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Vol. 2 ISSN 1862-5258<br />

Special editorial Focus:<br />

Films, trays<br />

03 | 2007<br />

bioplastics magazine<br />

Show preview | 13<br />

Industrial Composting | 36<br />

Logos, Part 5 | 38


Visit us:<br />

K 2007,<br />

Hall 5,<br />

Stand B21<br />

Don’t worry,<br />

the raw material for Ecovio ®<br />

is renewable.<br />

Ecovio ® , a biodegradable plastic from the PlasticsPlus TM product line,<br />

is keeping up with the times when it comes to plastic bags and food<br />

packaging. Ecovio ® is made of corn starch, a renewable raw material,<br />

and it has properties like HD-PE, which translates into a double plus<br />

point for you. Films made of Ecovio ® are water-resistant, very strong<br />

and degrade completely in composting facilities within just a few weeks.<br />

www.ecovio.com<br />

I N N O VAT I O N R E L I A B I L I T Y PA R T N E R S H I P D I V E R S I T Y


Editorial<br />

dear readers<br />

Bottles made from bioplastics, particularly PLA bottles for the<br />

beverage and dairy industries, were the main editorial focus of our<br />

last issue. And since this special field of application is such a dynamic<br />

one, bioplastics MAGAZINE hosted the 1st PLA Bottle Conference in<br />

Hamburg in mid September. I must admit, the interest and participation<br />

at this conference exceeded our expectations. It was a great success,<br />

and you can read our summary report in this issue.<br />

One of the points frequently discussed about PLA is its limited market<br />

availability. Different courses of action are being taken with the aim of<br />

increasing production capacity. However, PLA is not the only bioplastic<br />

material. Many people who briefly evaluate the bioplastics scene come<br />

to a misleading conclusion: „bioplastics = PLA = not available, hence<br />

bioplastics are not available“. And that is clearly wrong. There are a<br />

number of different bioplastics available in sufficiently large quantities,<br />

including starch based materials or starch blends, cellulose based<br />

materials and more.<br />

So knowing this, the editorial focus of this issue is firmly on films and<br />

trays. We are grateful to Stuart Lendrum of Sainsbury‘s in the UK, who<br />

gave us the benefit of his experience and Sainsbury‘s philosophy in<br />

an interview. Sainsbury‘s announced last year that they were going to<br />

replace the packaging material of 500 product lines with biodegradable<br />

materials.<br />

Another highlight that plastics people (and not only<br />

bioplastics people) are looking forward to is the world‘s<br />

biggest plastics show – the K‘2007 in Düsseldorf,<br />

Germany from October 24 – 31. For those of our readers<br />

who are going to the „K“ show we have put together a<br />

preview, so that you can easily find your way through this<br />

mega event, and see all the exhibitors that are active in<br />

the field of bioplastics. And please don‘t forget to see the<br />

booth of bioplastics MAGAZINE in Hall 7, booth number<br />

C09.<br />

Special editorial Focus:<br />

Films, trays<br />

03 | 2007<br />

Vol. 2 ISSN 1862-5258<br />

And of course in this issue, you’ll find much more of the<br />

latest bioplastics news, updates on materials, applications,<br />

politics, basics, opinions, events and much more.<br />

Michael Thielen<br />

Publisher<br />

K‘2007 preview | 13<br />

Industrial Composting | 36<br />

Logos, Part 5 | 38<br />

bioplastics MAGAZINE<br />

bioplastics MAGAZINE [03/07] Vol. 2


Content<br />

October 03|2007<br />

Editorial 03<br />

News 05<br />

Suppliers Guide 42<br />

Events 46<br />

Materials<br />

PHBV from Tianan-Biologic 24<br />

Bio-Ethanol based Polyethylene 26<br />

Applications<br />

Trays made from sugarcane 28<br />

New Closures for Beverage Bottles 29<br />

Politics<br />

Overview of the Current Biopolymers 31<br />

Market Situation<br />

Basics<br />

PHA Bioplastics and how they’re made 34<br />

Industrial Composting: An Introduction 36<br />

Logos Part 5: GreenPla Logo (Japan) 38<br />

Glossary 40<br />

Opinion<br />

Preview<br />

Careful use of terms like 39<br />

“Biodegradable and compostable”<br />

K’2007 preview 12<br />

Special<br />

Interview with Stuart Lendrum, Sainsbury‘s 16<br />

Compostable Films and Trays 18<br />

Biodegradable foam trays for fresh food 22<br />

Impressum<br />

Publisher / Editorial<br />

Dr. Michael Thielen<br />

Samuel Brangenberg<br />

Dr. Thomas Isenburg, Contributing Editor<br />

Layout/Production<br />

Mark Speckenbach, Jörg Neufert<br />

Head Office<br />

Polymedia Publisher GmbH<br />

Hackesstr. 99<br />

41066 Mönchengladbach, Germany<br />

phone: +49 (0)2161 664864<br />

fax: +49 (0)2161 631045<br />

info@bioplasticsmagazine.com<br />

www.bioplasticsmagazine.com<br />

Media Adviser<br />

Elke Schulte, Katrin Stein<br />

phone: +49(0)2359-2996-0<br />

fax: +49(0)2359-2996-10<br />

es@bioplasticsmagazine.com<br />

Print<br />

Tölkes Druck + Medien GmbH<br />

Höffgeshofweg 12<br />

47807 Krefeld, Germany<br />

Print run: 8,000 copies<br />

bioplastics magazine<br />

ISSN 1862-5258<br />

bioplastics magazine is published<br />

4 times in 2007 and 6 times a year from 2008.<br />

This publication is sent to qualified<br />

subscribers (149 Euro for 6 issues).<br />

bioplastics MAGAZINE is read<br />

in more than 80 countries.<br />

Not to be reproduced in any form<br />

without permission from the publisher<br />

The fact that product names may not<br />

be identified in our editorial as trade<br />

marks is not an indication that such<br />

names are not registered trade marks.<br />

bioplastics MAGAZINE tries to use British<br />

spelling. However, in articles based on<br />

information from the USA, American<br />

spelling may also be used.<br />

Cover<br />

bioplastics MAGAZINE is grateful to real<br />

supermarkets for the permission to shoot the<br />

cover photo<br />

bioplastics MAGAZINE [03/07] Vol. 2


News<br />

Clearly much tougher<br />

Sukano announces unique impact modifier for<br />

transparent PLA applications<br />

Highly transparent polylactide (PLA) packaging with significantly<br />

enhanced impact resistance is now a reality, thanks to SUKANO®<br />

PLA im S550. The special feature of this revolutionary impact modifier,<br />

which has been optimised for use with FDA-approved food<br />

contact biodegradable PLA, is that it does not impair the transparency<br />

or the heat stability of the PLA. At a concentration of just<br />

4% impact resistance is improved by a factor of 10, so preventing<br />

cracks and splinters in PLA sheet and film during cutting or<br />

stamping. In comparison with competitive products SUKANO®<br />

PLA im S550, in addition to its compostability and excellent transparency,<br />

is highly cost-effective. In comparison with other products<br />

in the market this unique impact modifier is compostable and is<br />

above all highly transparent. PLA processors can use the impact<br />

modifier in combination with other Sukano PLA masterbatches,<br />

such as the PLA dc S511 slip/antiblock concentrate or white and<br />

black colour masterbatches, to produce a tailor-made blend with<br />

no loss of performance.<br />

www.sukano.com<br />

Impect strength of PLA film<br />

Impact strength of PLA film<br />

China‘s Livan to<br />

build plants in<br />

Hungary for<br />

20 million EUR<br />

Chinese packaging firm Livan Biodegradable<br />

Product Co. Ltd. will set up two plants<br />

in Hungary at a combined cost of HUF 5 billion<br />

(EUR 19.6 million) , the Hungarian Ministry<br />

of Economic Affairs has said.<br />

Livan will build plants in Alsózsolca and<br />

Edelény (eastern Hungary) in scope of a<br />

green-field investment. The deal is the first<br />

Chinese investment of this kind in Hungary.<br />

The plants, which will create 800 jobs,<br />

are to be built by 2009. Initially, it is planned<br />

to produce 50,000 metric tonnes a year of<br />

environmentally friendly packaging material<br />

and double that amount by a later date<br />

when Livan adds new capacities to the facility.<br />

The company will use corn to make<br />

packaging boxes for the food industry.<br />

1.4<br />

1.2<br />

Impact Strength ISO 6603/2 @ RT<br />

PLA film 500 µm with<br />

2% SUKANO ® PLA dc S511<br />

1.0<br />

Total Energy (J)<br />

0.8<br />

0.6<br />

0.4<br />

0.2<br />

0.0<br />

0% 4% 8%<br />

% S UKANO®<br />

PLA im S550<br />

bioplastics MAGAZINE [03/07] Vol. 2


News<br />

OnColor TM BIO Colorants and<br />

OnCap TM BIO Additives based on<br />

sustainable raw materials<br />

PolyOne Corporation recently introduced its new OnColor BIO Colorants and OnCap BIO Additives<br />

for use in biodegradable polymers such as polylactide (PLA), polyhydroxybutyrate- valerate<br />

copolymer (PHBV), polybutylene succinate (PBS), polybutylene adipate- co-terephthalate (PBAT)<br />

and starch blends.<br />

„We developed these new colorants and additives in direct response to requests from our customers<br />

around the world for products based on sustainable materials,“ said John Van Hulle, vice<br />

president and general manager, North American Color for PolyOne color and additives products<br />

and services. „OnColor BIO Colorants and OnCap BIO Additives enable our customers to manufacture<br />

products with low environmental impact.“<br />

OnColor BIO Colorants are available in a wide range of transparent and opaque colors. The<br />

OnCap BIO Additives product line includes denesting, antistatic, slip, antiblock, UV protection,<br />

blue tone and anti-fog additives. PolyOne also offers OnColor SmartbatchTM BIO masterbatches,<br />

which combine OnColor BIO Colorants and OnCap BIO Additives into a single masterbatch.<br />

In addition to offering several standard product grades, PolyOne can customize an OnColor BIO<br />

Colorant or OnCap BIO Additive to meet a customer‘s specific processing need or end-use application.<br />

PolyOne‘s OnColor BIO Colorants and OnColor BIO Additives meet several global industry<br />

and composting standards, including EN 13432 (European Union), ASTM D6400 (U.S.A.), BPS<br />

GREENPLA (Japan) and DIN CERTCO (Germany).<br />

www.polyone.com<br />

PLA based bioplastics from sugar<br />

beet and sugarcane residues<br />

Bio-On, an Italian start-up company is entering the bioplastics market with a process that<br />

produces polylactide based bioplastics (PLA) from sugar beet and sugarcane residues with a<br />

claimed efficiency of 95%: Waste streams become valuable resources that can be converted almost<br />

in their entirety in a useful product. Sugar beet pulp, one of the prime feedstocks, is usually<br />

used as low value animal feed or disposed of at additional cost. Likewise, bagasse and mollases<br />

from sugarcane have a relatively low value and are abundantly available.<br />

PLA based bioplastics are currently produced almost exclusively from corn and grain starch.<br />

But given that prices for these feedstock keep rising because of their use in the production of<br />

ethanol, the utilization of new raw materials becomes an attractive proposal. The production<br />

of sugar crops, on the contrary, is outstripping demand. Both Brazil and India delivered record<br />

crops, and sugar prices have declined in the EU.<br />

The production process would reduce energy costs and as it is based on a multi-feedstock<br />

strategy, costs for raw materials would be substantially lower than those for traditional PLA production.<br />

A first range of products to be developed by Bio-On are a range of biodegradable plastics<br />

with natural flame retardants to be used for automotive applications:<br />

The planned location of the production plant is quite significant: ‚Plastic Valley‘ in Bologna,<br />

the region with a long tradition of developing innovative plastics, with some leading research<br />

organisations working on bioproducts. There, Bio-On is creating relations with universities and<br />

scientists, and aims to have a production facility ready by 2009. Output would be 10,000 tons.<br />

bioplastics MAGAZINE [03/07] Vol. 2


News<br />

First Commercial Launch of<br />

Amcor NaturePlus heat-seal<br />

Materbi film for Fresh Produce<br />

Major UK retailer Sainsburys and its potato packer Greenvale are the first to commercially<br />

launch Amcor NaturePlus’ heat-seal Materbi VFFS film within the fresh produce<br />

sector on their JS SO Organic Baby Salad Potatoes, 750g. This launch is part of the environmental<br />

plan set out by Sainsbury’s in September 2006, where it vowed to change traditional<br />

packaging across its SO organic food lines to use more environmentally friendly<br />

compostable packaging.<br />

The Amcor NaturePlus heat-seal Materbi VFFS film is manufactured from renewable<br />

materials and is fully compostable. The 40 micron co-extruded material is produced at<br />

Amcor’s extrusion site in Ilkeston in the UK and is then printed and converted at AF Ledbury<br />

– the centre of excellence for Fresh Produce packaging. This novel new extrusion<br />

offers a differential heatseal film suitable for VFFS packing of fresh produce. Conventional<br />

grades of MaterBi require impulse seals so are not suitable for the majority of VFFS vegetable<br />

pacing lines currently used by UK retail packers.<br />

This compliments the growing range of environmental films supplied by Amcor Flexibles<br />

under the Amcor NaturePlus umbrella and enhances Amcor’s position as a leading supplier<br />

in this growing market.<br />

www.amcor.com<br />

No mandatory deposit for<br />

bottles made from bioplastics<br />

German Cabinet Decision to Modify<br />

Packaging Ordinance<br />

The European Bioplastics industry association appreciates the German Cabinet Decision<br />

of Sept. 19, 2007. Within the framework of the 5th amendment to the German<br />

Packaging Ordinance beverage bottles made of a minimum of 75% of bioplastics shall<br />

be exempted from the mandatory deposit. Another prerequisite is the participation of the<br />

packaging producers in an appropriate waste disposal system. The association values<br />

this as a clear commitment by the German Government towards the support of innovation<br />

leading to a sustainable development.<br />

By this exemption, which is limited until 2010, the necessary and cost-intensive buildup<br />

of a sorting- and recycling-system for bioplastic bottles, normally obligatory within<br />

the mandatory deposit, can be delayed until a later date. Until that time the collection<br />

and recycling can be done via the so-called “dual systems”, such as the yellow sacks or<br />

yellow bins.<br />

“It absolutely makes sense to invest in the development of technology and marketing of<br />

bioplastic bottles first, and then later to create the best end of life solution”; says Harald<br />

Kaeb, chairman of European Bioplastics.<br />

bioplastics MAGAZINE [03/07] Vol. 2


www.fkur.com<br />

Hall 7.1<br />

Stand A20/A22


News<br />

New Zealand‘s first ever<br />

Bio-Bottle<br />

“Try Me, NZ’s first ever Bio-Bottle” reads the swing tag hanging<br />

from New Zealand’s first bottled water product made from PLA.<br />

After two years of product research and development, ‘good’ was<br />

launched in September by The Good Water Company. CEO Grant<br />

Hall claims ‘good’ is the world’s most sustainable bottled water<br />

package. The Good Water Company will donate 10 cents for every<br />

bottle sold to support The Sir Peter Blake Trust. Sir Peter Blake’s<br />

famous quote “good water, good life” is being used to market this<br />

initiative to reinforce how significant water is in sustaining quality<br />

of life and how we must commit to protecting the environment.<br />

While these bio-bottles cost more to produce, The Good Water<br />

Company doesn’t want to penalise the consumer at the retail end<br />

for making the right purchasing decision, so ‘good’ will also be<br />

competitively priced in relation to non-sustainable plastic rivals.<br />

After ‘Biota’ in the US and the UK-based ‘Belu’, Hall says ‘good’<br />

uses that same technology and goes one step further by using a<br />

compostable wood pulp label complete with a water-based adhesive.<br />

The actual water itself is certified bio-gro organic and comes<br />

from a unique silica rich source at the Kauri Springs in Kaiwaka,<br />

Northland. The projects biggest challenge has been formulating an<br />

end of life plan for the bottles once consumers have used them. Approximately,<br />

