

In addition the PHA (polyhydroxyalcanoate) does not contain any BPA, phthalates, or PVC. In fact, the bioplastic used to make Zoë b is even FDA-approved for food contact.

“Not that we recommend your child eating sand out of the bucket,” Valerie adds. They meet U.S. and international safety requirements: EN 71, ASTM F963 and CPSIA.

www.zoeborganic.com www.zoebtoys.com

Even though Zoë b toys are durable and designed to hold up to playing just like ordinary beach toys.

“And don’t worry about exposure to the hot, summer sun. The material we use is performance bioplastic that can withstand endless sunlight and extreme heat—it’s even dishwasher-safe.

And when the toys are not forgotten and lost at the beach — which should be an exception anyway — the proper way to dispose of them is ordinary composting. Valerie Leceour: “Unlike most other bioplastics, the material we use to make our toys doesn’t require the high temperatures of an industrial-composting facility to biodegrade—which is a good thing, since many communities in the US don’t even have these facilities. So when you’re done with the toys, please just put them in your compost or bury them in your backyard—or better still, give them to someone else who can use them.”

For the production of the beach toys Valerie Lecoeur found a custom injection molding company in Pennsylvania. Valerie invested in the molds which had to be adopted and optimized for the PHA resin, “which really was a challenge,” as she points out. The people in Pennsylvania repaired my first Chinese

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Cover Story

made molds and made them work properly. But finally — after more than three years Zoë b is still successfully selling the products. They have even extended their product range to a series of PHA kids dishes. After all these investments and expenses for marketing and communication that certainly needs to be continued — “many consumers don’t know anything about biodegradation” — Valerie is concerned about sufficient resin supply for an affordable price. “As soon as I can afford it, I’d invest in more molds for different new products,” she says. One idea for example is a placemat to complement the kids dished product line.

But her long-term goal is not to be the only supplier of such products. “My wish is that every beach toy should be biodegradable”, Valerie says. “I wish Walmart and Target would come and ask their suppliers to provide biodegradable beach toys.” This would also certainly help to bring the resin price down. MT

ISSN 1862-5258

September / October

05 | 2014

Highlights Fibers & Textiles | 12

countries ... is read in 91

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Beach toys by Zoë b made from PHA, p. 44

Fachkongress 2014 Biokunststoffe – Bausteine für eine Bioökonomie 21./22. Oktober, Berlin Anmeldung und Informationen unter: http://veranstaltungen.fnr.de/biokunststoffe2014

fé ld Ca re r o W lym0e14 o p o Bi 1.10.2 am 2

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A waste-to-toys effort Luke’s Toy Factory makes safe, sustainable toys from local sources

A

few years ago, Jim Barber’s children were all off to college or working, so it seemed like a perfect time throw out some of the old toys cluttering up the basement. While going through them, he noticed that most were imported. After doing a little research, he found out that some of them had been recalled for lead paint and other safety hazards. He thought“There has to be a better way to make toys”.

Fast forward to today. His company, Luke’s Toy Factory, is just about to launch its first product- a fire truck made for pre-school children, ages 2-5.

The unusual part is that it’s made using Wood Plastic Composites (WPC), and it’s made locally — not shipped half around the globe. He used a Kickstarter Project to build awareness and raise some of the funding for the toy. Kickstarter is crowd-funding platform that in the case of Like’s Toy Factory especially addressed parents who take a genuine interest in where and how their kids’ toys are manufactured.

Barber decided that he wanted to make the toys out of WPC, using sawdust, rice holes and wheat straw— waste materials outside the food stream, and combine this with plastic.

“The toys then feel and act like wood— durable and attractive, and yet contain 40% less plastic than conventional toys,” Barber explains. By using an injection molding process, they could design toys that would be too expensive

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bioplastics MAGAZINE [05/14] Vol. 9

to make with traditional methods, and with more realistic details. He enlisted his son, Luke, as the Toy Designer.

After Luke designed each toy, they used a 3D printer to make a working model. They were played with and tested in order to fine tune the fit and function.

The toys Luke came up with are a line of trucks, designed to be assembled out of 4 to 6 parts into a working toy. “Most toys are either baby toys or aimed at the older kids”, says Luke. “We decided that we wanted to make the toys have a bit of a challenge to keep young children interested, but not so difficult that they are frustrated.” All the trucks share a common chassis with wheels attached, so that you can take off the fire truck body and put on a dump truck, or a flatbed truck. The toys have walls that are 3mm thick. This adds weight and makes them much stronger than most injection molded toys.

Real WPC truck

Jim says, “I was lucky, in one respect, because I didn’t have any idea of what a big project it would turn out to be.

Otherwise, I might have been scared off at the beginning! When I first started looking into WPC, I found that, while Europe had a thriving market for WPC products, most of the interest in the US was in extruded building products.

Injection molding of WPC was almost non-existent.”

