bioplasticsMAGAZINE_0905
ioplastics magazine Vol. 4 ISSN 1862-5258
Highlights:
Fibre Applications | 10
Paper Coating | 18
Basics:
Land Use - part 2 | 34
Starch Bioplastics | 42
05 | 2009
bioplastics MAGAZINE
is read in
85 countries
Plastics For Your Future
Another New Resin For a Better World
Knife handle made of BIO-FLEX ® P 7550
FKuR Kunststoff GmbH | Siemensring 79 | D - 47877 Willich
Tel.: +49 (0) 21 54 / 92 51-0 | Fax: +49 (0) 21 54 / 92 51-51 | sales@fkur.com
www.fkur.com
Editorial
dear
readers
bioplastics MAGAZINE Vol. 4 ISSN 1862-5258
Highlights:
Paper Coating /
Laminating | XX
Fibres, Textiles,
Nonwovens | XX
Coverphoto courtesy DuPont
05 | 2009
bioplastics MAGAZINE
is read in
85 countries
September is over, and so too is our 2 nd PLA Bottle Conference. The very well
received event in Munich again attracted a good number of delegates and a
great deal of positive comment. For those interested in bottle applications
please see the detailed report on page 8.
Otherwise you might prefer to read more about paper coating or fibre and
textile applications. These are the two topics of our editorial focus in this
issue. Furthermore, we present an extract from the new book’Technische
Biopolymere‘, effectively serving as part two of the ‘land use for bioplastics‘
discussion.
In the ‘Basics‘ section you‘ll find out about starch and starch based biopolymers,
and last but not least we also cover the ‘oxo-subject‘ once again.
This summer a number of press publications reported on different standpoints
concerning the ‘pros‘ and ‘cons‘ of oxo-degradable plastics. However, instead
of the rather tabloid way of reporting, and calling the debate a “lively spat“, a
“rumbling row“ or even a “battle“, bioplastics MAGAZINE is trying a more factual
approach. Thus we contacted the main stakeholders and offered to let them
put their points of view in our magazine and to provide the scientific support for
their claims. In this issue we publish a slightly shortened version of the position
paper from European Bioplastics. And while we are still waiting for Symphony‘s
scientifically based article on their products and their compliance with ASTM D6594 the
Canadian supplier EPI sent us copies of old scientific papers by Chiellini et. al and Wiles
& Scott.
I hope you enjoy reading this issue of bioplastics MAGAZINE and look forward to your
comments, opinions or contributions.
Yours
Michael Thielen
bioplastics MAGAZINE [05/09] Vol. 4
Content
Editorial 03
News 05
Application News 22
Event Calendar 49
Suppliers Guide 46
September/October 05|2009
Fiber Applications
Meltblown PLA Nonwovens 10
End of Life
A new Cradle-to-Cradle Approach for PLA
0
PLA Floor Mat 11
New carpet made from PLA fibres 11
Innovative Tea-Bags From PLA Fibres 12
Plant-Based Materials for Automobile Interiors 13
Fibers of PTT Receive New U.S. Generic, ‘Triexta’ 14
Processing
Twin-Screw Extruders for Biopolymer Compounding 17
Report
Fraunhofer IAP
2
Basics
Raw Materials and Arable Land for Biopolymers 34
Position Paper ‘Oxo-Biodegradable‘ Plastics 38
Basics of Starch-Based Materials 42
Paper Coating
Improved Paper Coatings 18
Sustainable Cups from Georgia-Pacific 20
Materials
Biobased Engineering Plastic 26
Injection Moldable High Temperature Bioplastic 27
Versatile Precursor Made From Cashew Nuts 28
Impressum
Publisher / Editorial
Dr. Michael Thielen
Samuel Brangenberg
Layout/Production
Mark Speckenbach
Head Office
Polymedia Publisher GmbH
Dammer Str. 112
41066 Mönchengladbach, Germany
phone: +49 (0)2161 664864
fax: +49 (0)2161 631045
info@bioplasticsmagazine.com
www.bioplasticsmagazine.com
Media Adviser
Elke Schulte
phone: +49(0)2359-2996-0
fax: +49(0)2359-2996-10
es@bioplasticsmagazine.com
Print
Tölkes Druck + Medien GmbH
47807 Krefeld, Germany
Total Print run: 3,500 copies
bioplastics magazine
ISSN 1862-5258
bioplastics magazine is published
6 times a year.
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bioplastics MAGAZINE is printed on
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bioplastics MAGAZINE is read
in 85 countries.
Not to be reproduced in any form
without permission from the publisher.