14,000 tonnes of plastic bottles go to landfill each year<br />

and the rest go to China. The Good Water Company wants to lead<br />

the way on the sustainable recycling of bottles in New Zealand and<br />

is a foundation partner in Greenplastics Incorporated, the countries<br />

first ever product stewardship organisation set up to manage end<br />

of life options for bio-polymers. The challenge is that the end of life<br />

program for bio-bottles can only work if enough of them are collected,<br />

which means the plan needs the support of retail customers<br />

in enough volume to make it viable. “It’s up to the public,” says<br />

Hall whose sales promotion for good offers purchasers the chance<br />

to win a trip to Antarctica. “If enough people support this project<br />

then we will be able to recycle the bottle here in New Zealand and<br />

that would be a first for any bottled water product in the country.”<br />

A natural container<br />

for natural products<br />

Silita, Spanish packaging manufacturer, is working<br />

together with a major producer and bottler of<br />

edible olive oil to test the behaviour of their product<br />

when packed in PLA bottles.<br />

The company, which specialises in manufacturing<br />

PET containers, has produced its first bottles with<br />

this new material and is conducting storage trials<br />

with different products, including oils, water, juices<br />

and dairy products.<br />

The NatureWorks PLA material was supplied by<br />

Safiplast S.L. , who also helped to co-ordinate the<br />

project. Safiplast S.L., (Barcelona, Spain) has been<br />

supplying machinery and services to produce bottles<br />

and drums using a range of technologies and<br />

materials for over 40 years. This project shows its<br />

interest in implementing projects for bottles made<br />

with the new bioplastic materials.<br />

www.safiplast.com<br />

www.goodwater.org.nz<br />

10 bioplastics MAGAZINE [03/07] Vol. 2


Event Review<br />

1 st PLA Bottle Conference<br />

The 1 st PLA Bottle Conference hosted by bioplastics<br />

MAGAZINE (September 12-13, Hamburg, Germany)<br />

attracted over 100 experts from more than 25 countries.<br />

Delegates from the beverage industry as well as<br />

bioplastics experts came from all over Europe, North<br />

America and countries as far away as Hawaii, Australia,<br />

South Africa and even Bhutan in the Himalayas.<br />

In the first session speakers from Uhde Inventa<br />

Fischer and NatureWorks introduced the basics of<br />

PLA. How is starch (e.g. from corn) converted into lactic<br />

acid and then into PLA? What properties of PLA lead<br />

to which applications, including stretch blow moulded<br />

bottles?<br />

Husky and SIG Corpoplast, being the machine suppliers<br />

for the first commercially available PLA preforms<br />

and bottles, covered the issues surrounding the<br />

particular processing characteristics of PLA.<br />

Caps and labels made from bioplastics were the<br />

subject of the next session with contributions from<br />

Novamont, Netstal and Wiedmer.<br />

The presentations about possibilities and challenges<br />

were rounded off by a presentation by Bernd Merzenich<br />

about the successful market launch of the German<br />

„Vitamore“ bottle. Bill Horner of Naturally Iowa commented<br />

on his experience with PLA milk bottles in a<br />

series of video clips.<br />

Distilling all of the experiences discussed, it can be<br />

stated, that until now the most significant limitations<br />

to the use of PLA as a bottle material are its low heat<br />

resistance and the poor barrier against water vapour<br />

and gases such as oxygen and carbon dioxide.<br />

However, „until now“ is an important phrase, which<br />

Mike Gamble of Coca-Cola also stressed in his presentation<br />

on „a brand owners perspective“. „A few year<br />

ago we might have been sitting here together and discussing<br />

the same questions about PET,“ he said.<br />

And, as the third subtitle of the conference was<br />

„prospects“, a presentation from Purac showed the<br />

possibilities to enhance the heat resistance of PLA<br />

by applying a stereocomplexation of PLA with PDLA.<br />

The presentation by SIG Pasmax on the other hand focussed<br />

on the prospects of improving the barrier properties<br />

of PLA by applying a thin glass-like (SiOx) layer<br />

on the inside of the bottle. This method exhibited barrier<br />

improvement factors (BIF) of about 90 for oxygen<br />

and of 4.5 for water vapour.<br />

The presentations were rounded off with talks by<br />

Polyone and Colormatrix about processing and colour<br />

additives. Erwin Vink of NatureWorks addressed the<br />

important issue of life cycle analyses and the possibilities<br />

to further reduce the environmental footprint<br />

of PLA.<br />

The conference ended with a panel discussion about<br />

possible „end of life options“. A clear conclusion to<br />

the question for the best option could of course not<br />

be found at this stage. However, the opinion that composting<br />

is not the best option was widely agreed. And<br />

as long as the (at present) limited amounts of PLA do<br />

not reach a critical mass for sorting and recycling, incineration<br />

with energy recovery seems to be a good<br />

solution. The technologies for sorting (e.g. via NIR =<br />

Near Infrared) and recycling, mechanical as well as<br />

chemical, are available. It is only a question of reaching<br />

the critical mass.<br />

After the conference the delegates were invited<br />

to visit the SIG Corpoplast and SIG Plasmax plant in<br />

Hamburg. Here the companies demonstrated the<br />

stretch blow moulding of PLA on a laboratory machine<br />

as well as the plasma coating of bottles.<br />

As the conference was considered by many – delegates<br />

as well as speakers, and by the organisers – as<br />

a great success, the second PLA Bottle Conference is<br />

definitely planned for 2008. However, date and place<br />

are still to be chosen.<br />

www.pla-bottle-conference.com<br />

bioplastics MAGAZINE [03/07] Vol. 2 11


News<br />

show<br />

preview<br />

Oct. 24-31, 2007 Düsseldorf, Germany<br />

Foams from the fields<br />

Biodegradable plastics and plastics based on renewable<br />

raw materials are a constant part of BASF’s research<br />

and development activities. After the market introduction<br />

of Ecovio ® LBX 8145 at the beginning of 2006, the first lab<br />

samples of the new Ecovio ® L Foam will be available in<br />

October 2007. The material is designed for foamed food<br />

trays and fast-food boxes. Like its predecessor the new<br />

Ecovio ® L Foam consists of Ecoflex ® , BASF’s biodegradable<br />

polyester, and the renewable raw material polylactide<br />

(PLA).<br />

BASF (Hall 5 - Booth B21) www.basf.com<br />

Biopolymers and<br />

natural fibrereinforced<br />

plastics<br />

M-Base is a leading supplier of material information<br />

systems and thus of course also engaged in the relatively<br />

new group of biopolymers and natural fibre materials.<br />

Unfortunately, only very little qualified information about<br />

these materials is available. M-Base is involved in a series<br />

of projects in this field which are to be presented at<br />

K‘2007:<br />

• www.N-FibreBase.net, is an information portal about<br />

natural fibre reinforced plastics including a database<br />

for polymers and fibres.<br />

• NF-Guidelines is a research project for the development<br />

of design catalogues and style guides for natural<br />

fibre reinforced plastics.<br />

• A campaign to industrially establish polypropylene-natural<br />

fibre injection moulding (PP-NF) and wood-plasticcomposites<br />

(WPC)<br />

• A biopolymer database (first public presentation at the<br />

exhibition).<br />

These projects are carried out in cooperation with a network<br />

of institutions such as Nova Institut Hürth, Faserinstitut<br />

Bremen, TU Clausthal, Fachhochschule Hannover.<br />

M-Base‘s goal is to create structures for the new materials<br />

so that information will be available equal to conventional<br />

materials.<br />

M-Base (Hall 5 - Booth F04) www.m-base.de<br />

At K‘2007, the world’s No. 1 plastics and rubber fair, to be<br />

staged from 24 to 31 October 2007 in Düsseldorf, Germany, more<br />

than 3,000 companies will showcase their latest developments<br />

for all industry segments. Among them quite a few companies<br />

that are busy in the field of bioplastics. In this K-show prview<br />

bioplastics MAGAZINE gives an overview of what visitors can<br />

expect in terms of bioplastics.<br />

All-natural colour and<br />

additive masterbatches<br />

provide earth-friendly<br />

option for biopolymers<br />

A new family of all-natural colorants and additives from<br />

Clariant Masterbatches complements the environmentally<br />

friendly biopolymers that are becoming popular in “green”<br />

packaging and consumer goods applications. Based on<br />

natural materials such as flowers, the new RENOL ® -natur<br />

colour masterbatches and CESA ® -natur additive masterbatches<br />

are biodegradable and renewable, making them<br />

ideal for marketers who emphasize conservation and sustainability.<br />

Additional details on the new products can be<br />

expected to be announced at K2007 in October.<br />

Clariant Masterbatches Division (Hall 8A - Booth J11)<br />

www.clariant.masterbatches.com<br />

Masterbatches based<br />

on biodegradable<br />

polymers<br />

A. Schulman a global leader in masterbatches, compounds<br />

and distribution/trading offers a wide range of products.<br />

In response to market trends the range also includes<br />

masterbatches which are based on biodegradable polymers.<br />

In addition various oxy- and photodegradable formulations<br />

for applications in polyolefins are available. Detailed information<br />

upon request. A. Schulman is an independent manufacturer<br />

thus tailor-made solutions can be discussed!<br />

A. Schulman GmbH (Hall 8a - Booth D12) www.polybatch.net<br />

Photo: Clariant<br />

12 bioplastics MAGAZINE [03/07] Vol. 2


Biopolymer line adds injection<br />

molding, paper coating grades<br />

Telles, Lowell, MA, USA, bioplastics production joint venture between Metabolix<br />

Inc., Cambridge, MA, USA, and Archer Daniels Midland Co., Decatur, IL, USA, introduces<br />

three grades of Mirel semi-crystalline, biobased polyester: Mirel P1001,<br />

Mirel P1002 for injection molding applications; Mirel P2001 for paper coating. Mirel<br />

P1001 replaces styrenics, exhibits high modulus, high gloss, heat resistance. Mirel<br />

P1002 substitutes for polyolefins, offers higher flow, medium stiffness, heat resistance.<br />

Mirel P2001 provides an alternative to petroleum-based paper coatings,<br />

enables production of fully biodegradable coated paper cups, food packaging such<br />

as ice cream cartons. Attributes include heat sealability, good barrier properties,<br />

good printability, adhesion to substrates.<br />

News<br />

Telles (Metabolix/ADM) (Hall 5 - Booth G19-9) www.metabolix.com<br />

Photo: Telles<br />

DuPont‘s<br />

sustainable<br />

presence<br />

Highlights of the DuPont exhibit<br />

of the will include the latest<br />

developments in terms of polymer<br />

production from renewable<br />

sources. One of the early proponents<br />

of bio-sourced materials,<br />

DuPont is already processing<br />

corn grain to make Bio-PDO at<br />

a facility constructed with Tate &<br />

Lyle, which was officially opened<br />

in June 2007. DuPont is now exploring<br />

the refining of other cellulosic<br />

materials, such as corn<br />

stover – the residual from the<br />

plant that remains after the<br />

corn is harvested – to sugars<br />

for processing into value-added<br />

chemicals such as Bio-PDO.<br />

In 2008, the company is expected<br />

to participate in the construction<br />

and operation of a pilot cellulosic<br />

biorefinery for ethanol. “With<br />

the growing demand for sugars<br />

for industrial intermediates and<br />

biofuels, cellulosic conversion is<br />

an essential step in a biorefinery<br />

concept,” comments Dr. Nandan<br />

Rao, technology director for Du-<br />

Pont Performance Materials.<br />

DuPont (Hall 6 - Booth D27)<br />

www.dupont.com<br />

Biodegradable bags with<br />

Roll-o-Matic equipment<br />

In the past few years the plastic industry has experienced considerable product<br />

development – and naturally Roll-o-Matic has been a part of it. Today the market<br />

demands for converting equipment are higher as there is a need for innovative<br />

solutions that are both on the cutting edge of technology and also live up to new<br />

environmental standards. Roll-o-Matic too have noticed the bio-trend and applied<br />

the bio-principles to their converting equipment. The result is the Delta Line that<br />

can produce biodegradable bags on roll as well as plastic bags from standard<br />

material. At K-2007 Roll-o-Matic will exhibit a state-of-the-art Delta Line in order<br />

to demonstrate the equipment’s flexible design, running capacity, technological<br />

innovation and not least its ability to produce bags of various types.<br />

www.roll-o-matic.com Roll-o-Matic (Hall 3 - Booth D06)<br />

“Creative Solutions”<br />

for value-added plastics<br />

At K 2007 Sukano Products Ltd.is presenting its full range of functional and<br />

visually enhancing masterbatches. The spotlight will be on the latest product developments.<br />

Besides additives and masterbatches for “traditional“ plastics one<br />

highlight will be a transparent impact modifier for PLA.<br />

On the stand there will be full details of the well-established and successful<br />

range of slip/antiblock concentrates, matting agents, mould release agents and<br />

melt flow enhancers, antistatic agents, UV blockers, colours including black and<br />

white, optical brighteners, nucleating concentrates, and flame retardants, plus<br />

information on new applications. The main focus is on PET, PETG, PC and PLA<br />

applications. A particular highlight will be the PLA slip/antiblock masterbatch for<br />

use in biodegradable applications. In recognition of this development Sukano was<br />

selected as a finalist in the “Best Innovation in Bioplastics” competition at the<br />

28th Bioplastics Conference in Frankfurt, December 2006.<br />

Sukano (Hall 8A - Booth H28) www.sukano.com<br />

bioplastics MAGAZINE [03/07] Vol. 2 13


News<br />

Photo: Grafe<br />

GRAFE Advanced Polymers GmbH<br />

(Hall 7.1 - Booth C/25) www.grafe.com<br />

Masterbatches for<br />

biodegradable plastics<br />

The Grafe Group has developed biodegradable colour masterbatches available<br />

in the same brilliant colors and with the same technical characteristics<br />

as the „classic“ masterbatches. With these newly developed products, Grafe<br />

meets the challenges of increased environmental awareness and ever stricter<br />

environmental legislation.<br />

With immediate effect the Grafe Group will offer masterbatches for colouring<br />

biodegradable plastics under the brand name “Biocolen“. Plastics made from<br />

renewable raw materials pave the way for using closed recycling loops.<br />

Compostability of bioplastic products containing inorganic mineral pigments<br />

or organic synthetic dyes is reduced. However, products made with Biocolen<br />

masterbatches, which are produced with vegetable dyes, are completely biodegradable.<br />