80% of the toys sold in the US are imported, so there is very little infrastructure left for creating toys locally. Fortunately, Jim was able to join forces with Chris Budnick, of Vanguard Plastics, in Southington, Connecticut, USA. Vanguard helped with tooling, and sourcing of the WPC. They decided to go with Rhetech’s RheVision line of bio fiber reinforced polypropylene. “I was intrigued by the interesting variety of fillers they had

Previous 3D-mockup

Toys

tested,” Jim Barber said. “From wood flour to coconut and agave fibers, they were looking for waste products that did not pull resources from the food stream, and I found that attitude exciting”. Rhetech quickly signed on to the project, sending samples to test.

“We are starting our initial toy production with the maple reinforced product, at a 30% loading, using virgin polypropylene. Mostly this is because we wanted to start with the product that had the most information available. As a startup, you have to balance the known with the unknown, and as a toy company, you must keep safety at the forefront”, says Jim Barber. “A large part of the appeal of this material is that we can color it in the mold with FDA approved pigments, so there is no surface paint to flake off. Consumers are very aware of heavy metals in paint coatings, as well as additives such as phtalates or Bisphenol A (BPA). At age 2, kids are still putting things in their mouth and chewing on them. Going forward we expect to be able to incorporate recycled resin or maybe even biobased plastic into the fillers, but for now we needed to be as safe as possible”.

One advantage Luke’s Toy Factory enjoys is the ability to quickly react to market demand. “We can produce toys and get them to the market while other toys are still on a ship travelling halfway around the world. It’s better for the environment, and better for us.

100 per cent of these toys are made locally, here where we live and where we sell the products.” says Jim Barber.

The toys are produced on a Boy model 50E. “We use a standard molding process with these toys. Even with the thick walls that are an integral part of the toys, we are running normal cycle times,” remarked Chris Budnick.”Drying is important, as these materials do have a larger than normal moisture component. Additional venting also needs to be considered in the mold design.”

The target audience, children in the 2-5 age group, likes bright colors. The advantage of the maple filler is that it takes color readily, so vibrant reds, blues and greens are easy to produce. “We’ve also run some trucks with natural color.

I think this may appeal to an older audience,” Jim Barber added. “My plan is to expand the range of fillers we utilize. By doing this, we can get different colors and textures, which in turn will allow us to make some very interesting toys- trucks with coconut wheels, oak bodies and flax fiber accessories.

The possibilities are endless. It will be really fun to be able to say “This toy is made from coconut and sawdust.”

Luke added, “The whole idea of sustainable and recycled materials is a journey, and we are just at the beginning.” MT Editor’s note: In the next issue we will feature a special on 3d-prining www.lukestoyfactory.com

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bioplastics MAGAZINE [05/14] Vol. 9

47

Politics / Markets

A bright future for bioplastics ?

What are the barriers to developing bioplastics markets in Europe and how can we overcome them?

T

The European bioplastics market is expanding rapidly. Between 2008 and 2013, it developed at an annual growth rate of 20%, reaching a market value of €485 million in 2013. This upward trend is expected to be maintained up to 2030 where even modest projections envisage European bioplastics demand to be between €5.2 and €6.7 billion. In the presence of the right incentives, however, these market figures could even be exceeded.

down re-use and recycling as the norm and aims to keep materials in productive use for as long as possible. Whether derived from shrimp shells [7], wastewater [8] or tomato skins and peels [9], bioplastics can find applications in many sectors including packaging, sanitary products, agriculture, automotive and consumer goods. Specialty polymers and packaging applications are considered to have the greatest potential for future growth.

Several recent policy developments have the potential to provide a significant impetus for the development of bioplastics in the EU, either through increasing interest and/ or boosting demand. Among these, recent proposals for EU waste targets [1] have put waste recycling and reuse at the very top of the policy and R&D agenda and the desire to reduce the risk of littering have prompted both the EU and several member states to propose taxes or bans on plastic bags [2, 3, 4]. The Court of Justice of the EU has even recently ruled against Greece for breaching EU landfill law and subsequently endangering the environment [5].

Market drivers for biobased plastics include rising and increasingly volatile fossil oil prices, the potential for reduction of CO2 emissions up to material carbon neutrality, an efficient use of resources, and their potential contribution to EU waste targets. In addition, more and more consumers are starting to show positive attitudes towards biobased and biodegradable materials. However, it is difficult to assess whether end user demand influences consumer brands, or whether consumer companies want to use bioplastics due to CSR (Corporate Social Responsibility) practices. Whatever the reasons, it is expected that the bioplastics market will bloom through to 2030 and even beyond.

Some bioplastics (for example those made from PLA or PHA) can be composted alongside the biodegradable fraction of household waste in industrial composting facilities.

Methods to recycle PLA are currently being developed.

Other bioplastics such as bio PE and PET are chemically identical to their fossil fuel-based equivalents, and thus can be recycled in the same manner and in the same waste stream. Bioplastics therefore comply with the Commission’s recently published circular economy package [6] which sets

Breaking through the barriers to bioplastics in Europe So how do we ensure this ambitious goal is reached, and even exceeded? The following considerations are built upon the findings of the FP7 [10] funded BIO-TIC project which focuses more specifically on PLA and PHA.