The fact that product names may not be
identified in our editorial as trade marks is
not an indication that such names are not
registered trade marks.
bioplastics MAGAZINE tries to use British
spelling. However, in articles based on
information from the USA, American
spelling may also be used.
Editorial contributions are always welcome.
Please contact the editorial office via
mt@bioplasticsmagazine.com.
Envelope
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of bioplastics MAGAZINE is wrapped in
a compostable film manufactured and
sponsored by alesco (www.alesco.net)
Coverphoto courtesy DuPont
bioplastics MAGAZINE [05/09] Vol. 4
News
Comprehensive
biopolymer database
with new features
Certification of
Bio-Based Content
The content of renewable resources of products, which can
be measured by 14 C determination as the fraction of ‘bio-based
carbon content’, enjoys much attention in the environmental
and resource discussion. It is also the focus of several political
initiatives like for example in the U.S.A. (USDA’s ‘biopreferred’
program) Japan (Biomass Nippon Plan) and the EU Lead Markets
Initiative (LMI). One of the core activities within the LMI focuses
on the development of suitable standards for defining ‘bio-based
products’ and for the determination of the bio-based content
– similar to ASTM D-6866. Industry is involved in a dialogue with
the European Commission about the LMI and participates actively
in the respective working groups, also at the CEN level. Based
on the future standards, it is intended to develop independent
certification and market surveillance of claims concerning the
bio-based content. So far however, the LMI working groups
have not arrived yet at the certification part, so independent
certification is not available yet.
European Bioplastics (EuBP) has now started to coordinate
with partners along the bioplastic value chain for a joint approach
towards the development of a ‘bio-based content’ certification
system. Says Joeran Reske of EuBP, coordinator of the project
within the association: “We are aiming at a system as simple as
possible, on the other hand we think that independent certification
is a must, so that users have a both transparent and reliable
basis for their product-related communication. We consider the
bio-based content only one out of several parameters influencing
the environmental performance of a product.” Consequently,
labelling is seen as a very sensitive topic which needs a careful
and well balanced approach to be trustworthy. “Therefore we
thought we ought to deliver our contribution to the discussion
about the criteria of bio-based content certification”, adds EuBP-
Chairman Andy Sweetman.
European Bioplastics is seeking cooperation along the whole
product value chain, with the European Commission and with
other (national) authorities. It is intended to develop a system
that could be used finally also in policy making. The association
is in a dialogue with test laboratories, certification institutes and
other partners in and beyond Europe to include the best available
knowledge. - MT
The Biopolymer Database includes more than
100 biopolymer manufactures and more than
370 material types. Until now the data from the
material suppliers have been reported against
many different test standards and it has not been
possible to make a fair comparison between
different grades. Therefore the materials are now
tested under uniform and comparable conditions
in the University of Applied Science and Arts
(Hannover, Germany). The results of these tests
are to be made available in October 2009.
Through the biopolymer database customers,
converters and end users will be connected
with the bioplastic manufacturers. With the
biopolymer database it will also be much easier to
find information. At the first stage the users can
indicate whether their interest is pellets or film.
The biopolymer database allows extensive search
options for both variants, e.g. manufacturers,
including contact addresses, polymer types,
trade names, mechanical and thermal
properties, barrier properties, information about
certifications, biobased material content etc.
Furthermore the opportunity of comparing
functions is also given, i.e. a comparison of the
properties of different biopolymers. It is also
possible to search in the published literature.
All data are printable as datasheets. Datasheets
from the manufacturers are also available.
The database is available via the Internet in
German and English. Access is free of charge.
www.materialdatacenter.com
biobased@european-bioplastics.org
bioplastics MAGAZINE [05/09] Vol. 4
News
from left: Patrick Gerritsen, Frank
Eijkman, Jhon Bollen, Oliver Fraaije.
Bio4Pack offers
One-Stop Shopping
Two Dutch thermoforming companies, Nedupak
Thermoforming BV (of Rheden, NL) and Plastics2Pack (of
Uden, NL), recently announced the forming of ‘Bio4Pack‘
as a new packaging supply company. The new company is
headed by Managing Director Patrick Gerritsen, who brings
with him several years of know-how and expertise in the area
of biobased and biodegradable packaging.
Bio4Pack not only offers thermoformed packaging but
also all other kinds of packaging made from biobased and/or
biodegradable materials, including films, bags and netting,
and through to sugar cane trays made from the bagasse, a
by-product from the sugar cane industry.