“Stricter environmental legislation governing the use of plastics is bound to<br />

come - the political powers will see to that. Even today, we are already supplying<br />

the necessary raw materials to the plastics processing industry“, said<br />

Matthias Grafe, Manager of the Grafe Group.<br />

Nanostarch: the<br />

highlight of the year<br />

Novamont, leading company in the area of biodegradable<br />

polymers driven by its vision of “Living Chemistry for Quality of<br />

Life” and winner of the award “European Inventor of the Year<br />

2007”, will announce a further highlight at the K2007 show in<br />

Düsseldorf.<br />

Novamont has achieved a further significant technological<br />

breakthrough with Mater-Bi ® nanostarch, a range of products<br />

engineered to substantially improve the end-use performances<br />

of Mater-Bi grades containing starch, while maintaining<br />

its certified biodegradability even in home composting conditions.<br />

Nanostarch technology, patented by Novamont, will be a very<br />

powerful tool to produce super tough materials even in conditions<br />

of very low humidity, definitively overcoming the limitations<br />

of starch-based materials. Several applications will benefit<br />

of these new breakthrough of Novamont technologies to be<br />

announced at the K2007 show.<br />

Novamont is increasing its industrial capacity due to the new<br />

Biorefinery integrated in the territory<br />

NOVAMONT S.p.A. (Hall 6 - Booth E09) www.novamont.com<br />

show<br />

preview<br />

Oct. 24-31, 2007 Düsseldorf, Germany<br />

Plastics - made<br />

by Nature! ®<br />

Photo: FKuR<br />

FKuR together with Fraunhofer UMSICHT present<br />

their competence in the area of biodegradable films<br />

and compounds. “One of many highlights“ says Patrick<br />

Zimmermann of FKuR, “is a translucent film similar to<br />

HDPE“. Other examples include a wide range of biodegradable<br />

plastics primarily made of renewable raw<br />

material, e.g.: Bio-Flex ® (PLA/co-polyester-blends),<br />

Biograde ® (cellulose ester blends) or Fibrolon ® (Plastic-Wood-Compounds).<br />