The most frequently cited barriers to the uptake of biobased AND biodegradable plastics revolve around their cost-competitiveness PHA beach toys and performance.

(Zoë B / Metabolix) The process of becoming economically viable can be relatively long and complex – this is why, for instance, new polymers such as PLA that have been developed as long ago as the 1940’s and 1950’s are only expected to see significant market penetration in the coming years. However, it is thought that within an appropriate framework, commercial-scale production could be fostered while simultaneously enabling economies of scale. It has been suggested that in order to overcome the

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bioplastics MAGAZINE [04/14] Vol. 9

Politics / Markets

By: Claire Gray BIO-TIC Project Coordinator

PLA-Computer housing (Supla/Kuender)

cost-competitiveness barrier, temporary market creation through governmental support would be most helpful to the bioplastics industry. Such solutions imply, for example, ensuring a favorable environment for the development of biobased plastics in terms of investment incentives, selective tax exemptions, or the implementation of a public procurement program building on the bio preferred program in the US. Indeed, the outcome of the EU Lead Market Initiative (LMI) for biobased products has already outlined a series of recommendations to help stimulate markets for products made from renewable raw materials. Overall it is considered that positive regulation rather than bans and other prohibitory measures would provide the most effective method of engaging with consumers. These policies should consequently include players across the whole value chain, i.e. plastic converters, retail, brand owners and manufacturers.

Nevertheless, until then, brand owners have the power to facilitate early stage access to markets for bioplastics that are not yet entirely cost-competitive by integrating them in their production chains and temporarily absorbing the price difference (e.g. Coca Cola and their PlantBottle™).

The second biggest problem hampering the large-scale development of biobased plastics in the EU are perceived inferior properties and/or performance when compared to fossil-based alternatives. Consumer and end-user awareness of the benefits of bioplastics is crucial in ensuring the positive environment required for the uptake of biobased plastics and will facilitate the implementation of dedicated policies and technology fine-tuning. Dedicated communication activities should subsequently be implemented as soon as possible to build support for and appreciation of the unique features of biobased plastics and to facilitate their large-scale market uptake.

Bioplastics have a bright future in Europe. Not only will they help free us from our dependence upon fossil oil, but, by virtue of their biodegradability and/or their recyclability, they will help pave the way towards a circular economy.

The full benefits of bioplastics will however only be realised with measures to improve their cost-competitiveness and a concerted effort to address end user and consumer perception and awareness issues.

and Ioana Popescu Industrial Biotechnology Officer EuropaBIO, Brussels, Belgium

References [1] Proposal for a DIRECTIVE OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL amending Directives 2008/98/EC on waste, 94/62/EC on packaging and packaging waste, 1999/31/ EC on the landfill of waste, 2000/53/EC on end-of-life vehicles, 2006/66/EC on batteries and accumulators and waste batteries and accumulators, and 2012/19/EU on waste electrical and electronic equipment (2014) [2] Le Goff F., Portugal plans environmental tax reform, ENDS Europe [3] Bulleid R., Council could back plastic bag reduction target, ENDS Europe [4] Le Goff F., France to ban single-use plastic bags from 2016, ENDS Europe [5] Court of Justice of the European Union, PRESS RELEASE No 104/14, C-600/12 Commission v Greece [6] Communication from the Commission to the European Parliament, The Council, The European Economic and Social Committee and The Committee of the Regions, Towards a circular economy: A zero waste programme for Europe (2014) [7] Thielen M., Bioplastic from shrimp shell, Bioplastics Magazine, vol.9, n°3, p.31 [8] Johnson R., Prague Post.com, available at http://www.praguepost.com/technology/ 40774-pilot-project-turns-wastewater-to-bioplastic.

[9] European bioplastics News bulletin 03/2014, available at http://en.european-bioplastics.org/blog/2014/06/24/briefs-2/ [10] 7th Framework Programme for Research and Technological Development (European Commission) Conference on this Topic: The BIO-TIC project consortium is organizing a workshop entitled ‘Biobased Plastics - How do we Grow the EU Industry?’ which will take place on 1st December 2014 between 1pm and 6pm at the Square, Brussels. Further information on the workshop can be found at http://bio-tic-workshops.eu/bio-based_plastics/home.

The workshop is a satellite event to the 9th European Bioplastics Conference: Driving a Resource Efficient Europe’ on the 2nd and 3rd December 2014. For more information visit: http://en.europeanbioplastics.org/conference/.

Further information: This article has been based on the interim findings of the FP7 project BIO-TIC which aims to identify the hurdles to industrial biotechnology (IB) and develop solutions to overcome them in order to unlock the potential of this key enabling technology (KET) in Europe. Bioplastics are one of five product groups which have been identified to have significant potential for enhancing European economic competitiveness and introducing cross-cutting technology ideas.