“We want to offer our customers a total packaging
solution,“ says Oliver Fraajie, Commercial Director of
Nedupack, “not just a thermoformed tray or bulk pack.“
And thus the portfolio of Bio4Pack comprises the traditional
thermoformed packaging made from bioplastics such as
PLA or new thermoformable materials.
The range also includes films and bags for all kinds of
purposes, e.g shopping bags or flow wrap packaging made
from starch based bioplastics such as Biolice ® , Materbi ® or
Bioflex ® from FKUR, and also nets for onions, potatoes or
fruit and, of course, the labelling on the packaging.
“We also offer meat packaging consisting of a
thermoformed PLA tray with peelable SiOx coated PLA
film, having the same properties as conventional packing“
adds Frank Eijkman, Managing Director of Plastics2Pack.
“And for bakery goods such as cakes and cookies we have
thermoformed trays and folded boxes from a more rigid PLA
sheet. This kind of box is also available for the packaging of
bio-chocolate for example.“
Blisters for liquor gift packs or batteries round off the
list of examples. “In a nutshell: We are a trading company
that offers all types of packaging made from biobased or
biodegradable materials,“ says Patrick Gerritsen, “Those that
we don‘t produce ourselves at Nedupack or Plastics2pack,
we get from partners who I know from the past“.
Of course all products are certified according to EN 13432
and Patrick goes even one step further: “We are investigating
the possibility of having our products certified and labeled
with ‘Climate Neutral‘ (www.climatepartner.de)“.
Bio4Pack started operations in early August and is proud of
the first orders from leading companies in the fresh produce
and supermarket businesses. Even if the company initially
targets the European market, clients from all over the world
can be served via Nedupack‘s partners in many countries.
“Another big advantage is that Nedupack Thermoforming
have their own design and tool-making department, so we
are more flexible and can react much quicker than many
other suppliers,“ says Jhon Bollen, Technical Director of
Nedupack.
Although this new company was founded in a generally
difficult economic situation, the entrepreneurs have full
confidence in the development of this market. “We are
looking forward to convincing more and more supermarkets
and other suppliers to switch to bioplastic products - and
not only because the traditional resources are finite,“ says
Patrick Gerritsen. Oliver Fraaije is convinced that “the
customers who buy bio-food are also willing to buy biopackaging.“
- MT
www.bio4pack.com
Erratum:
In the last issue (04/2009) bioplastics MAGAZINE published an article on the NIR sorting field test of NatureWorks Ingeo PLA
bottles from a clear PET recycling stream. In table 1 on page 25 the removal efficiency was listed as 3 percent, when it should
have been 93 percent.
To be clear, 93 percent of the PLA bottles were removed from the clear PET stream. The resulting clear PET bail contained
just 453 ppm (parts per million) PLA. The bails were 99.95 percent PET and plastics other than PLA following the storing test.
We apologize for this error.
bioplastics MAGAZINE [05/09] Vol. 4
News
Completely
Biodegradable Food
Service for Dallas
Convention Center
Centerplate (Stamford, Connecticut, USA), the hospitality
partner to North America‘s premier convention centers and
sports stadiums, recently announced the introduction of a
completely biodegradable food service solution for the Dallas
Convention Center. All of the facility‘s disposable food
service items from cups to flatware to napkins will be 100 %
biodegradable, dramatically reducing the environmental impact
of the site‘s menu operations.
The initiative taps Centerplate‘s deep expertise in
implementing eco-friendly food service programs for major
convention centers and stadiums across North America
following its recent work helping the University of Colorado
at Boulder transform its 53,750 seat Folsom Field football
stadium into a zero-waste facility. For the Dallas Convention
Center, the biodegradable program augments the site‘s
position as one of the most environmentally sound convention
venues in the nation and one of the few to achieve the elite
ISO 14001:2004 certification, an international environmental
standard which helps organizations limit the negative impact
of their operations on the environment.
“When a two-million square foot plus operation like the
Dallas Convention Center commits to this level of change,
the benefits to the overall environment and to the health
of the immediate community are substantial,“ said Des
Hague, president and CEO of Centerplate. “As part of our
commitment to becoming the number one in hospitality
and a leader in sustainability, we intend to extend this
biodegradable food service solution to all our clients.“
Among the new biodegradable products being introduced
are cutlery made from potato starch; clear colored, cornbased
cups for beer and soda; and plates, bowls and togo
containers made from sugarcane pulp; hot cups that
are lined with plant-based plastic; and compostable lines
for trash receptacles.”It‘s a point of pride for us to be
able to operate a world class venue offering a world class
experience while simultaneously maintaining one of the
most environmentally responsible facilities in the country,“
said Frank Poe, the director of convention and event services
at the Dallas Convention Center. “Centerplate has been a
key partner of ours for several years and their ability to
successfully implement major changes such as this new
biodegradable food service program has played a key role in
our overall success.“ - PRNewswire - MT
www.centerplate.com.