Application examples are mulch<br />

films, waste bags, bottles made from PLA-blends and<br />

numerous injection moulded applications.<br />

FKuR Kunststoff GmbH (Hall 7-level 1 - Booth A20/A22)<br />

www.fkur.com , www.umsicht.fraunhofer.de<br />

14 bioplastics MAGAZINE [03/07] Vol. 2


New PHB formulation<br />

Biomer from Krailing, Germany introduce a new PHB<br />

formulation “with mechanical properties at least as good<br />

as polypropylene, if not better“, as Urs Hänggi of Biomer<br />

puts it. PHB is made of renewable resources, totally biodegradable<br />

(anaerobic and aerobic). Biomer‘s PHB compounds<br />

are free of catalysts, neither thrombogenic nor<br />

immunogenic. They offer a good creep resistance, faster<br />

cycle times and thinner walls, thus more complex structures<br />

become possible. The compounds are best for injection<br />

moulded technical applications.<br />

Biomer (Hall 7-Level 2 - Booth B30) www.biomer.de<br />

Polyethylene from<br />

bio-ethanol<br />

At the company’s Technology and Innovation Center the<br />

Brazilian company Braskem has developed the first internationally<br />

certified (ASTM D6866) polyethylene made from<br />

100% sugarcane based ethanol. The “green polymer“ developed<br />

by Braskem – a high-density polyethylene, one<br />

of the resins most widely used in flexible packaging – is<br />

the result of a research and development project in which<br />

already around 5 million US$ have been invested. To find<br />

out more, read the detailed article in this issue or meet<br />

Braskem at their Booth in Düsseldorf.<br />

New masterbatches<br />

PolyOne will introduce a range of new additive masterbatches<br />

designed to enhance the performance of biopolymers.<br />

Among these are<br />

• Enhanced impact & ductility of PLA sheet while maintaining<br />

transparency<br />

• Increase anti-fog properties for PLA film<br />

Besides the new masterbatches PolyOne will show the<br />

earlier developed color and additive masterbatches.<br />

The color masterbatches are especially designed to<br />

comply with the strict EN 13432 norm.<br />

The additive masterbatches offer improved processing<br />

and enhanced application performance<br />

PolyOne (Hall 8b - Booth G46) www.polyone.com<br />

News<br />

Braskem (Hall 6 - Booth E80) www.braskem.com.br<br />

Other companies exhibiting at K‘2007, that are involved<br />

in bioplastics but unfortunately did not provide us with<br />

detailed information in time for this issue are:<br />

Biotec Distribution, www.biotec-distribution.eu<br />

Hall 5 - Booth B13-3 and Hall 7-level 2 Booth E45<br />

CONSTAB Polyolefin Additives GmbH, www.constab.com<br />

Hall 7-level 1 - Booth C20<br />

Kaneka Belgium N.V., www.kaneka.be<br />

Hall 7a - Booth D32<br />

Kuraray Europe GmbH, www.kuraray.eu<br />

Hall 7a - Booth D06<br />

Marubeni Europe Plc, www.europe.marubeni.com<br />

Hall 7a - Booth D02<br />

SpecialChem, www.specialchem.com<br />

Hall 5 - Booth B41<br />

Technamation Technical Europe GmbH, www.technamation.com<br />

Hall 8b - Booth F8<br />

Toray Industries, Inc., www.toray.com<br />

Hall 7a - Booth D32<br />

Vanetti S.r.l. - Masterbatch, www.vanettimaster.com<br />

Hall 7-level 1 - Booth C03<br />

VTT Technical Research, Centre of Finland, www.vtt.fi<br />

Hall 11 - Booth C70<br />

Wells Plastics Limited, www.wellsplastics.com<br />

Hall 5 - Booth B40


Special<br />

“Make the difference” reusable carrier bags (Photo: Sainsbury’s)<br />

Photo: European Plastics News<br />

Interview<br />

with Stuart<br />

Lendrum,<br />

Sainsbury‘s<br />

Photo: Sainsbury’s<br />

stands for great products at fair prices.<br />

Our objective is simple; to serve customers well.<br />

“Sainsbury‘s<br />

We continually improve and develop our product<br />

ranges, and work hard to give customers an ever improving<br />

shopping experience. We also aim to fulfil our responsibilities<br />

to the communities and environments in which we operate.”<br />

(Soruce: www.jsainsburys.co.uk)<br />

bioplastics MAGAZINE spoke to Stuart Lendrum, Print and<br />

Packaging Manager of Sainsbury‘s Supermarkt Ltd.<br />

bpM: Mr. Lendrum, when did you start looking into bioplastics<br />

packaging materials? When did you actually start with your first<br />

products packed in biopackaging and which were these ?<br />

Stuart Lendrum: We first launched compostable packaging<br />

in 2002, certainly we were working on it some time before<br />

that. Predominatly that would have been trays based on palm<br />

leaves.<br />

bpM: What were the main reasons for you (for Sainsbury‘s) to<br />

introduce biodegradable packaging?<br />

Stuart Lendrum: The main reason for introducing biodegradable<br />

packaging was to make customers lives easier, we<br />

have a set of packaging brand standards; and the aim of our<br />

packaging brand standards, which is something that we apply<br />

across all our products is that we want to reduce the amount<br />

of packaging we use and make that packaging we do use, either<br />

reusable, home compostable or recyclable. So obviously<br />

different products are differently made and offer different opportunities<br />

but one of the big key strands is to introduce and<br />

to use home compostable packaging.<br />

bpM: How did the introduction start and progress?<br />

Stuart Lendrum: The first step to bring such products to the<br />

market, learn about them and get customers used to them<br />

was through our SO organic produce range. We see that the<br />

opportunity for home copostable packaging is much bigger<br />

than just SO organic produce for example ready meals. Last<br />

year we also launched the world‘s first compostable easter<br />

egg holder. That is a kind of a clamshell made of Plantic material.<br />

Concerning the progress: We have a large number of<br />

organic products across, we have the easter egg and we‘re<br />

16 bioplastics MAGAZINE [03/07] Vol. 2


Photo: Sainsbury’s<br />

Special<br />

just about to pack a whole chicken on a sugarcane tray<br />

and we are still working towards introducing the ready<br />

meal packaging. We are really happy with the progress we<br />

have made so far in terms of the introduction across our<br />

organic produce area and the other things we are doing. It<br />

is very challenging bringing new materials to the market<br />

place and putting them on the shelves, but we are committed<br />

to moving forward with these materials.<br />

bpM: Last year Sainsbury‘s announced the conversion of<br />

500 product lines or 3,550 tons respectively into biopackaging.<br />

How far are you at this point in time?<br />

Stuart Lendrum: The rollout in the ready meals category<br />

is taking longer than anticipated but we are pleased<br />

with our progress to date.<br />

bpM: What kind of biopackaging are you currently offering<br />

to your customers?<br />

Stuart Lendrum: We currently use sugarcane based<br />

materials, Natureflex – cellulose based films, Mater-Bi<br />

– starch based materials, Plantic – starch based water<br />

soluble materials and combinations of these with compostable<br />

labels. The only material that we do not use is<br />

PLA because we won‘t use any material where we can‘t<br />

guarantee that it is from non-GM sources. And we only<br />

want to offer our customers home compostable materials<br />

– PLA is not home compostable.<br />

bpM: Are you satisfied so far with the conversion to biopackaging?<br />

Stuart Lendrum: Yes. We‘ve done a lot and there‘s a lot<br />

more to do.<br />

bpM: What are your consumers responses? Do they accept<br />

it well? Do they ask for more?<br />

Stuart Lendrum: Certainly all the customer‘s feedback<br />

we get on compostable packaging is that they do like it<br />

and yes they do want more. But they want the packaging<br />

to perform as well as the existing packaging formats.<br />

That‘s the challenge for us: We know that materials do<br />

have limitations and do not always perform as per current<br />

materials and how customers would like them to.<br />

bpM: With which partners did or do you cooperate? Did or<br />

do you get a good support from them? How does such support<br />

look like?<br />

Stuart Lendrum: We cooperate with companies like Innovia,<br />

Novamont, Plantic, natura, Amcor, Telrol or Paragon<br />

Flexibles and of course our product suppliers. And<br />

yes, we do get support from all of them. We feel that everybody<br />

is motivated to try and make these developments.<br />

We do a lot of testing on products, trying to improve the<br />

performance. And it is only possible if all of us work together<br />

to make these improvements. The key thing is the<br />

commitment of the people involved.<br />

bpM: What is more important from your point of view:<br />

A) biobased packaging, i.e. made from renewable<br />

resources or<br />

B) compostable packaging ?<br />

Could you tell us why?<br />

Stuart Lendrum: The most important thing for us is to<br />

reduce the amount of packaging we use and make our<br />

packaging reusable, home compostable or recyclable.<br />

What we want to do is do all of that in a sustainable way.<br />

bpM: What future plans do you have? In short term (next<br />

365 days) – in long term (next few years)?<br />

Stuart Lendrum: We want to continue to introduce more<br />

compostable packaging and try to move forward the quality<br />

of what we do. All within the context of making our customer‘s<br />

life easier. Both short term and long term we want<br />

to reduce the amount af packaging we use, regardless of<br />

what hat material is – that would be the absolute goal.<br />

bpM: What are you (is Sainsbury‘s) particularly proud of (in<br />

terms of this overall topic)?<br />

Stuart Lendrum: What we are particularly proud of is<br />

that we are continually improving our customer offer to<br />

make our customer‘s life easier by offering them packaging<br />

that they can compost at home as opposed to send to<br />

landfills.<br />

bpM: Thank you very much.<br />

bioplastics MAGAZINE [03/07] Vol. 2 17


Special<br />

Compostable<br />

Films and Trays<br />

The revolution in the food<br />

packaging sector.<br />

Article contributed by<br />

Stefano Facco, New Business<br />

Development Manager<br />

Novamont S.p.A., Novara, Italy<br />

The development of compostable polymers in the<br />

trays and films sector has enjoyed a dramatic boost<br />

in recent years. We may describe it mainly based on<br />

two aspects. The first aspect is the technical improvement<br />

in terms of performance and processing: lately we have<br />

seen more and more “high tech” biopolymers with properties<br />

similar to or, in some very specific cases, even better<br />

than standard polymers. The second aspect is the change<br />

in attitude of retailers and consumers, and the approach to<br />

waste management issues.<br />

Compostable and biobased polymers have, in the last<br />

4 to 5 years, demonstrated a really outstanding development,<br />

which has enabled them to be used almost as standard<br />

polymers in specific packaging applications. Major<br />

producers are based in Europe (such as Wentus, Amcor,<br />

Innovia, Treophan etc), as well as in the USA. In the food<br />

sector in particular new packaging for different products<br />

has been shown to have reached performances as high<br />

as some standard products. Starting from thermoformed<br />

punnets and trays, the market today offers products which<br />

may be as tough as the equivalent conventional ones. Also,<br />

in terms of processing, standard extrusion lines such as<br />

used for PP may be used for bioploymers. Another important<br />

aspect is given by the capability of recycling these new<br />

materials. This is a very important aspect when considering<br />

extrusion and thermoforming, as some 30% of scrap<br />

may result from a standard thermoforming process. And<br />

not only toughness, but also puncture resistance and rigidity<br />

have reached very high levels. In terms of transparency,<br />

a variety of companies do offer either very transparent or<br />

white opalescent products. Linear shrinkage values are<br />

comparable to standard polymers and may vary as from<br />

PP to PS. The Tg values, which may be a reason to choose<br />

18 bioplastics MAGAZINE [03/07] Vol. 2


Special<br />

a particular polymer (depending whether a punnet is<br />

used under deep frozen or ambient conditions), range<br />

from below 0°C to above 40°C.<br />

If the development of rigid trays has already reached<br />

a very high industrial level, the expanded tray sector is<br />

very close to reaching similar standards. Some different<br />

products are starting to show up in first applications and<br />

there are a number of products which have been shown<br />

to perform quite well. The first one, very close to being<br />

introduced in the UK (produced by Sirap Gema), which<br />

is a new and very light product, has been demonstrated<br />

to be, in the case of packaging delicate produce, even<br />

better compared to a standard EPS in terms of its cushioning<br />

properties. It has a very soft touch, white colour<br />

and has been tested by a major packaging company<br />

which has carried out a comparable test amongst major<br />

producers of trays (rigid and expanded). The results<br />

were really astonishing, as this new material shows incredible<br />

performance profiles in terms of handling and<br />

cushioning.<br />

In addition some products are starting to slowly move<br />

into the market, although we still may not consider<br />

them as expanded, as they belong more to the sheets<br />

category, but which are lighter compared to a standard<br />

sheet / tray, showing an expanded core and a still-rigid<br />

skin. Most of these products described above do have,<br />

due to their morphology, a white or opaque colour.<br />

A very new technology is soon to be launched on the<br />

market, namely laminated paper / cardboard trays. In<br />

this case we do have different technologies available,<br />

either based on coatings from a solution, or laminated<br />

with a compostable film. A third technology is based on<br />

extrusion coating (Mondi Packaging). Specifically in this<br />

latter technology, the possibility to use such extrusion<br />

coated trays may open up applications such as for microwavable<br />

food, as it seems that the weakening and<br />

melting points do satisfy the needs of such “cooking<br />

technology”. For standard coated paper/board (for frozen<br />

and room temperature applications) different polymers<br />

are already available on the market.<br />

But, as a filled punnet should not loose its content,<br />

there is a need for specific films or nets, in order to<br />

complete the packaging unit.<br />

Compostable and biobased films started their development<br />

many years ago and the results are very well<br />

visible on the market, if we consider the very high percentage<br />

of biopolymers used. According to different<br />

studies some two thirds of the given applications in the<br />

biopolymers sector is covered by films. Newly introduced<br />

wicketed bags, films for VFFS and flow pack have<br />

demonstrated the very high level achieved.<br />

The 9th Annual<br />

Bioplastics Conference<br />

Performance through innovation<br />

Featuring presentations from<br />

■ NEC ■ Metabolix ■ FKuR ■ NNZ<br />

■ Utrecht University ■ Braskem<br />

■ PA Consulting ■ Natureworks<br />

■ Tianan Biologic ■ PSM<br />

■ Eosta / The Organic Salad Company<br />

Plus – includes the second<br />

annual Bioplastics Awards<br />

5 – 6 December 2007 - Hyatt Regency, Cologne, Germany<br />

To register - Tel: +44 (0)20 7554 5811<br />

(International) 0845 056 5069 (UK Only)<br />

Email: EPNconferences@emap.com<br />

Online: www.bpevent.com<br />

Organised by:<br />

2007<br />

Conference & Awards


Special<br />

There are different technologies available in order to<br />

complete the packaging unit with a film. Most common<br />

technologies are based on flow pack top seal films.<br />

Additionally, specifically for the packaging of food, one<br />

of the most common technologies is the one based on<br />

cling films. Today, especially based on biopolymers,<br />

there are different technologies available, depending<br />

on the needs of the product to be packed and/or the<br />

packaging technology.<br />

Most commonly used on transparent punnets are<br />

transparent top seal films. Different combinations in<br />

terms of transparency may be used, meaning a transparent<br />

film on an opaque punnet or vice versa, or both<br />

the same. The first products are meant for food that<br />

does not need special MAP treatment. New developments<br />

are proving that amongst biopolymers there are<br />

some, which do offer differential barrier properties<br />

(WVTR, N 2<br />

TR, O 2<br />

TR, CO 2<br />

TR) and that will open new applications<br />

for MAP packaging.<br />

Importantly, in order to obtain adequate sealing<br />

properties, the Tm of the sealing layer of the film does<br />

need to fit with the tray on which the film is sealed.<br />

New biopolymers which offer differential sealing properties<br />

seem to perfectly match such needs.<br />

Similar properties are given for flow pack films, in<br />

order to achieve both good sealing results and high<br />

speed processing. It is evident that for most of the applications<br />

good printing, COF, hot tack etc. are needed,<br />

whether they be top seal films or flow pack.<br />

For some years different development activities have<br />

been carried out in order to develop cling films based<br />

on compostable polymers. Some positive results have<br />

been claimed by the market, and it is expected that<br />

by next year some first producers will present their<br />

products. In this specific case the opportunity to use<br />

biopolymers will just enlarge the application range of<br />

PVC cling films, as there is already a certain trend (in<br />

some European countries) to replace it with PE or alternative<br />

polymers.<br />

But much of the success, on which the use of compostable<br />

packaging is based, is the need to find new solutions<br />

in terms of waste treatment, as food packaging<br />

means:<br />

• Highly food-contaminated plastic.<br />

• Difficult to recycle.<br />

• Low potential energy recovery content (due to the<br />

high contamination) in case of thermal recycling.<br />

The new opportunity given by compostable bioplastics<br />

has an added value for both retailers and consumers,<br />

as:<br />

• Retailers do not need any longer to separate the content<br />

from the packaging (when the product expires).<br />

• This means a space reduction in terms of waste collection<br />

(packaging and food may be collected and<br />

treated together).<br />

• Waste management and treatment of such products<br />

would save energy.<br />

• The consumer gets packaging, especially when he<br />

purchases organic produce, which is more coherent<br />

with the nature of the produce.<br />

Some European retailers are starting to adopt more<br />

and more such materials, as on the one hand consumers<br />

are starting to ask for them, on the other hand it is<br />

proven that recycling, meaning composting of packaging,<br />

when contaminated with food, offers a valuable way<br />

of recycling.<br />

It is not only the source of the biopolymers which defines<br />

their environmental contribution or impact, it is<br />

very often more the recycling system that stands behind<br />

them, which defines their impact.<br />

Conventional polymers, when clean and not contaminated<br />

(as in the case of industrial waste), do offer their<br />

highest potential (environmentally) if recycled. Biopolymers,<br />

when used as packaging, do offer their best profile<br />

when composted.<br />

20 bioplastics MAGAZINE [03/07] Vol. 2


Special<br />

Thermoformed trays<br />

Biodegradable<br />

Article contributed by<br />

Cesare Vannini, Packaging<br />

System R&D<br />

Coopbox Europe s.p.a.,<br />

Bibbiano, Italy<br />

Cross-section of foam<br />

Expanding film<br />