Any feedback is welcomed and should be sent to bio-tic@europabio. org. A summary of the draft findings on bioplastics, upon which this article is based, can be downloaded at www.industrialbiotecheurope.eu/downloads.

www.industrialbiotech-europe.eu

bioplastics MAGAZINE [04/14] Vol. 9

49

Basics

Biobased Building Blocks C2

H C

H

H

H

C

C

H

Ethylene C2 H4

C3 H3C

H

O

C

C

H OH

Lactic Acid C3 H6 O3

HO

H

C C O

H

C

C H

H

OH

H

1,3-PDO C3 H8 O2

H

O

H H

C

C

C

H

H H

C HO

H

H

OH

MEG C2 H6 O2

OH

C4

H C

HO

OH

H

Succinic Acid C4 H6 O4

C6

H

C

H

H

H

H H

C

C H

H

H H

C

C H

H

H C

H

NH2

H

HMDA C6 H16 N2

H HO

C C O

H H

C

C H

H

H H

C

C H

H

H H

C

C H

H

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bioplastics MAGAZINE [05/14] Vol. 9

O H C

H

Sebacic Acid C10 H18 O4

examples for building blocks

OH

C

1,4-BDO C4 H10 O2

H

H2N

C

C

HO

H

C10

M

ost plastics that are called bioplastics today are biobased, that means derived from plants or other renewable feedstock. The different kinds of biomass provide of course various options to obtain biobased building blocks, which can be used for polymerisation.

However, sugars in general and especially glucose is a molecule which is applied to produce a large number of different useful monomers mainly via fermentation.

Sugar cane is a well-known source for glucose, but also all starch containing plants such as wheat. Not to forget cellulose also consists of glucose units. Plants as castor oil plant, rapeseed, soy, palm, flax, sunflower and many more contain plant oils, many of which can be converted to biobased building blocks especially when long-chained molecules are of interest. In the following an overview on the most common already found in the market is given, but also materials that are yet to face a brighter future are examined.

H

C OH

Sugarcane provides bioethanol via the fermentation of glucose with yeasts. Bioethanol is not only important for the biofuel industry but the base for the important biobased ethylene monomer. In the simplest way ethylene is polymerized to PE. Biobased polyethylene, marketed as Green PE is already well known and established in the market. The ethylene building block can, however, be further used to produce biobased polypropylene via metathesis reactions. Technically this can already be done, but until now it is not commercially feasible to produce PP that way.

Another well established, partly biobased plastic, which depends on the ethylene building block, is PET (polyethylene terephthalate). In a follow up step monoethylene glycol (MEG) can be produced from biomass-derived ethylene, which can be considered as a C2 building block just as its precursor. The biobased MEG is used in Bio-PET30, a bioplastic, which consists of up to 30% from renewable content. The reason why PET cannot yet be fully produced biobased is the terephthalic acid building block, which is currently used in its fossil based version for the BioPET. As it is the case for several aromatic monomers in the biobased sector, research is not as much proceeded as e.g. for the aliphatic olefins or polyols. There are possibilities to produce terephthalic acid from biomass (e.g. via p-xylene produced from sugars), but it is currently not carried out in a large scale yet, nevertheless likely to become available in the next years.

Basics

By: Constance Ißbrücker Environmental Affairs Manager European Bioplastics e.V. Berlin, Germany

An alternative biobased building block, which can be considered as substitute for terephthalic acid is 2,5-furandicarboxylic acid or in short FDCA. This fivemembered ring is obtained by oxidation of hyroxymethylfurfural and methoxymethylfurfural, which can be derived by the dehydration of plant based sugars. FDCA forms together with the biobased MEG a new 100% biobased copolyester polyethylene furanoate (PEF). PEF is said to have a better barrier to oxygen, carbon dioxide and water and better mechanical properties compared to PET. First batches are supposed to be commercially available in 2016.

Fermentation of glucose with certain bacteria results in lactic acid monomers. Lactic acid is used to produce polylactic acid (PLA) usually via a ring-opening polymerisation. Depending on the type of bacteria used, D- or L-lactic acid is obtained (right or left left-turning or, more precise: dextrorotatory or laevorotatory). This is important, as dependant on the stereoisomerism of the monomers and their share and arrangement in the polymer chain the properties of the PLA will differ.

Another building block with three carbon atoms used for bioplastics is 1,3 - propanediol (PDO). Some years ago the only biotechnological way to produce PDO was by the fermentation of glycerine. However, DuPont has developed a modified microorganism to obtain a biobased PDO directly from glucose.

The monomer is for example used together with terephthalic acid to produce PTT (Polytrimethylenterephthalate).

Succinic acid, a C4 building block, can too be produced via a bacterial fermentation of carbohydrates such as starch. It is used to produce polybutylene succinate (PBS) a biodegradable polymer. The second component for this bioplastic is 1,4 butanediol (BDO), which in turn can be produced from succinic acid by a catalytic conversion, and thus be biobased as well.

Bio-BDO will further be a valuable building block to produce biobased PBT (polybutyleneterephthalate) and also PBAT (Poly(butylene adipate-co-terphthalate)), a biodegradable polymer, which is currently found in the market as a fossilbased version.