PLA Based Masterbatches
At FAKUMA 2009, to be held in Friedrichshafen, Germany in mid October, Austrian
Gabriel-Chemie from Gumpoldskirchen is presenting its new MAXITHEN ® BIOL
range of colour- and additive masterbatches based on Polylactide (PLA).
At a dosage rate up to 5% MAXITHEN BIOL colour masterbatches comply with
the composting regulations and the normative standard EN13432. The colour
masterbatches are characterised by transparency and high colour strength and
can be well processed on existing machines. All PLA based colour- and additive
masterbatches are compatible with a lot of other biogenic as well as petrochemical
(conventional) polymers and offer a wide range of applications.
MAXITHEN BIOL masterbatches can be used for the production of films, form
parts, boxes, cups, bottles and other commodities. This new product range is
mainly recommended for the colouring of short-dated packaging or thermoformed
products (e.g. beverage- or yoghurt cups, trays for meat, fruits and vegetables);
but also for the colouring and dressing of agricultural films (mulch and protective
films) and auxiliary gardening articles (seedling trays, plant holders, single-use
plant pots). www.gabriel-chemie.com
bioplastics MAGAZINE [05/09] Vol. 4
Event Review
2 nd PLA Bottle Conference
The 2 nd PLA Bottle Conference hosted by bioplastics
MAGAZINE (September 14-15, Munich, Germany) attracted
almost 80 experts from 18 different countries.
Delegates from the beverage industry as well as bioplastics
experts came from all over Europe, North America and from
countries as far away from the event venue as South Africa,
Kuwait and Syria. Organizers, speakers and delegates were
all well satisfied with the conference, as all presentations
as well as the discussions were considered to be “very substantial“,
“very much state-of-the-art“ and offered “many
opportunities for making valuable contacts“.
In an extremely well received keynote speech on ‘Land use
for Bioplastics‘ Michael Carus from the nova Institut gave a
comprehensive overview of the situation regarding the need
to use available arable land to feed humans and animals,
and its use for the production of biofuels and bioplastics.
The conference itself followed a central theme from
renewable feedstock to end-of-life. Starting with the
basics on how starch or sugar is converted into lactic acid
and then into PLA, the speakers addressed topics such as
preform making and bottle blowing. Special focuses were
on certain challenges such as barrier improvement (e.g. by
SiOx coating) or enhanced thermal stability. Here special
processing techniques were discussed as well as blending or
stereocomplexing L and D lactides. Colorants and additives
were introduced in order to achieve effects such as antiyellowing
or anti-slip.
Once a bottle has been produced and filled the next
steps are capping (with ongoing efforts being made in the
field of bioplastic caps and closures) and labelling. Shrink
sleeves made of PLA represent a viable solution that
neither compromises automated sorting nor compostability
(where desired). A world premier was the introduction of a
bioplastics shrink film (see page 24 for more details).
Reports on their experiences by PLA bottle pioneers
as well as brand new entrepreneurs gave an inspiring
impression of the possibilities and challenges. As a surprise
for all participants a Greek dairy company, together with their
consultant, gave an almost spontaneous presentation about
a very recently launched milk bottle in Greece, accompanied
by a goat‘s milk tasting experience for everybody.
The conference ended with a session on end-of-life or
better end-of-use options for PLA. The delegates learned
that NIR (= Near Infrared) is a technology that works well for
automated sorting but that, on the other hand, still has some
limitations. As at the previous two PLA conferences organised
by bioplastics MAGAZINE, almost all of the attendees agreed
that composting is not necessarily the best option. However,
in closed loop systems such as stadiums, big events or
similar, collection and composting may be a viable solution,
provided that composting facilities are available. Elsewhere,
where perhaps the volumes of collected PLA do not reach
a critical mass for sorting and recycling, incineration with
energy recovery seems to be a good solution. As one fairly
new option the chemical recycling of PLA back into lactic
acid was presented and can be reviewed in more detail on
page 30.
After the second day of the conference the delegates
were invited to visit drinktec, the world‘s number one trade
fair for beverage and liquid food technology in Munich.
And on Wednesday an encouraging number of lime-green
backpacks could be observed at the fairgrounds …
www.pla-bottle-conference.com
bioplastics MAGAZINE [05/09] Vol. 4
4 th
Next Generation: Green
SAVE THE DATE !
