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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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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.