PDO and BDO belong to the group of diols, which means these molecules have two hydroxyl (OH) groups. Generally, diols and molecules that have more than one hydroxyl group are called polyols. Polyols, however, can also be derived from oil plants such as castor, soy, canola, sunflower etc.. These usually long chain molecules can be used to produce PUR, more precisely partially biobased polyurethanes (PUR). The

isocyanate component required to carry out the polymerisation to PUR can currently only be produced from fossil resources.

Another polyol made from PDO as starting material is used to produce the thermoplastic elastomer Hytrel®.

Polyamides usually consist of dicarboxylic acids and diamines. Obtaining these both substance groups from biomass provides a large portfolio for the production biobased polyamides. Sebacic acid a C10 building block is already successfully produced from castor oil. With this monomer partially biobased polyamides as PA 4.10 or PA 6.10 are obtained and available in the market. 1,10 -Diaminodecane another C10 building block can be also produced from castor oil (via sebacic acid) and therefore a 100% biobased PA 10.10 is already available in the market. For a partially biobased PA10.12 the diaminodecane monomer can be used together with the fossil-based dodecanoic acid. However, also the C4 building block for polyamide is in principle available by derivatisation of succinic acid. For a C6 building block for polyamides adipic acid, which can also already be obtained from sugars is likely to become an important starting material. Via adiponitrile HDMA (hexamethylenediamine) can be produced, which will not only be the building block for PA 6.10 but for all other PA 6.X paving the way for biobased nylon. Aminoundecanoic acid a building block also made from castor beans is used to produce biobased PA 11, which is in fact not a bioplastic of the new generation but has been in the market for decades. Moreover, a route to obtain ω-amino lauric acid from palmoil has been recently developed to produce biobased PA 12.

The possibilities for biobased monomers in general, but also as building blocks for the production of bioplastics seem endless. However, there are still biobased feedstock and routes for a numerous amount of substances yet to be discovered and research in this field is constantly increasing.

Carbohydrate feedstock especially when it contains starch and sugars is already well investigated as well as possibilities oil-containing plants are carrying. When it comes to cellulose feedstock it is already well known that the polysaccharide is an alternative source for glucose. However, where cellulose is found there is also usually lignin. Lignin as a biopolymer consisting of a large variety of mainly phenolic and therefore aromatic monomers units is already used in the bioplastics sector but might also be as source for further building blocks in the near future.

bioplastics MAGAZINE [05/14] Vol. 9

51

Opinion

Sustainability Certification With reference to Mass Balance, Book and Claim etc.

Mass balance and minimum share?

Response to comments* by ISCC PLUS and RSB Comment by Michael Carus, nova-Institute

F

irst of all I very much appreciate that we can discuss these complex topics in bioplastics MAGAZINE from different points of view and thus make them accessible to a broader readership.

In the discussion, we should clearly differentiate between mass balance and mass balance approach. Mass balance simply means 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. Or as Jan Henke (ISSC PLUS) wrote for our specific case: “The certified sustainable output volume can never exceed the equivalent amount of certified feedstock”.

Coming from this definition it is obvious that the mass balance creates a higher transparency and safety in certification schemes than book-and-claim, which strictly speaking is not a defined method for the registration of the biomass flow at all. Therefore RSB should allow book-andclaim really only in the start-up phase.

The so-called mass balance approach goes one step further: it allows the free allocation of the biomass feedstock fed into the plant — or, as Jan Henke (ISSC PLUS) writes: “A mass balance approach would enable a company to allocate the bio content to a specific product”. This allocation leaves the ground of science and technology (on which mass balance is clearly based) and opens the door for allocation purely based on marketing aspects. Basically biomass can be dedicated to products that never contain any biomass at all.

Even if this could offer incentives for the chemical industry to apply more biomass, it poses is a considerable risk of damaging the image of the whole biobased economy (Green washing or Biobased washing).

Certainly, should the mass balance approach succeed in being established, companies that use special biomass for their specific biobased processes would be on a par with those that use low-grade biomass in rarely modified petrochemical plants… Is this the desired bio-economy then?

So it is only half the truth that Jan Henke (ISSC PLUS) writes about the use of biobased resources in the chemical sector : “In the beginning it is only possible with low physical shares in the final product”. This is only true for the huge petrochemical integrated sites “using thousands of tons of fossil and non-sustainable feedstock”, they really cannot “switch from one day to the other to certified sustainable bio based input”.

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bioplastics MAGAZINE [04/14] Vol. 9

So far however, the biobased economy, especially in the area of chemistry and polymers, is driven by innovative companies, which from the very beginning use high amounts of biomass.

Especially these new developments and investments, that in fact constitute the biobased economy, use new process routes and/or produce new building-blocks and polymers, that always display high amounts of biomass, because they were exactly designed for this. These are companies such as Naturworks (PLA: new process routes / new polymer) or Braskem (Bio-PE: new process).

Especially industrial biotechnology that opens completely new process routes, and stands in the focus of the EUresearch, is naturally working with high amounts of biomass.

The core aim of the mass balance approach is to open the huge petrochemical plants for biomass.