Coopbox S.p.A., headquartered in Reggio Emilia,<br />

Italy, is a producer of innovative packaging solutions<br />

for fresh foods. Coopbox has a very long<br />

history in the packaging industry. Founded in 1972, the<br />

company, always focused on innovation, recently became<br />

very active in the steady development of innovative<br />

and environmental friendly packaging solutions for<br />

retailers and the modern packaging industry.<br />

The idea of developing biodegradable foam<br />

packaging for fresh food started in 2003 and the first<br />

step was the selection of a material from the different<br />

biopolymers available on the market: starch, biopolyesters,<br />

polylactide, etc. Finally PLA was the chosen material,<br />

first of all for the good mechanical properties and<br />

the possibility to process the material with standard<br />

equipment. Not only has PLA a better mechanical performance<br />

than alternative traditional polymers used for<br />

rigid packaging (PET, PS, PP) but it is 100% produced<br />

from annually renewable resources such as corn. From<br />

this base a development project started with the involvement<br />

of the universities of Naples, Rome and Reggio<br />

Emilia, and the important collaboration of NatureWorks,<br />

the raw material supplier, all along the way.<br />

The basic idea was to use a foam solution because<br />

it allows a significant weight reduction of the pack. In<br />

general with traditional polymers, depending on the<br />

application, the foam tray is 30-50% lighter than rigid<br />

material. It is immediately evident that a biodegradable<br />

foam is a double environmentally friendly solution:<br />

firstly because it uses raw material from a renewable<br />

resource and secondly because of the weight reduction<br />

of up to 50% that is possible to obtain with the use of a<br />

foam instead of a rigid foil.<br />

Today Naturalbox ® is the first foamed PLA tray on the<br />

market with worldwide patent pending. Its first public<br />

presentation was at Interpack 2005, in the “Innovationparc<br />

Bioplastics in Packaging”. Naturalbox is recognised<br />

as a true innovation on the market, and has received<br />

several awards: the “Italian Oscar Dell’Imballaggio<br />

2005”, the “UK Meat Industry Award 2006”, and the<br />

22 bioplastics MAGAZINE [03/07] Vol. 2


Special<br />

foam trays for fresh food<br />

“Bioplastics Award 2006” for the best biodegradable<br />

food packaging.<br />

To obtain a PLA foam, extensive tooling modifications<br />

were necessary in comparison to the standard extruding<br />

technology for XPS (Extruded Polystyrene Foam). Coopbox<br />

invested two years in development, together with a<br />

new screw profile, new die and accessory equipment -<br />

everything was specifically projected to obtain the first<br />

commercially available PLA foam tray.<br />

The main characteristics of the product are: density of<br />

300 g/l and good mechanical performance. Naturalbox<br />

trays are certified in line with the European food contact<br />

standards and comply with the European standard<br />

EN13432 for compostable packaging.<br />

Naturalbox ideally is used to pack fresh food: fresh<br />

meat, processed meat, fish and vegetables. Closing can<br />

be performed with two different packaging technologies:<br />

top sealing or stretch-wrapping. With the top sealing<br />

solution using a top film in PLA (this film has excellent<br />

sealing resistance, natural antifog properties and<br />

enhanced transparency) a 100% biodegradable pack<br />

is obtained. Naturalbox can be closed on standard top<br />

sealing machines and has a gas barrier lower than PET<br />

but definitely higher than PP. Another possibility is to<br />

use a standard stretch-wrapping machine with a standard<br />

stretch film. In this case high packaging speeds<br />

can be reached and for this application the mechanical<br />

properties are very important and the foam tray solution<br />

is very appropriate. Currently both PE and PVC film are<br />

used, as any biodegradable stretch film able to work on<br />

automatic wrapping machine is available today.<br />

Commercial introduction is entering a very crucial<br />

phase. Several trials have been, and are currently being,<br />

conducted all over Europe and, given the novelty of<br />

the product, Coopbox has encountered a lot of interest.<br />

The number of awards provided visibility, but only an<br />

entrepreneurial pioneering vision, the growth of people‘s<br />

consciousness about the environment and some<br />

legislative “effort” (as a result also of the activities of<br />

European Bioplastics) is now supporting the company‘s<br />

development. Today Naturalbox is present in Dubai (organic<br />

food), in Denmark (potatoes), in Italy (poultry, fish<br />

and cheese at the Finiper retail chain), and in France (at<br />

Bodin industries for organic poultry). Moreover, at the<br />

moment Coopbox is testing a new application for frozen<br />

fish for an important retailer in the UK and is approaching<br />

the German organic meat/poultry market developing<br />

a system with VC999 machines.<br />

Looking ahead the company foresees a 2008 full of<br />

opportunities, with growing interest from several promising<br />

prospects.<br />

www.coopbox.it<br />

bioplastics MAGAZINE [03/07] Vol. 2 23


Materials<br />

PHBV from<br />

Tianan-Biologic<br />

Article contributed by<br />

Dr. Jim Lunt, VP Sales & Marketing,<br />

Tianan Biologic Materials Co. Ltd,<br />

Ningbo, PR China<br />

and<br />

Ruud Rouleaux, Managing Director,<br />

Peter Holland bv, Zwijndrecht,<br />

The Netherlands<br />

Product examples<br />

Tianan Biologic Material Co. Ltd is located in Ningbo,<br />

one of the major cities in China’s economically dynamic<br />

Zhejiang Province. Ningbo is situated in the<br />

central part of China‘s coastline and south flank of<br />

the Yangtze River Delta, bordering Shanghai and Hangzhou.<br />

The Ningbo Economic and Technical Development Zone<br />

(NETD) is located in the north-east of Ningbo city, behind the<br />

largest deepwater port in China-Beilun port. Established in<br />

1984, NETD is one of the earliest and largest development<br />

zones at the national level in China. NETD has established a<br />

reputation as the most promising location for development<br />

in China with its strategic geographic location, numerous<br />

natural resources, wide variety of industries and a modern<br />

transportation network.<br />

Today, Tianan Biologic is the world’s largest producer of<br />

PHBV, a fully biobased and 100% biodegradable polymer<br />

that is derived through a completely natural fermentation<br />

process. PHBV is short for Poly-β-Hydroxy Butyrate-co-<br />

Valerate and is a crystalline biopolymer with high temperature<br />

resistance. After the production facility with a capacity<br />

of 1,000 tonnes of PHBV was installed in Ningbo China in<br />

December 2003, about one month later Tianan began to sell<br />

PHBV on a trial basis. In April 2004, Tianan was certified by<br />

ISO 14855. The company presently produces 1,000 tonnes of<br />

PHBV and by the end of November Tianan will be increasing<br />

capacity to 2,000 tonnes per year.<br />

Tianan Biologic’s mission is to become and remain a world<br />

leading producer of PHBV bioplastics while positively contributing<br />

to the world’s environment and economy. The com-<br />

24 bioplastics MAGAZINE [03/07] Vol. 2


Materials<br />

pany’s future plans are to grow the market for PHBV to<br />

create sufficient demand to install additional capacity of<br />

10,000 tonnes in mid 2009 and then further<br />

additional capacity of 50,000 tonnes to<br />

come on line mid 2011.<br />

To achieve these goals, Tianan will follow<br />

a disciplined and focused approach to the<br />

marketplace. Today the key demand for such<br />

products is in the USA, Canada, Europe, Japan<br />

Australia, and New Zealand. Over time an<br />

increasing demand is expected in China, Korea<br />

and other Asian markets as well as South<br />

America.<br />

The key targeted market segments for Tianan<br />

Biologic’s PHBV product can be divided into three<br />

general categories:<br />

1. Bioplastic applications, where 100% renewable<br />

resource and 100% biodegradability are required.<br />

Typical applications envisaged are in injection molded<br />

cosmetic containers such as lipstick casing, and other<br />

cosmetic products. Blow molded or injection stretch<br />

blow molded shampoo bottles. Paper coated products.<br />

2. Biodegradable products, where 100% renewable<br />

resource is not needed but biodegradability is still required.<br />

Typical products in this category are blends of PHBV<br />

with other biodegradable products, such as the starch<br />

based materials and synthetic biodegradable polyesters.<br />

Potential applications include thermoformed or<br />

injection molded non-clear containers, with improved<br />

flexibility and a wider property spectrum than can be<br />

achieved from PHBV alone, and blown film products.<br />

3. Biobased products for more durable applications<br />

where full biodegradability and 100% renewable<br />

resource would be preferred, but blends with non renewable<br />

and non biodegradable Petrochemical based<br />

products are an option. This may be required to achieve<br />

the required properties and still achieve a meaningful<br />

reduction in the overall use of petrochemical derived<br />

plastics and an improved environmental footprint.<br />

Typical products in this category could include: Blends<br />

of PHBV with non degradable impact modifiers for gift<br />

card /credit card applications. Blends of PHBV with natural<br />

fibers and petroleum based impact modifiers and<br />

other plastics for computer casings, automotive, cellular<br />

phone, Ipod and other hand held consumer devices.<br />

As a biopolyester, PHBV is made by bacteria, using<br />

natural sugars as the food source, and can be fully digested<br />

by naturally occurring bacteria. When finally<br />

disposed of in compost or bacterially rich environments<br />

such as soil and water, it completely decomposes into<br />

carbon dioxide, water and biomass<br />

PHBV also has high biological compatibility and good<br />

barrier properties to water, gas and aroma permeation.<br />

Potential product applications, in addition to those discussed<br />

above, exist for a wide range of other applications<br />

such as medical materials (sutures), films products<br />

(mulch films, shopping bags, and compost bags),<br />

disposable items (pens, tableware), packaging materials<br />

(especially for food packaging), etc.<br />

Tianan Biologic is accelerating its product development<br />

and manufacturing and marketing efforts to bring<br />

these goals to reality. The company is looking for dedicated<br />

partners who share this same vision.<br />

Initial quantities of Tianan’s PHBV products (less than<br />

200Kg), for sampling, and/or technical information can<br />

presently be acquired through<br />

r.rouleaux@peterholland.nl (for Europe)<br />

or directly from Tianan jl@tianan-enmat.com<br />

www.tianan-enmat.com<br />

www.peterholland.nl<br />

bioplastics MAGAZINE [03/07] Vol. 2 25


Materials<br />

Article contributed by<br />

Antonio Morschbacker,<br />

Innovation &<br />

Technology Center,<br />

Braskem S.A.,<br />

Rio Grande do Sul, Brazil<br />

Bio-Ethanol based<br />

Polyethylene<br />

Natalie, our covergirl grew<br />

up in Ghana: „As kids we ate<br />

sugarcane just as it came.<br />

I‘m truly amazed that<br />

sugarcane today can be<br />

converted into plastic“<br />

Braskem is a leading Brazilian company manufacturing<br />

thermoplastic resins in Latin America. At the company’s<br />

Technology and Innovation Center Braskem has<br />

developed the first internationally certified polyethylene<br />

made from 100% sugarcane based ethanol. The certification was<br />

conducted by Beta Analytic Inc., a leading international laboratory,<br />

according to the ASTM-D6866 standard. This standard describes<br />

how to determine the biobased content as indicated by 14 C isotope<br />

content (see bioplastics MAGAZINE 01/2007 p. 36ff). Polyethylene<br />

is the resin with the largest manufacturing capacity in the world,<br />

but is currently produced using fossil based raw materials such as<br />

naphtha or natural gas.<br />

The “green polymer“ developed by Braskem – a high-density polyethylene,<br />

one of the resins most widely used in flexible packaging<br />

– is the result of a research and development project in which already<br />

around 5 million US$ have been invested. Part of this amount<br />

of money was allocated to implement an ethylene pilot unit using<br />

a high yield ethanol dehydration technology. This is the basis for<br />

the production of polyethylene at Braskem’s polymerization pilot<br />

plants, which are already producing sufficient quantities for commercial<br />

development of the product. One of the biggest advantages<br />

of this biopolymer production route is that it will be produced in<br />

the same polymerization plants as regular polyethylene. It can be<br />

transformed into a wide variety of final products, using the same<br />

machines that already exist at Braskem’s customers with no need<br />

to invest in new industrial equipment. The stable properties of the<br />

ethanol-based plastic and its high energy of combustion, like any<br />

other polyethylene, permit it to be fully recovered through mechanical<br />

or energy recovery recycling at the end of its useful life. All these<br />

aspects indicate a very favorable life cycle analysis for the whole<br />

system when compared to the traditional fossil oil based resins or<br />

with other biobased alternatives.<br />

26 bioplastics MAGAZINE [03/07] Vol. 2


Materials<br />

Brazil has many natural competitive advantages for<br />

the development and manufacture of products made<br />

from renewable raw materials. Its ethanol fuel program<br />

was started in 1975 and is totally based on the sugar<br />

cane crop. Since then, the alcohol productivity has been<br />

growing about 2.5% per year, from 3.3 m 3 /hectare to<br />

6.9 m 3 /hectare. The total amount produced last season<br />

was 17.6 million m 3 and the projections show that there<br />

will be an average growth of 9% during the next 8 years,<br />

when the current capacity will be doubled.<br />

One main characteristic of the sugar cane crop is that<br />

it is able to fix a large quantity of carbon and its stalks<br />

can be harvested at least four times before they need to<br />

be replanted. The amount of lignocellulosic carbon in<br />

their leaves and fibres (the so called bagasse) is about<br />

twice the amount of sucrose carbon. This feature allows<br />

the ethanol process to be self-sufficient in biobased energy<br />

with a surplus of 20-30%, when burning just the<br />

bagasse. Additionally, a part of the leaves that can be<br />

recovered will supply an extra source of energy that can<br />

be used in the ethylene process and in the polymerization<br />

step of an integrated plant.<br />

The project, with an annual productive capacity of<br />

200,000 tonnes, is now under technical and economic<br />

specification process and the start up of the “green<br />

polyethylene“ production on an industrial scale is expected<br />

at the end of 2009. For this first unit Braskem is<br />

evaluating the production of some grades from its huge<br />

ethylene polymers portfolio, including high density, low<br />

density, linear low density, very low density and ultra<br />

high molecular weight grades. The plant will be located<br />

in Brazil in a place to be determined within the next few<br />

months. As the process requires 2.3 m 3 of ethanol to<br />

make 1 metric ton of the new plastic, the ethanol consumption<br />

will be just a small proportion of the total Brazilian<br />

production capacity.<br />

The company’s production of plastics from ethanol<br />

seeks to supply the main international markets that require<br />

products with superior performance and quality,<br />

in particular for the automotive, food packaging, cosmetics<br />

and personal hygiene industries. Braskem has<br />

contacted many leading brands in Brazil and around the<br />

world about the possibility of integrating the “green“<br />

plastic into their product lines, enabling them to offer<br />

a modern product for the modern needs of millions of<br />

consumers.<br />

José Carlos Grubisich, Braskem´s CEO, said:<br />

“Braskem´s leadership in the green polyethylene project<br />

confirms our commitment to innovation and sustainable<br />

development and points to the extremely positive<br />

prospects for the development of plastic products made<br />

from renewable raw materials”.<br />

Photo: Hannes Grobe (Wikipedia)<br />

bioplastics MAGAZINE [03/07] Vol. 2 27


Applications<br />

Trays made<br />

from sugarcane<br />

By Thomas Isenburg<br />

The previous article is just one example that shows that there is considerable<br />

potential in growing sugarcane to extract the building block sugar – not only<br />

to produce ethanol – and to exploit the potential that can be found in the<br />

stalks and leaves – the bagasse.<br />

Natura Verpackungs GmbH from Rheine in Germany has focused its activities on<br />

this particular area. In addition to sugar, a large amount of bagasse, the biomass<br />

remaining after the stalks are crushed, is produced during the sugar refining process.<br />

Bagasse is used as energy source and also to produce paper, cardboard and<br />

packaging material due to its high cellulose content. According to Natura‘s sales<br />

director, Patrick Gerritsen, the company has been manufacturing sugarcane trays<br />

for some time.<br />

The sugarcane trays are not made from bioplastic, but rather from a pulp made<br />

of plant fibres. Therefore the stalks and leaves (the bagasse) are crushed and then<br />

the fibrous pulp is compression moulded into trays<br />

Being used as a substitute for polystyrene trays based on renewable raw materials,<br />

sugarcane trays are greenhouse gas neutral. When they are incinerated, the<br />

same amount of carbon dioxide is released as was absorbed by photosynthesis<br />

when the plant was growing. The product is fully biodegradable in accordance with<br />

the EN 13432 standard. The material breaks down completely within six to twelve<br />

weeks – even in home comosting. This means consumers can dispose of the product<br />

on their garden compost heap.<br />

Sugarcane trays are used mainly in packaging for fruit, vegetables, potatoes,<br />

meat products and industrial packaging. The material has many advantages: Unlike<br />

conventional plastic packaging, the trays are permeable to water vapour and<br />

oxygen. It has been observed that this considerably prolongs the shelf life of fruit.<br />

Sugarcane products retain their shape, which allows them to be processed more<br />

easily. Compared with products made from paper-pulp, they are considerably more<br />

waterproof and have a price advantage. Sugarcane trays are more expensive than<br />

polystyrene products, but this situation could change with rising oil prices.<br />

In order to service the growing market better, Natura has made a vertical backwards<br />

integration in the supply chain by co-operating with Earth Buddy in China.<br />

Earth Buddy is the world’s largest manufacturer of sugarcane products with all<br />

necessary certifications in place. There are plans to quadruple production in China<br />

within two years. The target is to produce one billion trays per year. Natura is developing<br />

its own machines, in order to satisfy customer requirements and, in view of<br />

the depletion of oil supplies, an even greater market potential is anticipated in the<br />

future. Furthermore Natura has established with Natura ASP in the UK, Natura-<br />

Modiplast in Israel and Natura Iberia in Portugal and Spain a supplier network in<br />

Europe and the Middle East to serve their customers throughout all the seasons.<br />