Let us finally come back to the topic of labelling. Should (in connection with a Sustainability Certification) the amount of used biomass or the real biobased content of a product be mentioned (as suggested by nova institute) or not (as suggested by ISCC PLUS)? Or is the approach of RSB the better way, as proposed by Melanie Williams (RSB): “RSB has set a requirement for a minimum of 25% biobased content.

This requirement specifies that the annual, average biobased content, measured according to ASTM D6866, CEN/TS 16137 (or any equivalent protocol) shall not be less than 25% by weight”.

I like the idea of an “annual, average biobased content” because this can be a bridge to the huge petrochemical sites to work with. But I would not agree to a minimum content of 25%. Why? Because it is extremely dependant on the specific application! In some cases 80% biobased share is easy to achieve and other cases 10% is already a huge challenge (and the biomass used should also be sustainable). From our point of view, we don’t need any minimum, we need transparency!

Every industrial and public customer shall learn about the biobased share of the product and whether this share is certified sustainable or not.

*: cf. bioplastics MAGAZINE 04/2014 nova-Institut GmbH Hürth, Germany www.nova-institut.de

Opinion

100% organic?

50 % organic??

Comparing apples with apples

Hää ???

Comment by Philippe Dewolfs, Vinçotte / OK biobased (Belgium) When I buy an organically produced apple I want it to be the genuine article, particularly when it features the logo of an independent organisation.

I am expecting more than a declaration claiming that 50% of the total production of that farmer is organic, obliging me to ask (and decide ?) myself whether the apple I am holding is 50% organic, 100% organic, or not organic at all?

The same applies to bio-based products. Manufacturers are not allowed to tell final consumers that the cups they are thinking of buying are 50 % bio-based if that is not actually the case.

Except that unlike an apple’s origin the bio-based carbon content of a cup may be easily verified.

Standardisation activities in Europe are developed with this in mind. In charge of communication and certification, the TC 411’s (Technical Group 411) WG5 (Working Group 5) on “bio-based products” has decided to make a distinction between B2B communication and communication intended for final consumers.

In the case of B2B communication, a mass-balance based declaration is allowed, as it is indicative of a company’s efforts to switch to organic sources.

However, any claim in a B2C communication has to be verifiable (and therefore measurable) in the finished product. Hence the mass balance approach is not acceptable in this case because the specific values of a given item may vary considerably depending on the country, the factory or even the date of manufacture.

By opting for the C14 (ASTM D6866 in 2009, which then became CEN/ TS 16137) method, Vinçotte has chosen a precise method that can be replicated, in keeping with the organisation’s reputation as a leading certifier of bioplastics.

The approach allows all entities (whether they are major international companies or small local businesses) to have their products certified on the basis of a reliable and affordable method.

All products may be certified OK biobased, provided the carbon accounts for at least 30% of the finished product’s weight and the carbon is at least 20% bio-based.

The product will then be assigned 1 to 4 stars depending on the biobased carbon level.

The development of the biobased economy is dependent on the availability of a reliable declaration method that is affordable to all market participants.

Vinçotte

www.okbiobased.be

bioplastics MAGAZINE [04/14] Vol. 9

53

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

Shandong Fuwin New Material Co., Ltd. Econorm® Biodegradable & Compostable Resin North of Baoshan Road, Zibo City, Shandong Province P.R. China.

Phone: +86 533 7986016 Fax: +86 533 6201788 Mobile: +86-13953357190 CNMHELEN@GMAIL.COM www.sdfuwin.com

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

Simply contact:

Tel.: +49 2161 6884467 suppguide@bioplasticsmagazine.com 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.

39 mm

For Example:

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

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

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 PolyOne DuPont de Nemours International S.A. www.xinfupharm.com Avenue Melville Wilson, 2 2 chemin du Pavillon Zoning de la Fagne 1218 - Le Grand Saconnex 5330 Assesse 1.1 bio based monomers Switzerland Belgium Tel.: +41 22 171 51 11 Tel.: + 32 83 660 211 Fax: +41 22 580 22 45 www.polyone.com plastics@dupont.com www.renewable.dupont.com www.plastics.dupont.com

Tel: +86 351-8689356 Fax: +86 351-8689718 www.ecoworld.jinhuigroup.com jinhuibio@126.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 1.2 compounds

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.

www.facebook.com www.issuu.com www.twitter.com www.youtube.com

54

bioplastics MAGAZINE [05/14] Vol. 9

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

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

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

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

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

Natureplast 11 rue François Arago 14123 Ifs – France Tel. +33 2 31 83 50 87 www.natureplast.eu t.lefevre@natureplast.eu

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!

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 6. Equipment

1.6 masterbatches

6.1 Machinery & Molds

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

Taghleef Industries SpA, Italy Via E. Fermi, 46 33058 San Giorgio di Nogaro (UD) Contact Frank Ernst Tel. +49 2402 7096989 Mobile +49 160 4756573 frank.ernst@ti-films.com www.ti-films.com 4. Bioplastics products

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

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

Wuhan Huali Environmental Technology Co.,Ltd. No.8, North Huashiyuan Road, Donghu New Tech Development Zone, Wuhan, Hubei, China Tel: +86-27-87926666 Fax: + 86-27-87925999 rjh@psm.com.cn, www.psm.com.cn

PolyOne Avenue Melville Wilson, 2 Zoning de la Fagne 5330 Assesse Belgium Tel.: + 32 83 660 211 www.polyone.com Minima Technology Co., Ltd. 2. Additives/Secondary raw materials 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 GRAFE-Group Skype esmy325 Waldecker Straße 21, www.minima-tech.com 99444 Blankenhain, Germany Tel. +49 36459 45 0 www.grafe.com

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

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

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

www.earthfirstpla.com www.sidaplax.com www.plasticsuppliers.com Sidaplax UK : +44 (1) 604 76 66 99 Sidaplax Belgium: +32 9 210 80 10 Plastic Suppliers: +1 866 378 4178

ProTec Polymer Processing GmbH Stubenwald-Allee 9 64625 Bensheim, Deutschland Tel. +49 6251 77061 0 Fax +49 6251 77061 500 info@sp-protec.com www.sp-protec.com 6.2 Laboratory Equipment

MODA: Biodegradability Analyzer SAIDA FDS INC. 143-10 Isshiki, Yaizu, Natur-Tec® - Northern Technologies Shizuoka,Japan Tel:+81-54-624-6260 4201 Woodland Road Info2@moda.vg Circle Pines, MN 55014 USA www.saidagroup.jp Tel. +1 763.404.8700 Fax +1 763.225.6645 info@natur-tec.com 7. Plant engineering www.natur-tec.com

3. Semi finished products 3.1 films

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

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

President Packaging Ind., Corp.

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

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

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

bioplastics MAGAZINE [05/14] Vol. 9

55

Suppliers Guide 9. Services

Biopolynov 11 rue François Arago 14123 Ifs – France Tel. +33 2 31 83 50 87 www. biopolynov.com t.lefevre@natureplast.eu

10.2 Universities

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

UL International TTC GmbH Rheinuferstrasse 7-9, Geb. R33 47829 Krefeld-Uerdingen, Germany Tel.: +49 (0) 2151 5370-370 Fax: +49 (0) 2151 5370-371 ttc@ul.com www.ulttc.com 10. Institutions

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

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

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

10.1 Associations

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

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

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

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

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

‘Basics‘ book on bioplastics This book, created and published by Polymedia Publisher, maker of bioplastics MAGAZINE is available in English and German language (German now in the second, revised edition).

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

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

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

110 pages full color, paperback ISBN 978-3-9814981-1-0: Bioplastics ISBN 978-3-9814981-2-7: Biokunststoffe neu: 2. überarbeitete Auflage

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

Or subscribe and get it as a free gift (see page 57 for details, outside German y only) 56

bioplastics MAGAZINE [05/14] Vol. 9

Events

Event Calendar BioEnvironmental Polymer Society

14.10.2014 - 17.10.2014 - Kansas City, USA Kauffman Foundation Conference Center

Subscribe now at bioplasticsmagazine.com the next six issues for €149.–1)

www.beps.org

4. Kooperationsforum Biopolymere 21.10.2014 - Straubing, Germany Joseph-von-Fraunhofer-Halle

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

http://www.bayern-innovativ.de/biopolymere2014

World Bio Markets USA

27.10.2014 - 29.10.2014 - San Diego (CA), USA http://www.greenpowerconferences.com/BF1410US

“Naturfaserverstärkte Kunststoffe”– Anwendungen, Innovationen und Trends

2) aged 35 and below.

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

04.11.2014 - Kaiserslautern, Germany IVW-Institut für Verbundwerkstoffe GmbH www.avk-tv.de

Ecochem The Global Sustainable Chemistry & Engineering Event 11.11.2014 - 13.11.2014 Congress Center Basel http://ecochemex.com/

Bio-based Plastics – How do we Grow the EU Industry?

01.12.2014 - Brussels, Belgium The Square Brussels

http://bio-tic-workshops.eu/bio-based_plastics/

3rd Conference on Carbon Dioxide as Feedstock for Chemistry and Polymers 02.12.2014 - 03.12.2014 - Essen, Germany Haus der Technik http://www.co2-chemistry.eu/registration

9th European Bioplastics

02.12.2014 - 03.12.2014 - Brussels, Belgium The Square, Brussels www.european-bioplastics.org

BioPlastics: The Re-Invention of Plastics via Renewable Chemicals 28.01.2015 - 30.01.2015 - Miami, Florida, USA InterContinental on Biscayne Bay http://bioplastconference.com

World Bio Markets 2015

10.03.2015 - 12.03.2015 - Amsterdam, The Netherlands http://www.greenpowerconferences.com/BF1503NL

Green Polymer Chemistry 2015

18.03.2015 - 19.03.2015 - Cologne, Germany Maritim Hotel, Cologne, http://www.amiplastics.com/events/event?Code=C637