Further subsidiaries in key areas will follow soon.<br />

28 bioplastics MAGAZINE [03/07] Vol. 2


Applications<br />

Universal Closures Limited,<br />

headquartered in Tewkesbury,<br />

UK, in collaboration with<br />

Plantic Technologies Limited<br />

from Altona (VIC) Australia, have<br />

developed a barrier closure with<br />

printed Plantic ® liners.<br />

New Closures for<br />

beverage Bottles with<br />

Printed Plantic<br />

Barrier Liners<br />

Universal Closures’ new barrier closure is<br />

based on a three-component closure design<br />

– closure shell, barrier liner and closure<br />

liner are made from different materials with<br />

the barrier liner being made from Plantic ® . The barrier<br />

liner is sandwiched between the closure liner and the<br />

closure shell, thereby providing enhanced gas barrier<br />

protection to the contents, and effective in-mold decoration.<br />

Barrier closures with Plantic barrier liners are a<br />

technological breakthrough in packaging, complementing<br />

the existing functional properties of barrier bottles<br />

which are currently used for applications where extended<br />

shelf-life is targeted. The new barrier closures<br />

facilitate CO 2<br />

retention, beneficial for carbonated drinks<br />

and prevent oxygen ingress which can cause certain<br />

products such as sauces, preserved fruits, juices and<br />

beer to degrade.<br />

Plantic barrier liners are made from non-genetically<br />

modified renewable resources – high amylose corn<br />

starch. They are high resolution printable and excellent<br />

gas, taint and odor barriers. They are also anti-static ,<br />

sealable and laser etchable. The barrier liners are dis-<br />

bioplastics MAGAZINE [03/07] Vol. 2 29


Applications<br />

persible and biodegradable in water, and therefore comply<br />

with European draft standards. Plantic materials are<br />

certified with AIB-Vincotte’s “OK Biodegradable Water”<br />

conformity mark.<br />

The new barrier liners allow for efficient in-mold decoration,<br />

enabling high resolution printing of promotional<br />

and branding images. This presents many commercial<br />

benefits for Plantic Technologies, as the gas barrier materials<br />

it seeks to replace for this application do not possess<br />

high resolution printing capabilities.<br />

Mr. Rod Druitt, Managing Director of Universal Closures<br />

said, “The combination of factors such as excellent gas<br />

barrier properties, efficient in-mold decoration and high<br />

resolution printability present an innovative offering to<br />

global food and beverage industries that is differentiated<br />

from current barrier closure systems.”<br />

Amylose molecule<br />

Additionally, Plantic barrier liners offer a cost-effective<br />

and environmentally friendly alternative to established<br />

barrier liners. Currently the recycling and recovery rates<br />

of PET – particularly PET bottles – are the highest of any<br />

other plastic. Some European countries boast a 60-70%<br />

recovery rate of PET bottles 1 . Since recycled PET is repeatedly<br />

used to make new bottles and fibres, keeping the<br />

PET recycling stream clean is of paramount importance.<br />

This requirement restricts the use of EVOH barrier closures<br />

because they contaminate the recycling stream with<br />

“black specks”. The new barrier liners, however, produce<br />

flakes in the recovery process which disperse and simply<br />

“wash away”, allowing for uncontaminated PET recycling.<br />

In commenting, Plantic’s Innovation Manager, Dr. Frank<br />

Glatz said, “The market potential for these barrier closures<br />

is significant. Through our strategic alliance with<br />

Universal Closures, Plantic has been able to offer an innovative<br />

product to the food and beverage industries. This<br />

innovation demonstrates our commitment to offering end<br />

users key functional benefits in using sustainable Plantic<br />

packaging material.”<br />

1 Organisation for Economic Co-operation and Development (2006)<br />

Improving Recycling Markets, OECD Publishing, p. 124.<br />

www.plantic.com.au<br />

www.universalclosures.com<br />

30 bioplastics MAGAZINE [03/07] Vol. 2


Politics<br />

Overview of the<br />

Current Biopolymers<br />

Market Situation<br />

In the late eighties and early nineties new biopolymers<br />

on the basis of starch or polyhydroxyalkanoates<br />

produced by fermentation were first introduced<br />

onto the market. Despite initial enthusiasm<br />

and favourable predictions this first generation of biodegradable<br />

biopolymers was not able to establish itself<br />

commercially. This could at least partially be attributed<br />

to the material properties, some of which were not yet<br />

fully developed, but also to unfavourable political and<br />

commercial conditions, and to the fact that there was<br />

simply not enough ecological pressure on the decision<br />

makers in politics and industry to respond to unfavourable<br />

conditions at that time.<br />

A strong increase in the research and development of<br />

biopolymers was prompted by important developments<br />

in recent years, most of all by changing political conditions,<br />

a rising awareness of the limitation of petrochemical<br />

resources and soaring prices for raw materials, and<br />

of course by a growing ecological awareness among the<br />

general public, politics, industry and consumers. These<br />

second generation biopolymers currently established<br />

on the market are comparable to petrochemically-produced<br />

commodity plastics as far as their manufacture,<br />

processing and utilisation properties are concerned.<br />

Rising oil prices and ecologically motivated political<br />

support have been leading to price advantages for biopolymers,<br />

especially with regard to raw materials and<br />

disposal. Consequently, the remaining economic disadvantages<br />

due to limited production capacity can be<br />

compensated and biopolymers are becoming more and<br />

more competitive compared to conventional plastics,<br />

especially in the packaging industry. Meanwhile, the<br />

production of some of these second generation biopolymers<br />

has reached an industrial scale (Table 1).<br />

Article contributed by: Hans-Josef Endres,<br />

Andrea Siebert, Yordanka Kaneva*,<br />

University of Applied Sciences and Arts,<br />

Hanover, Germany Department of<br />

Bio Process Engineering<br />

*Supported by the German DBU<br />

(German Foundation for the Environment)<br />

Table 1: Current stage of development (2007)<br />

of thermoplastic biopolymers<br />

At the same time efforts are being made to retain the<br />

conventional processing methods used for petrochemical<br />

polymers, applying them to natural raw materials,<br />

e.g., bio-based alcohol for synthesis of polyethylene<br />

(Bio-PE) and polyamides (Bio-PA) or polyurethanes<br />

(Bio-PUR)<br />

bioplastics MAGAZINE [03/07] Vol. 2 31


Politics<br />

Capacity [1000t/a]<br />

Capacity [1000t/a]<br />

Capacity [1000t/a]<br />

1.500<br />

1.250<br />

1.000<br />

750<br />

500<br />

250<br />

0<br />

500<br />

450<br />

400<br />

350<br />

300<br />

250<br />

200<br />

150<br />

100<br />

50<br />

0<br />

35<br />

30<br />

25<br />

20<br />

15<br />

10<br />

5<br />

0<br />

100<br />

90<br />

80<br />

70<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

0<br />

Petrochemical raw material base<br />

Petrochemical additives/Blend components<br />

Renewable raw material base<br />

44<br />

81<br />

189<br />

2000 2007 2010<br />

Table 2: Dynamic progress of manufacturing capacities of<br />

biodegradable, thermoplastic polymers (2000 – 2007 – 2010)<br />

Starch/Starch-Blends<br />

Table 3: Availability of materials 2007<br />

and expected potential 2010<br />

Cellulose regenerates<br />

Polylactides (PLA)<br />

Producers<br />

Types<br />

Others<br />

Table 4: Overview of the numbers of commercial<br />

material types and producers<br />

USA<br />

PLA/Polyester-Blends<br />

Degradable Celluloseesters<br />

Cellulose regenerates<br />

Polyhydroxyalkanoates<br />

Polycaprolactones<br />

Polylactides (PLA)<br />

Degradable Polyesters<br />

Water soluble/degradable PVAL<br />

Starch/Starch-Blends<br />

Cellulose regenerates<br />

Polylactides (PLA)<br />

PLA/Polyester-Blends<br />

Polycaprolactones<br />

Degradable Polyesters<br />

Others<br />

Water soluble/degradable PVAL<br />

Polyhydroxyalkanoates<br />

Degradable Celluloseesters<br />

West Europe<br />

Asien<br />

Australien<br />

Table 5: Main production countries of thermoplastic biopolymers<br />

Polyhydroxyalkanoates<br />

Polycaprolactones<br />

Degradable Celluloseesters<br />

PLA/Polyester-Blends<br />

110<br />

368<br />

901<br />

Capacity 2007<br />

Caoacity 2010<br />

Water soluble/degradable PVAL<br />

Degradable Polyesters<br />

Others<br />

Starch/Starch-Blends<br />

Manufacturing capacities have grown significantly<br />

in recent years due to the rapidly increasing<br />

market demand. As of August 2007, the<br />

worldwide annual capacity for biodegradable<br />

polymer materials adds up to 315,000 tonnes.<br />

(Source: own investigations, personal communication,<br />

manufacturers‘ information, European<br />

Bioplastics). Based on statements by different<br />

raw material suppliers capacities are expected<br />

to reach approximately 1,400,000 tonnes by 2010<br />

(Table 2).<br />

To get a precise picture and to avoid double<br />

counting, those fractions of biopolymers that<br />

are simply blended with other components to<br />

form “new” biopolymers would have to be subtracted.<br />

Therefore, the actual availability as<br />

shown in table 2 is somewhat less than generally<br />

published. It is difficult however to present<br />

exact data because the particular amounts of<br />

production and composition of material types<br />

are not revealed.<br />

Basically, both renewable and petrochemical<br />

raw materials, especially petrochemically-based<br />

additives, are used in so-called natural-based<br />

biopolymer blends. Because the percentage of<br />

these additives and of the petrochemical blend<br />

components is not exactly known, as mentioned<br />

before, it could not be separated from the biopolymers<br />

blends that are based on renewable<br />

resources. Therefore, based on careful<br />

estimates, 30% by weight of the natural-based<br />

biopolymers blends were assigned to the petrochemical<br />

raw materials (light blue area in table<br />

2). Hence the real percentage of renewable raw<br />

materials for production of biopolymers is less<br />

than generally assumed.<br />

It should be noted that this paper only deals<br />

with those partially biodegradable polyvinyl alcohol<br />

(PVAL) and cellulose acetate (CA) materials<br />

that are used explicitly as biodegradable<br />

materials. Also, only those cellulosic materials<br />

are considered, which are known to be used explicitly<br />

as biodegradable films in the packaging<br />

industry. Not considered in this paper are other<br />

cellulosic applications and in particular cellulosic<br />

fibres as used in, for instance, textile applications.<br />

32 bioplastics MAGAZINE [03/07] Vol. 2


The general availability of the biopolymers can be divided<br />

into different material types. The most important<br />

are starch, polylactide (PLA) and polyester polymers,<br />

plus blends made out of these. Table 3 shows the different<br />

currently available types of biopolymer materials<br />

(including blends), and their potential by 2010.<br />

From an application viewpoint there is a significant<br />

diversity in the number of currently commercially available<br />

material types and the number of manufacturers<br />

(Table 4).<br />

Based on a detailed investigation it can be established<br />

that there are 26 commercial producers of biopolymers.<br />

In addition many more companies and<br />

research entities are currently active at the R&D level<br />

and/or operate on the Asian market only. Altogether,<br />

approximately 60 companies are currently known to be<br />

active in the field of biopolymers.<br />

The most important countries producing biodegradable,<br />

thermoplastic biopolymers on an industrial level<br />

include the USA, Western Europe, the Far East and<br />

Australia (Table 5). Various countries have their own<br />

priorities concerning the material types. This may be<br />

attributed to their particular R&D history, the local<br />

availability of raw materials or simply the company location.<br />

Looking at the future, there is reason to assume that<br />

the market for biopolymers will continue to expand<br />

rapidly and undergo further changes in the coming<br />

years. While the second generation of biopolymers was<br />

developed almost exclusively for use as biodegradable<br />

packaging, a third generation will be developed for application<br />

in other fields, e.g., the automotive industry,<br />

consumer electronics, textiles or building, etc. Beside<br />

the utilisation of renewable raw materials and their<br />

different end of life options additional new technical<br />

questions will have to be addressed, including heat deflection,<br />

fogging, colouring, impact behaviour, UV-stabilisation<br />

etc. And finally the search for new biopolymer<br />

additives and refined manufacturing technologies will<br />

continue.<br />

The project on which this paper is based (see bioplastics<br />

MAGAZINE 01/2007 p. 12) is carried out in cooperation<br />

with M-Base, Aachen, Germany and supported by<br />

the German BMELV (German Federal Ministry of Food,<br />

Agriculture and Consumer Protection), represented by<br />

FNR (Professional Agency for Renewable Resources).<br />

Week 1<br />

Week 2<br />

Week 3<br />

Week 4<br />

BIODEGRADATION PROCESS<br />

EcoWorks ®<br />

www.EcoFilm.com<br />

info@CortecVCI.com<br />

1-800-4-CORTEC<br />

St. Paul, MN 55110 USA<br />

© Cortec Corporation 2006<br />

70®<br />

100%<br />

Biodegradable EcoWorks<br />

Replacement for Plastic and Polyethylene<br />

Up to 70% Bio-based With<br />

Annually Renewable Resources<br />

From thick rigid plastic cards to fl exible protective wrap,<br />

EcoWorks ® 70 by Cortec ® Research Chemists offers universal,<br />

biodegradable replacement to traditional plastic<br />

and polyethylene films. This patent pending breakthrough<br />

meets ASTM D6400 and DIN V 54 900. EcoWorks ® 70<br />

does not contain polyethylene or starch but relies heavily<br />

on renewable, bio-based polyester from corn. 100%<br />

biodegradable, it turns into water and carbon dioxide in<br />

commercial composting.<br />

EcoWorks BioPlastic.indd 1 8/2/06 8:44:40<br />

bioplastics MAGAZINE [03/07] Vol. 2 33


Basics<br />

PHA<br />

Bioplastics<br />

and how<br />

they’re made<br />

Article contributed by<br />

Daniel Gilliland, Business<br />

Development Director of Telles,<br />

the joint venture between Metabolix<br />

Figure 3, Mirel is formed into numerous items<br />

in a variety of conversion processes<br />

and Archer Daniels Midland,<br />

Cambridge, MA, USA<br />

Years ago, scientists noticed that micro-organisms<br />

utilized a different “nutrient buffer” system than humans<br />

did. Instead of storing fat in their cells like we<br />

humans do, they stored a naturally occurring plastic in<br />

their cells, polyhydroxyalkanoate (PHA). This interesting<br />

material was discovered in the 1920s and has been<br />

vigorously investigated for the past 30 to 40 years in attempts<br />

to understand it and to commercially exploit its<br />

potential. Most recently, companies have begun using<br />

this material as a substitute for traditional plastic derived<br />

from petroleum or fossil fuel. Clearly, much has<br />

changed in the past 80 years and this paper will try to<br />

explain, in layman’s terms, how PHA like Mirel is made<br />

today and the environmental impact it can make on the<br />

world.<br />

PHA is really a family of polymers. The polymers<br />

differ from one another by the nature of the pendant<br />

groups or side chains attached to the polymer. Large<br />

pendant groups tend to break up crystalinity and form<br />

more rubber like properties with lower melting points<br />

and low glass transition temperatures (Tg). Polyhydroxyoctanoate<br />

(PHO) is one such material. Short chain<br />

pendant groups such as polyhydroxybutyrate (PHB) are<br />

more highly crystalline with higher melting points and<br />

higher Tg. This results in higher melting points, higher<br />

levels of stiffness and higher heat distortion temperatures.<br />

Methods for making these various types of PHAs are<br />

becoming well understood due to the intense effort by<br />

scientists at assessing metabolic pathways. Scientists<br />

can use different micro-organisms and different feed<br />

stocks to create a cellular factory that efficiently produces<br />

the right polymer. A variety of naturally occurring,<br />

renewable feed stocks ranging from glucose, dextrose,<br />

fatty acids, and vegetable oils can be used, depending<br />

upon the type of PHA desired. Figure 1 shows a microphotograph<br />

of PHA accumulating in cells of a microbe.<br />

The PHA is the large white nodules. This particular<br />

microbe grows to over 80% plastic in just a few hours!<br />

For those wishing a detailed understanding of the cellular<br />

biology and enzyme pathways to the various PHAs,<br />

please see Oliver People’s article in Chemtec 1 .<br />

Now that the biology discussion is over, we can talk<br />

about why these PHAs are good for us. To understand<br />

the impact of PHA on us, we need to understand society’s<br />

needs for plastics. First, society has come to rely<br />

upon plastic for its many advantages over more traditional<br />

materials like paper, steel, aluminum: keeping<br />

food safe, protecting products in shipping, replacing<br />

heavy materials, etc. Secondly, responsible consumers<br />

want the plastic to be easy to dispose of at the end<br />

of its usefulness or to not persist in the environment.<br />

Third we would like plastic that does not create harm-<br />

34 bioplastics MAGAZINE [03/07] Vol. 2


Basics<br />

Figure 1, microscopic thin<br />

section of microbes with<br />

white nodules of PHA. The<br />

microbe is 80% plastic,<br />

just prior to recovery.<br />

Figure 2, parts made of<br />

Mirel before and after<br />

60 days submersion in<br />

the ocean.<br />

1: Chemtec, Biodegradable<br />

Plastics from plants, 1996,<br />

38-44, Oliver Peoples et al<br />

2: American Chemical Society,<br />

ACS Symposium Series 939<br />

June 2006, Ramani Narayan<br />

ful emissions, such as greenhouse gases like carbon<br />

dioxide, during its manufacturing and disposal. Finally,<br />

we want plastic that minimizes the use of “non-renewable”<br />

resources like fossil fuels. Before we discuss the<br />

functionality of PHA, we should summarize the environmental<br />

aspects:<br />

• They can reduce greenhouse gases: since PHAs are<br />

made from renewable resources, they can be produced<br />

and used in ways that can actually remove<br />

greenhouse gases from the atmosphere, not just reduce<br />

emissions! In most end of life scenarios, use<br />

of the right PHA instead of a fossil based plastic will<br />

reduce greenhouse gas emissions by 80% to 100%.<br />

For a more complete discussion of the carbon cycle,<br />

please read Ramani Narayan’s treatise 2 on the<br />

subject. It is important to understand the life cycle<br />

assessment of both the process used to make PHA<br />

and the usage of the material to understand its true<br />

impact on greenhouse gases. Early processes used<br />

to make PHA were energy intensive and released<br />

significant amounts of greenhouse gases, but new<br />

processes have superseded them, resulting in breakthroughs<br />

that make PHA economically and environmentally<br />

viable.<br />

• PHAs will quickly return to nature at the end of their<br />

usefulness: since PHAs are made by the “cousins”<br />

of naturally occurring microbes found broadly in nature,<br />

and since these cousins already have the enzymes<br />

required to digest PHA, they will be digested<br />

and returned to nature in virtually any environment<br />

supporting a healthy microbial population such as<br />

soil, lakes, rivers, oceans, home and industrial composting<br />

systems. Figure 2 shows samples of Mirel<br />

bioplastic, made from PHA, before and after 60 days<br />

submersion in the ocean. Though these Mirel bioplastics<br />

quickly return to nature, they are durable in<br />

use.<br />

• PHAs can considerably reduce fossil energy usage.<br />

Depending upon how they are manufactured, PHAs<br />

can significantly reduce the amount of fossil energy<br />

used to produce them compared to the traditional<br />

plastic they replace. Mirel Bioplastics reduce fossil<br />

energy usage by over 90% in some applications.<br />

The future seems even brighter, since this remaining<br />

fossil energy is used to harvest the feed stocks, and<br />

much of this fossil energy can and probably will be<br />

converted to renewable fuels in the future.<br />

Mirel bioplastic is a family of PHA resins that can replace<br />

fossil fuel based plastics in a growing variety of<br />

applications. There are various grades of Mirel being<br />

developed. Some have “film like” properties with the<br />

look and feel of low density polyethylene. Other grades<br />

perform more like polystyrene or polypropylene in injection<br />

molded applications such as soil stabilization<br />

stakes, caps and closures, food containers or cosmetic<br />

cases. Grades have been developed for coating paper<br />

board to replace polyethylene in cups and food containers<br />

and still other grades for sheet used in thermoforming<br />

applications such as storage containers, lids, and<br />

other food service items. Future grades are being developed<br />

for foam and fiber applications replacing polystyrene<br />

and polyester. Figure 3 depicts some common<br />

applications under development.<br />

Beyond the production of PHA in microbial bio-factories,<br />

research is continuing to find ways to make PHA<br />

commercially viable using waste products as feed stock<br />

or by growing the plastic in sugar cane or in non food<br />

crops such as switch grass. Although these potential<br />