NPE 2015 - The international Plastics Showcase 23.03.2015 - 27.03.2015 - Orlando FL, USA http://bit.ly/1lCHjPA

You can meet us

+

or

Mention the promotion code ‘watch‘ or ‘book‘ and you will get our watch or the book3) Bioplastics Basics. Applications. Markets. for free 1) Offer valid until 31 Dec. 2014 3) Gratis-Buch in Deutschland nicht möglich, no free book in Germany

bioplastics MAGAZINE [05/14] Vol. 9

57

Companies in this issue Company

Editorial

Aalto University

24

Genomatica

28

President Packaging

Acordis

24

Gevo

28

ProTec Polymer Processing

55

ADM

28

Grabio Greentech

55

PSM

55

Agrana Starch Thermoplastics

54

Grafe

7,16

PTT-MCC Biochem

28

AIMPLAS

7,32

Granvio

28

Qmilch Deutschland

20

Akro Plastic

35

Green Dot Holdings

42

Rhein Chemie

55

Amyris

28

Hallink

55

Rhetech

46

API

54

Helian Polymers

8

Rodenburg

11

API-Institute

15

Huhtamaki Films

55

Roquette

28

Arkema

22

IFA Tulln

41

RSB

52

Bangor Univ.

33

IfBB Inst. Biopl. & Biocomposites 7

RTD Services

30

BASF

8,11,28,31

ISCC PLUS

Saida

55

BeginAgain

42

JinHui

BioAmber

28

Kingfa

54

Shenzhen Esun Industrial

54

Biobased Packaging Innovations

9

Kuender

10,49

Showa Denko

54

Biomer

7

Kuraray

28

Sidaplax

55

Biopolynov

56

Lake Constance

34

Sider Arc

19

Bioseries

37

Lanxess

28

Solvay

28

Biotec

55

Leibniz-Institut für Agrartechnik

33

Sulzer

10

Bio-Tic

48

Lenzing

24

Supla

10,49

BPI

56

Limagrain Céréales Ingrédients

54

Swiss Coffee Company

11

Bureau Waardenburg

11

Loick

38

Synbra

10

Cargill

8,28

Luke‘s Toys

46

Taghleef Industries

31,34

Cathay

12

Metabolix

44, 48

TianAn Biopolymer

55

CET ECE

32

Michigan State University

56

TNO

30

CIB-CSIC

30

Mico Pac

31

Toray

28

Coca-Cola

5

Minima Technology

55

Uhde

28

Composites Evolution

34

Mitsubishi Chemical

28

Uhde Inventa-Fischer

55

Corbion

10,28

Mitsui

28

UHU

11

Dow

28

Monnet

22

UL International

56

Dr. Boy

47

Myriant

28

Univ. North Texas

5

Druckhaus Rahning

31

narocon

56

Univ. of Natural Research

41

DSM

28

Natureplast

54

Univ. Stuttgart (IKT)

6

DuPont

25,28

54

NatureWorks

36,37

Vanguard Plastics

46

Ecochem

47

Natur-Tec

55

Viessmann

36

Erema

43,55

Netzsch

Vinçotte

53

Virent

5

Europa Bio

49

European Bioplastics

3

Evonik

28

Fachag. Nachw. Rohstoffe FNR

Advert

Company

54

Editorial

Advert

54,55

56

52 23, 54

55

17

Company

Editorial 55

55

Shandong Fuwin

26,54

Nova Nature

36

33,56

nova-institute

52

40,56

Vollmer

36

54,59

Novamont

28

55,60

WinGram

54

45

Novozymes

8,28

Withbread Wilkinson

36

41

OPX Bio

28

Wuhan Huali

Faurecia

28

OWS

6

Zandonella

10

FKuR

8

Plastic Suppliers

55

24

plasticker

Zhejiang Hangzhou Xinfu Pharmaceutical

54

Fraunhofer IAP Fraunhofer UMSICHT

56

polymediaconsult

56

Ziehl-Abegg

35

GEA 2H Water Technologies

11

PolyOne

37

Zoë b

44, 48

37

54,55

55

56

Fasal

2,54

Advert

14,55

2014

Editorial Planner Issue

Month

Publ.-Date

edit/ad/ Deadline

Editorial Focus (1)

Editorial Focus (2)

06/2014

November/December

01.12.14

01.11.14

Films / Flexibles / Bags

Consumer Electronics

Editorial Focus (3)

Basics

3D Printing

Sustainability

Subject to changes

www.bioplasticsmagazine.com

58

bioplastics MAGAZINE [05/14] Vol. 9

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VESTAMID® Terra

High Performance Naturally

Technical biobased polyamides which achieve performance by natural means VESTAMID® Terra DS VESTAMID® Terra HS VESTAMID® Terra DD

(= PA1010) (= PA610) (= PA1012)

100% renewable 62% renewable 100% renewable

• Outstanding mechanical and physical properties • Same performance as conventional engineering polyamides • Significant lower CO2 emission compared to petroleum-based polymers • A wide variety of compound solutions are available 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