pathways are most likely years from commercialization,<br />

they demonstrate the variety and environmental potential<br />

some of the production methods for this new family<br />

of plastics.<br />

bioplastics MAGAZINE [03/07] Vol. 2 35


Basics<br />

Industrial<br />

Composting:<br />

An Introduction<br />

Article contributed by Bruno De Wilde,<br />

Organic Waste Systems n.v., Gent, Belgium<br />

Biofilter (Photo: OWS)<br />

Industrial composting – Curing phase (Photo:VLACO vzw, Belgium)<br />

One of the major advantages of many<br />

bioplastics is the fact these are compostable.<br />

To support this claim one<br />

can use the European EN 13432 or American<br />

ASTM D.6400 standards. Yet these norms specifically<br />

refer to industrial composting which<br />

is just one, albeit the most important, option<br />

for biological (solid) waste treatment. Other<br />

options include home composting and biogasification.<br />

Industrial composting refers to<br />

centralised composting facilities where large<br />

amounts of biological waste, collected from<br />

many sources, are treated. The technological<br />

level can be rather different from one plant to<br />

another but they all have in common the fact<br />

that large volumes are treated and hence high<br />

operating temperatures can be maintained.<br />

Home or backyard composting refers to composting<br />

at (individual) household level. In contrast<br />

to composting in which oxygen plays an<br />

important role in the degradation of waste and<br />

which is therefore called “aerobic” biodegradation<br />

(aerobic = in the presence of oxygen),<br />

biogasification is a biological waste treatment<br />

system in the absence of oxygen, called<br />

“anaerobic” biodegradation.<br />

All these systems are “bio-inspired”, as in<br />

nature waste is also degraded either aerobically<br />

(e.g. in surface waters or on soil), or<br />

anaerobically (e.g. at the bottom of rivers<br />

and lakes where oxygen is depleted). Microorganisms<br />

consisting of bacteria and, in the<br />

case of aerobic conditions also fungi and actinomycetes<br />

(a kind of filamentous bacteria),<br />

will degrade waste (e.g. leaves of trees, dead<br />

animals, and other biomass) and convert it<br />

partially into new micro-organisms and humus<br />

but mainly into CO 2<br />

and water, and in the<br />

case of anaerobic conditions also into methane<br />

(CH 4<br />

). Under aerobic conditions the biodegradation<br />

process will also release a certain<br />

amount of energy in the form of heat, which is<br />

mostly dispersed immediately and hence not<br />

measurable. However, when large quantities<br />

of biowaste are aerobically degrading (e.g.<br />

as in industrial composting) significant temperature<br />

increases can be measured. Under<br />

anaerobic conditions the energy is released<br />

in the form of methane and much less heat is<br />

generated. As methane can be used as a fuel<br />

for heating or for electricity production, biowaste<br />

in such cases is converted not only to<br />

compost but also to (useful) energy.<br />

36 bioplastics MAGAZINE [03/07] Vol. 2


Basics<br />

Home composting (Photo: OWS)<br />

Biogasification plant, Brecht (Belgium) (Photo: OWS)<br />

Composting of municipal solid waste (MSW) is not<br />

really new. In the 1960s for example several composting<br />

plants were built for the treatment of mixed MSW. Yet<br />

this was never really successful as landfill was much<br />

cheaper and the compost produced was of inferior quality.<br />

Later, in the 1970s, several mass-burn incinerators<br />

were also built, offering another relatively cheap option<br />

for waste treatment. Only in the 1980s after some<br />

heavily publicised dioxin scandals which caused massburning<br />

to become very unpopular, was composting reconsidered.<br />

Nevertheless, it quickly became apparent<br />

that high-quality compost was an essential prerequisite<br />

and that this could only be obtained by source-separated<br />

waste collection - clean feedstock going in, clean<br />

product coming out. In areas of several countries (The<br />

Netherlands, Germany, etc.) biowaste was collected<br />

separately and composted to produce a high-quality<br />

compost. Biowaste was defined as kitchen and garden<br />

waste which comes directly from natural origin (“biogenic”).<br />

Anything “man-made” was forbidden in order<br />

not to compromise the quality of the compost.<br />

As mentioned already, the technology of industrial<br />

composting systems is quite variable. At the low-tech<br />

end windrow systems are being used in which the waste<br />

is aerated by placing it in long heaps to facilitate air diffusion<br />

into the waste. These windrows can be turned<br />

with different types of turning machines at different<br />

frequencies, again to promote aeration and accelerate<br />

degradation. Nowadays windrow systems are mainly<br />

used for garden waste. For biowaste, which includes<br />

also kitchen waste, more advanced systems are being<br />

used in order to avoid problems with odour and vermin.<br />

They mostly include an initial phase of some weeks of<br />

intensive forced aeration which is done either in “bay”<br />

or table systems, tunnels or containers. Afterwards<br />

this is followed by a maturing or curing phase in which<br />

the “semi-ripe“ compost is further gently aerated, either<br />

forced or by diffusion. In all systems a screening<br />

step is also included, which can be at the beginning, at<br />

an advanced stage or at the end, and which serves to<br />

retrieve non-compostable contaminants as well as objects<br />

too big to compost in a given time frame such as<br />

branches of wood. The goal is to obtain a nice, crumbly<br />

homogeneous compost. Because of the large quantities<br />

of waste, high temperatures are achieved (60-65°C)<br />

which are also needed to kill off pathogens in the waste.<br />

On the other hand, temperatures of 55-65°C as well as<br />

a relative humidity of almost 100% are needed for the<br />

population of micro-organisms to live and grow and do<br />

an efficient “bio-conversion job”.<br />

The consequences of adding bioplastics to biowaste<br />

and industrial composting include a potential threat but<br />

also some significant benefits. The major threat is obviously<br />

a decrease of the feedstock quality. It should be<br />

ascertained that only truly compostable materials are<br />

coming in, and not visually similar but non-compostable<br />

plastics or packaging. Hence, the importance of the<br />

communication aspect and the different compostability<br />

logo systems. Some composting systems might also<br />

need to be slightly technically modified (most often<br />

shifting the screening step in the process from the beginning<br />

or an intermediate stage to the end).<br />

The first benefit lies in a higher volume to be composted<br />

and hence higher income for the composting<br />

plant. In some cases the use of bioplastics will have a<br />

kind of snowball effect and convert larger volumes of<br />

waste from non-compostable into compostable (e.g. catering<br />

waste). On a more technical level the addition of<br />

bioplastics will increase and improve the C/N (carbon/<br />

nitrogen) ratio of the biowaste leading to easier odour<br />

control (less ammonia production). Also the density of<br />

the biowaste will be decreased making aeration easier<br />

and more efficient and decreasing the need for the addition<br />

of structural material and energy input for aeration.<br />

Industrial composting plants are able to cope with large<br />

volumes of bioplastics as long as they are well mixed<br />

with other material such as kitchen and yard waste. As<br />

for all living organisms a balanced and varied diet is<br />

needed to stay healthy!<br />

bioplastics MAGAZINE [03/07] Vol. 2 37


Basics<br />

A certain number of products made from bioplastics are already on<br />

the market. Almost all of them are labelled with some kind of a logo<br />

that tells the consumer about the special character of the plastic<br />

material used. In this series of articles these logos and their background<br />

are introduced by <strong>bioplasticsMAGAZINE</strong>. Here we will address<br />

such questions as: What is the origin and history of a logo? What does<br />

it mean? Which type of legislation or regulation is it concerned with?<br />

Logos Part 5:<br />

Waste Bags<br />

Misc.<br />

Civil Eng.<br />

11%<br />

GreenPla Logo &<br />

Agricultural<br />

17%<br />

38%<br />

Packaging<br />

Labelling System<br />

“GreenPla” logo of the Japan BioPlastics Association (JBPA)<br />

Printing<br />

Textile<br />

Daily Goods<br />

Food Ware<br />

Shopping Bags<br />

13%<br />

Stationary<br />

In Japan biodegradable plastics are called „GreenPla“,<br />

and there is a GreenPla Identification and Labelling System<br />

established in June 2000 by the JBPA (formerly BPS)<br />

to distinguish biodegradable plastics from ordinary plastics.<br />

Plastic products that meet certification standards for product<br />

composition, biodegradability, environmental safety,<br />

etc., will be certified as GreenPla products.<br />

GreenPla as described here means a substance or a product<br />

consisting of biodegradable organic components that<br />

may be degraded by microorganisms in a natural environment<br />

and may finally be decomposed to carbon dioxide and<br />

water.<br />

The utilization of biodegradable plastics is one of the key<br />

issues to promote the establishment of a sustainably based<br />

society and JBPA has been making various efforts to promote<br />

the popularization and the business development of<br />

biodegradable plastic products. Most of the products made<br />

from biodegradable plastics look like their counterparts<br />

made from conventional plastics. And clear differentiation<br />

and recognition by everybody is most required to encourage<br />

the popularization of biodegradable plastics. The special<br />

properties of biodegradability can be displayed and be<br />

recognized by the presence of the “GreenPla“ logo on the<br />

products itself or the package of the products.<br />

JBPA has been operating the GreenPla identification and<br />

labelling system for more than seven years and the number<br />

of registered GreenPla products now exceeds 800.<br />

Especially in agricultural and horticultural use and civil<br />

engineering, the GreenPla logo is recognized as the certificate<br />

of reliable, eco-friendly products which can utilize biodegradability<br />

as one of the main product performances.<br />

The GreenPla Identification and labelling system is based<br />

on<br />

• A positive list system for all components of the products<br />

• Biodegradability specification based on Japanese and<br />

international standard analytical methods<br />

• A safety certificate for all components<br />

and no hazardous effect to the soil even after<br />

biodegradation<br />

Registered products in the GreenPla logo system<br />

The distribution of registered products is shown in the pie<br />

chart.<br />

Besides the products for which biodegradability is a key<br />

requirement, such as films for agricultural use or waste bag<br />

applications, about two thirds of the registered products are<br />

general packaging, stationery and broad general applications<br />

which are recognized as environmentally friendly even<br />

at the waste stage, as they can be finally bio-recycled to carbon<br />

dioxide and water and will not leave permanent plastic<br />

waste in the natural environment.<br />

Global harmonization<br />

To proceed with global harmonization JBPA (formerly BPS)<br />

established a co-operation with BPI (USA) and DIN CERTCO<br />

(EU) in 2001 and with BMG (China) in 2004. JBPA will continue<br />

to establish co-operation with other Asian countries.<br />

www.jbpaweb.net<br />

38 bioplastics MAGAZINE [03/07] Vol. 2


Article contributed by Gaëlle Janssens,<br />

Prevention & R&D Manager<br />

FOST Plus, Brussels, Belgium<br />

Opinion<br />

Careful<br />

use of terms<br />

Gaëlle Janssens<br />

like “Biodegradable<br />

and compostable”<br />

In the world of packaging, bioplastics are one of<br />

the most exiting innovations. The consumers seem<br />

motivated for “greener“ shopping and like the idea<br />

of biopackaging… . But they are very confused: in<br />

a recent consumer survey in Belgium, to the question<br />

“what is a biopackaging?”, the majority would answer<br />

“a packaging that is better for the environment”. A quite<br />

broad concept. When prompted further, most consumers<br />

(62%) are driven by motivations related to renewable<br />

resources– reduce CO 2<br />

emissions, promote local agriculture<br />

and use renewable resources.<br />

But even though it may have nothing to do with it, the<br />

word used by the consumers, as well as the by industry,<br />

to name a renewable resource based packaging is ‘biodegradable<br />

packaging’.<br />

The big problem with the word biodegradable is that<br />

it may lead to problems of litter: 27% of the consumers<br />

agree that “you can throw away biodegradable packaging<br />

into the environment and it will disappear without<br />

any human help”. It is interesting to note that, to avoid<br />

this problem, Belgian law will forbid the use of the term<br />

‘biodegradable’ on packaging. An interesting suggestion<br />

for the rest of Europe or even for all of the countries<br />

in the world?<br />

Another problem is that a ‘biodegradable’ packaging<br />

supposes an end-of-life treatment, which is, for most<br />

of the people, obviously compost. This is not a problem<br />

for home compostable packaging, except for the<br />

understanding of the logo: for 73% of the consumers,<br />

a ‘compostable’ logo means they may dispose of the<br />

packaging in their garden compost… and they will still<br />

see it 2 years later! Let’s change the logo to avoid confusion<br />

and use ‘compostable’ only for ‘home compostable’<br />

and ‘industrially compostable’ for packaging that needs<br />

a high degradation temperature, moisture and certain<br />

microorganisms.<br />

Regarding industrially compostable packaging, only<br />

very few consumers worldwide have access to organic<br />

waste collection and, when they do have access, packaging<br />

is generally not welcome (risk of pollution with conventional<br />

plastic and strict norms). As green consumers<br />

watch very closely the claims of green marketing, the<br />

risk of negative publicity is very high if ‘compostable’ is<br />

used without any composting solution. By the way, the<br />

composting property may be very interesting in some industrial<br />

applications, where communication to the consumer<br />

is not needed – tomato clips, organic waste from<br />

distributors, medical ties,…<br />

The option of incineration is considered by more and<br />

more producers as the most ecological solution as it<br />

produces energy, but the infrastructure has to exist locally.<br />

Landfill doesn’t meet the composting condition in<br />

terms of oxygen, humidity and micro-organisms.<br />

As we can see, the end-of-life treatment is certainly<br />

not so obvious! So, as long as no industrial composting<br />

solution exists for the majority of citizens, and as long<br />

as compost is not proved to be the best local end-of-life<br />

treatment for packaging, we should communicate about<br />

compostability only in the case of home compostable<br />

packaging and concentrate communication on renewable<br />

resources, which is tomorrow’s biggest issue.<br />

Therefore, the industry should develop a new, recognized<br />

certification and an easily marketable name.<br />

www.fostplus.be<br />

bioplastics MAGAZINE [03/07] Vol. 2 39


Basics Glossary<br />

Glossary<br />

In bioplastics MAGAZINE again<br />

and again the same expressions<br />

appear that some of our readers<br />

might (not yet) be familiar with.<br />

This glossary shall help with<br />

these terms and shall help avoid<br />

repeated explanations such as<br />

„PLA (Polylactide)“ in various<br />

articles.<br />

Amylopectin<br />

Polymeric branched starch molecule with very high<br />

molecular weight (biopolymer, monomer is à Glucose).<br />

Amylose<br />

Polymeric non-branched starch molecule with high<br />

molecular weight (biopolymer, monomer is à Glucose).<br />

Biodegradable Plastics<br />

Biodegradable Plastics are plastics that are completely<br />

assimilated by the à microorganisms present a defined<br />

environment as food for their energy. The carbon of the<br />

plastic must completely be converted into CO 2<br />

.during the<br />

microbial process. For an official definition, please refer<br />

to the standards e.g. ISO or in Europe: EN 14995 Plastics-<br />

Evaluation of compostability - Test scheme and specifications.<br />

[bM* 02/2006 p. 34f, bM 01/2007 p38].<br />

Blend<br />

Mixture of plastics, polymer alloy of at least two microscopically<br />

dispersed and molecularly distributed base<br />

polymers.<br />

Cellophane<br />

Clear film on the basis of à cellulose.<br />

Cellulose<br />

Polymeric molecule with very high molecular weight<br />

(biopolymer, monomer is à Glucose), industrial production<br />

from wood or cotton, to manufacture paper, plastics<br />

and fibres.<br />

Compost<br />

A soil conditioning material of decomposing organic<br />

matter which provides nutrients and enhances soil structure.<br />

Compostable Plastics<br />

Readers who know better explanations or<br />

who would like to suggest other explanations<br />

to be added to the list, please contact the editor.<br />

Explanantions we are currenty looking for<br />

are for example “organic“ or “renewable“<br />

[*: bM ... refers to more comprehensive article previously<br />

published in bioplastics MAGAZINE)<br />

Plastics that are biodegradable under “composting“<br />

conditions: specified humidity, temperature, à microorganisms<br />

and timefame. Several national and international<br />

standards exist for clearer definitions, for example<br />

EN 14995 Plastics - Evaluation of compostability - Test<br />

scheme and specifications [bM 02/2006 p. 34f, bM 01/2007<br />

p38].<br />

Composting<br />

A solid waste management technique that uses natural<br />

process to convert organic materials to CO 2<br />

, water and<br />

humus through the action of à microorganisms.<br />

40 bioplastics MAGAZINE [03/07] Vol. 2


Basics Glossary<br />

Copolymer<br />

Plastic composed of different monomers.<br />

Fermentation<br />

Biochemical reactions controlled by à microorganisms<br />

or enyzmes (e.g. the transformation of sugar into<br />

lactic acid).<br />

Gelatine<br />

Translucent brittle solid substance, colorless or slightly<br />

yellow, nearly tasteless and odorless, extracted from<br />

the collagen inside animals‘ connective tissue.<br />

Glucose<br />

Monosaccharide (or simple sugar). G. is the most important<br />

carbohydrate (sugar) in biology. G. is formed by<br />

photosyntheses or hydrolysis of many carbohydrates e.g.<br />

starch.<br />

Humus<br />

In agriculture, “humus“ is often used simply to mean<br />

mature à compost, or natural compost extracted from<br />

a forest or other spontaneous source for use to amend<br />

soil.<br />

Hydrophilic<br />

Property: “water-friendly“, soluble in water or other<br />

polar solvents (e.g. used in conjunction with a plastic<br />

which is not waterresistant and weatherproof or that absorbs<br />

water such as Polyamide (PA)).<br />

Hydrophobic<br />

Property: “water-resistant“, not soluble in water (e.g. a<br />

plastic which is waterresistant and weatherproof, or that<br />

does not absorb any water such as Polethylene (PE) or<br />

Polypropylene (PP)).<br />

Microorganism<br />

Living organisms of microscopic size, such as bacteria,<br />

funghi or yeast.<br />

PCL<br />

Polycaprolactone, a synthetic (fossil based), biodegradable<br />

bioplastic, e.g. used as a blend component.<br />

PHA<br />

Polyhydroxyalkanoates are linear polyesters produced<br />

in nature by bacterial fermentation of sugar or lipids. The<br />

most common type of PHA is à PHB.<br />

PHB<br />

Polyhydroxyl buteric acid (better poly-3-hydroxybutyrate),<br />

is a polyhydroxyalkanoate (PHA), a polymer belonging to the<br />

polyesters class. PHB is produced by micro-organisms apparently<br />

in response to conditions of physiological stress.<br />

The polymer is primarily a product of carbon assimilation<br />

(from glucose or starch) and is employed by micro-organisms<br />

as a form of energy storage molecule to be metabolized<br />

when other common energy sources are not available.<br />

PHB has properties similar to those of PP, however it is<br />

stiffer and more brittle.<br />

PLA<br />

Polylactide, a bioplastic made of polymerised lactic acid.<br />

Sorbitol<br />

Sugar alcohol, obtained by reduction of glucose changing<br />

the aldehyde group to an additional hydroxyl group. S. is<br />

used as a plasticiser for bioplastics based on starch .<br />

Starch<br />

Natural polymer (carbohydrate) consisting of à amylose<br />

and à amylopectin, gained from maize, potatoes, heat,<br />

tapioca etc.<br />

Sustainable<br />

An attempt to provide the best outcomes for the human<br />

and natural environments both now and into the indefinite<br />

future. One of the most often cited definitions of sustainability<br />

is the one created by the Brundtland Commission,<br />

led by the former Norwegian Prime Minister Gro Harlem<br />

Brundtland. The Brundtland Commission defined sustainable<br />

development as development that „meets the needs of<br />

the present without compromising the ability of future generations<br />

to meet their own needs.“ Sustainability relates to<br />

the continuity of economic, social, institutional and environmental<br />

aspects of human society, as well as the non-human<br />

environment).<br />

Thermoplastics<br />

Plastics which soften or melt when heated and solidify<br />

when cooled (solid at room temperature).<br />

Yard Waste<br />

Grass clippings, leaves, trimmings, garden residue.<br />

bioplastics MAGAZINE [03/07] Vol. 2 41


Suppliers Guide<br />

Simply contact:<br />

Tel.: +49-2359-2996-0 or suppguide@bioplasticsmagazine.com<br />

Stay permanently listed in the Suppliers Guide with your company logo and contact information.<br />

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

1. Raw Materials<br />

1.1 bio based monomers<br />

Du Pont de Nemours International S.A.<br />

2, Chemin du Pavillon, PO Box 50<br />

CH 1218 Le Grand Saconnex,<br />

Geneva, Switzerland<br />

Phone: + 41(0) 22 717 5176<br />

Fax: + 41(0) 22 580 2360<br />

thomas.philipon@che.dupont.com<br />

www.packaging.dupont.com<br />

1.2 compounds<br />

R.O.J. Jongboom Holding B.V.<br />

Biopearls<br />

Damstraat 28<br />

6671 AE Zetten<br />

The Netherlands<br />

Tel.: +31 488 451318<br />

Mob: +31 646104345<br />

info@biopearls.nl<br />

www.biopearls.nl<br />

BIOTEC Biologische<br />

Naturverpackungen GmbH & Co. KG<br />

Werner-Heisenberg-Straße 32<br />

46446 Emmerich<br />

Germany<br />

Tel.: +49 2822 92510<br />

Fax: +49 2822 51840<br />

info@biotec.de<br />

www.biotec.de<br />

FKuR Kunststoff GmbH<br />

Siemensring 79<br />

D - 47 877 Willich<br />

Tel.: +49 (0) 2154 9251-26<br />

Tel.: +49 (0) 2154 9251-51<br />

patrick.zimmermann@fkur.de<br />

www.fkur.de<br />

1.3 PLA<br />

Uhde Inventa-Fischer GmbH<br />

Holzhauser Str. 157 - 159<br />

13509 Berlin<br />

Germany<br />

Tel.: +49 (0)30 43567 5<br />

fax: +49 (0)30 43567 699<br />

sales.de@thyssenkrupp.com<br />

www.uhde-inventa-fischer.com<br />

1.4 starch-based bioplastics<br />

BIOTEC Biologische<br />

Naturverpackungen GmbH & Co. KG<br />

Werner-Heisenberg-Straße 32<br />

46446 Emmerich<br />

Germany<br />

Tel.: +49 2822 92510<br />

Fax: +49 2822 51840<br />

info@biotec.de<br />

www.biotec.de<br />

Plantic Technologies Limited<br />

Im Tanzbühl 15<br />

77833 Ottersweier<br />

Germany<br />

Tel.: +49 657 195 1248<br />

Tel.: +44 794 096 4681 (UK)<br />

Fax: +49 657 195 1249<br />

info@plantic.eu<br />

www.plantic.eu<br />

1.5 PHA<br />

1.6 masterbatches<br />

PolyOne<br />

Avenue Melville Wilson, 2<br />

Zoning de la Fagne<br />

5330 Assesse<br />

Belgium<br />

Tel.: + 32 83 660 211<br />

info.color@polyone.com<br />

www.polyone.com<br />

1.7 reinforcing fibres/fillers<br />

made from RRM<br />

2. Additives /<br />

Secondary raw materials<br />

Du Pont de Nemours International S.A.<br />

2, Chemin du Pavillon, PO Box 50<br />

CH 1218 Le Grand Saconnex,<br />

Geneva, Switzerland<br />

Phone: + 41(0) 22 717 5176<br />

Fax: + 41(0) 22 580 2360<br />

thomas.philipon@che.dupont.com<br />

www.packaging.dupont.com<br />

3. Semi finished products<br />

3.1 films<br />

Maag GmbH<br />

Leckingser Straße 12<br />

58640 Iserlohn<br />

Germany<br />

Tel.: + 49 2371 9779-30<br />

Fax: + 49 2371 9779-97<br />

shonke@maag.de<br />

www.maag.de<br />

Treofan Germany GmbH & Co. KG<br />

Am Prime Parc 17<br />

65479 Raunheim<br />

Tel +49 6142 200-0<br />

Fax +49 6142 200-3299<br />

www.biophanfilms.com<br />

www.earthfirstpla.com<br />

www.sidaplax.com<br />

www.plasticsuppliers.com<br />

Sidaplax UK : +44 (1) 604 76 66 99<br />

Sidaplax Belgium: +32 9 210 80 10<br />

Plastic Suppliers: 1 866 378 4178<br />

3.1.1 cellulose based films<br />

4. Bioplastics products<br />

natura Verpackungs GmbH<br />

Industriestr. 55 - 57<br />

48432 Rheine<br />

Tel.: +49 5975 303-57<br />

Fax: +49 5975 303-42<br />

info@naturapackaging.com<br />

www.naturapackagign.com<br />

Veriplast Holland BV<br />

Stadhoudersmolenweg 70<br />

NL - 7317 AW Apeldoorn<br />

www.veripure.eu<br />

Info@veripure.eu<br />

4.1 trays<br />

5. Traders<br />

5.1 wholesale<br />

6. Machinery & Molds<br />

Molds, Change Parts and Turnkey<br />

Solutions for the PET/Bioplastic<br />

Container Industry<br />

284 Pinebush Road<br />

Cambridge Ontario<br />

Canada N1T 1Z6<br />

Tel.: 001 519 624 9720<br />

Fax: 001 519 624 9721<br />

info@hallink.com<br />

www.hallink.com<br />

SIG CORPOPLAST<br />

GMBH & CO.KG<br />

Meiendorfer Str. 203<br />

22145 Hamburg, Germany<br />

Tel. 0049-40-679-070<br />

Fax 0049-40-679-07270<br />

sigcorpoplast@sig.biz<br />

www.sigcorpoplast.com<br />

7 Ancillary equipment<br />

8. Services<br />

9. Research institutes / Universities<br />

Transmare Compounding B.V.<br />

Ringweg 7, 6045 JL<br />

Roermond, The Netherlands<br />

Phone: +31 (0)475 345 900<br />

Fax: +31 (0)475 345 910<br />

info@transmare.nl<br />

www.compounding.nl<br />

Sukano Products Ltd.<br />

Chaltenbodenstrasse 23<br />

CH-8834 Schindellegi<br />

Phone +41 44 787 57 77<br />

Fax +41 44 787 57 78<br />

www.sukano.com<br />

INNOVIA FILMS LTD<br />

Wigton<br />

Cumbria CA7 9BG<br />

England<br />

Contact: Andy Sweetman<br />

Tel.: +44 16973 41549<br />

Fax: +44 16973 41452<br />

andy.sweetman@innoviafilms.com<br />

www.innoviafilms.com<br />

42 bioplastics MAGAZINE [03/07] Vol. 2


Internet survey<br />

Potential<br />

of<br />

bioplastics<br />

In the last issue we published the results of an<br />

internet poll carried out by the German internet<br />

portal „plasticker“. As this was a „German only“<br />

poll asked to the whole plastics industry, we promised<br />

to expand that survey globally to all ouf our<br />

readers and visitors to our website. Below you see<br />

the result of „our“ poll. Obviously our readers are<br />

more optimistic. 67% think that bioplastics will play<br />

a big role in many application areas (56% in the<br />

german survey) and even 9% (6%) believe that they<br />

will substitute most of todays commodity plastics.<br />

9<br />

A<br />

67<br />

B<br />

21<br />

C<br />

4<br />

D<br />

0% 10% 20% 30% 40% 50% 60% 70%<br />

A) They will substitute most of<br />

today‘s commodity plastics<br />

B) They will play a major role in<br />

many application areas<br />

C) They will remain niche products<br />

D) The hype, and with it the<br />

materials, will disappear


Companies in this issue<br />

Company Editorial Advert<br />

A. Schulman 12<br />

AIB Vincotte 30<br />

Amcor 8, 17, 18<br />

Archer Daniels Midland 13,34<br />

BASF 12 2<br />

Beta Analytics 26<br />

Bio-On 6<br />

Biomer 15<br />

biopearls 23,42<br />

bioplastics24.com 15<br />

Biotec 21,42<br />

BMELV 33<br />

BMG 38<br />

Bodin Industries 23<br />

BPI 38<br />

Braskem 15,26<br />

Clariant 12<br />

Coca-Cola 11<br />

Colormatrix 11<br />

Coopbox Italia 22<br />

Cortec 33<br />

DBU Deutsche Bundesstiftung Umwelt 31<br />

DINCertco 38<br />

DuPont 13 42<br />

Earth Buddy 28<br />

European Bioplastics 8<br />

European Plastics News 16 19<br />

Fachhochschule Hannover 12,31<br />

Faserinstitut Bremen 12<br />

Finiper 23<br />

FkuR 14 9,42<br />

FNR 33<br />

FOST Plus 39<br />

Fraunhofer UMSICHT 14<br />

german bioplastics 11<br />

Good Water 10<br />

Grafe 14<br />

Hallink 42<br />

Husky 11<br />

Ihr Platz 11<br />

Innovia 17,18 42<br />

JBPA Japan BioPlastics Assiciation 38<br />

Livan 5<br />

Company Editorial Advert<br />

M-Base 12,33<br />

Maag 42<br />

Metabolix 13,34<br />

Mondi Packaging 19<br />

natura 17,28 42, 47<br />

Naturally Iowa 11<br />

NatureWorks 10, 11, 22<br />

Netstal 11<br />

Nova Institut 12<br />

Novamont 11, 14, 17, 18 48<br />

OWS Organic Waste Systems 36<br />

Paragon Flexibles 17<br />

Peter Holland 24<br />

Plantic 17,29 42<br />

Plastic Suppliers 42, 43<br />

plasticker 43 33<br />

PolyOne 6, 11, 15 42<br />

Purac 11<br />

Roll-o-Matic 13<br />

Safiplast 10<br />

Sainsbury‘s 16<br />

Sidaplax 42, 43<br />

SIG Corpoplast 11 42<br />

SIG Plasmax 11<br />

Silita 10<br />

Sirap Gema 19<br />

Sukano 5,13 42<br />

Tate & Lyle 13<br />

Telles 13,34<br />

Telrod 17<br />

Tianan Biologic 24<br />

Transmare 42<br />

Treofan 18<br />

TU Clausthal 12<br />

Uhde Inventa Fischer 11 7,42<br />

Universal Closure 29<br />

University of Reggio Emilia 22<br />

University of Rome 22<br />

Univesity of Naples 22<br />

Veriplast 42<br />

VLACO 36<br />

Wentus 18<br />

Wiedmer 11<br />

Next Issue<br />

Special editorial Focus:<br />

Films, trays<br />

03 | 2007<br />

Vol. 2 ISSN 1862-5258<br />

For the next issue of bioplastics MAGAZINE<br />

(among others) the following subjects are scheduled:<br />

Special:<br />

Basics:<br />

Events:<br />

Next issues:<br />

Bags<br />

Life Cycle Analysis (LCA)<br />

Logos part 6<br />

review: K‘2007<br />

different conferences<br />

04/07 December 2007<br />

01/08 January 2008<br />

02/08 March 2008<br />

03/08 April 2008<br />

04/08 June 2008<br />

K‘2007 preview | 13<br />

Industrial Composting | 36<br />

Logos, Part 5 | 38<br />

bioplastics MAGAZINE<br />

44 bioplastics MAGAZINE [03/07] Vol. 2


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please fill in the form and fax to +49-2161-631045<br />

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bioplastics MAGAZINE [03/07] Vol. 2 45


Events<br />

Event-Calendar<br />

October 17-18, 2007<br />

Renewable Raw Materials for Industry:<br />

Contribution to Sustainable Chemistry<br />

Thon Hotel Bruxelles City (former Tulip Inn),<br />

Brussels, Belgium<br />

www.greentech.eu<br />

October 17-19, 2007<br />

BioEnvironmental Polymer Society 14 th Annual Meeting<br />

INTERNATIONAL SYMPOSIUM ON POLYMERS AND THE<br />

ENVIRONMENT: EMERGING TECHNOLOGY AND SCIENCE<br />

Hilton Vancouver Hotel, Vancouver, Washington<br />

Call for Papers: gmg@pw.usda.gov<br />

October 24-31, 2007<br />

K‘2007, International Trade Fair<br />

No 1 for Plastic and Rubber Worldwide<br />

Düsseldorf, Germany<br />

www.k-online.de<br />

Come and see us at K’2007.<br />

bioplastics MAGAZINE would be happy to<br />

welcome you in hall 7, booth 7C09.<br />

November 21-22, 2007<br />

2nd European Bioplastics 2007<br />

Convention Centre Newport Bay Club<br />

Disneyland Paris, France<br />

http://conference.european-bioplastics.org<br />

November 29-30, 2007<br />

InterTech Pira: Bioresins 2007<br />

Doubletree Guest Suites Atlanta /<br />

Galleria - Atlanta, Georgia USA<br />

www.intertechpira.com<br />

December 4-5, 2007<br />

Zweiter Deutscher WPC-Kngress<br />

Maritim Hotel, Köln, Germany<br />

www.wpc-kongress.de<br />

December 5-6, 2007<br />

Bioplastics 2007<br />

including Bioplastics Awards 2007<br />

Frankfurt/Main, Germany<br />

www.bpevent.com<br />

for the awards contact chris.smith@emap.com<br />

February, 18-20, 2008<br />

Agricultural Film 2008<br />

Fira Palace Hotel, Barcelona, Spain<br />

www.amiplastics.com<br />

March 3-4, 2008<br />

3rd International Seminar on<br />

Biodegradable Polymers<br />

Valencia, Spain<br />

http://www.azom.com/details.asp?newsID=7345<br />

June 18-19, 2008<br />

7th Global WPC and Natural<br />

Fibre Composites<br />

Congress and Exhibition<br />

Kongress Palais, Stadthalle,<br />

Kassel, Germany<br />

www.wpc-nfk.de<br />

46 bioplastics MAGAZINE [03/07] Vol. 2


A real sign<br />

of sustainable<br />

development.<br />

There is such a thing as genuinely sustainable development.<br />

Since 1989, Novamont researchers have been working<br />

on an ambitious project that combines the chemical<br />

industry, agriculture and the environment: “Living<br />

Chemistry for Quality of Life”. Its objective has been to<br />

create products that have a low environmental impact.<br />

The innovative result of Novamont’s research is the new<br />

bioplastic Mater-Bi ® .The Mater-Bi ® polymer comes from maize starch and<br />

other vegetable starches; it is completely biodegradable and compostable.<br />

Mater-Bi ® performs like plastic, but it saves energy, contributes to reducing<br />

the greenhouse effect, and at the end of its life cycle, it closes the loop by<br />

changing into fertile humus. Everyone’s dream has become a reality.<br />

Living Chemistry for Quality of Life.<br />

www.novamont.com<br />

Mater-Bi ® : certified and recommended biodegradability and compostability.

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