10 / 11 November, 2009
The Ritz-Carlton, Berlin
www.conference.european-bioplastics.org
Conference Contact:
conference@european-bioplastics.org
Phone: +49 30 284 82 358
Fiber Applications
Melt Blown Line (Photo
Courtesy Biax-Fiberfilm)
Meltblown
PLA
Nonwovens
Two grades of NatureWorks‘ Ingeo PLA resin are now commercially available for the
production of meltblown nonwovens, fabrics widely used in such products as wipes and
filters.
“As interest grows in polymers made from renewable resources, equipment manufacturers,
process developers, and researchers have been exploring solutions that offer meltblown
nonwoven fabrics that both perform well and achieve a lower carbon footprint than the
existing petroleum-based incumbents,” said Robert Green, director of fibers and nonwovens,
NatureWorks, at the recent 2009 International Nonwovens Technical Conference (INTC) in
Denver, Colorado, USA.
Green was referring to meltblown fiber equipment manufacturer Biax-FiberFilm, Greenville,
Wisconsin, USA, which earlier this year conducted meltblown tests of Ingeo PLA. Researchers
at the University of Tennessee Nonwovens Research Lab (UTNRL) also evaluated Ingeo for its
suitability for meltblown fabric substrates using conventional meltblowing equipment.
“Our development of an Ingeo meltblown substrate significantly broadens the variety of
applications in which this material can be used,” said Doug Brown, president, Biax-FiberFilm. “An
Ingeo meltblown nonwoven offers an estimated 30 to 50 percent cost savings over conventional
fiber-based nonwoven roll goods and a significant advantage in price stability compared to
petroleum-based products.” Brown also noted that mixing the meltblown fiber with wood pulp
or viscose greatly enhanced the material’s absorption, making it suitable for a broad range of
performance wipes products.
In its development work, Biax-FiberFilm demonstrated excellent performance of two
Ingeo grades in their meltblown process. The grades 6252D and 6201D each provided broad
processing windows and quality fabrics that meet requirements for a range of applications. The
high pressure die design unique to Biax FiberFilm meltblown lines allow processing of higher
viscosity grades, such as 6201D, offering even higher fabric strength than seen on conventional
meltblowing equipment.
These recent advances provide the nonwoven market with a full range of Ingeo fabrics that
can now be produced with all major fabric forming technologies from spunmelt to conventional
carded nonwovens, offering the ability to meet consumers’ convenience needs with an annually
renewable low environmental impact material. The attached graphic shows the significant
environmental advantage Ingeo offers over conventional petroleum based products.
NatureWorks and Biax FiberFilm presented the results of this work in separate sessions at
the INTC. Also at the conference, Fiber Innovation Technologies presented a paper on thermal
bonding with Ingeo, and the University of Tennessee as well as Oklahoma University reviewed
research into Ingeo mulch fabrics and fiber production. MT
www.natureworksllc.com
www.biax-fiberfilm.com
10 bioplastics MAGAZINE [05/09] Vol. 4
Fiber Applications
New carpet
made from
PLA fibres
PLA
Floor Mat
A
special floor mat available for the fully
remodeled third-generation Toyota Prius uses
an advanced Ingeo based PLA fiber. Known
as the world’s most eco-conscious car, Toyota Prius
features world-leading mileage (2.6 L/100 km or 89 Miles
per Gallon), a solar powered ventilation system, and
environmentally friendly plant-derived plastics for seat
cushion foam, cowl side trim, inner and outer scuff
plates, and deck trim cover. Now, the new Prius adds to
these biobased materials by offering optional floor mats
(deluxe type) using an advanced Ingeo fiber system.
As a result of reducing the use of fossil resource as much
as possible in its manufacturing process from feedstock
to factory shipment, Ingeo reduces the fossil fuel use by
65% and cuts by 90% the CO 2
emission when compared to
the petroleum-derived nylon resin used in traditional floor
mats. By adopting the PLA mat products, Toyota benefits
from the unique environmental advantages of a fiber
made from plants, not oil. This adoption of new floor mats
exemplifies Toyota’s belief that the use of environmentally
friendly materials is as equally important as design and
product performance.
“We have long looked at Japan as an ‘innovation
engine’ for our Ingeo business,” noted Marc Verbruggen,
NatureWorks CEO. “With Toyota’s latest development, we
recognize their achievement in leading the automotive
industry’s efforts with excellence in biobased product
performance and innovation”.
NatureWorks in Japan supplied Ingeo to Toyota Tsusho
Corporation, who developed the new environmentally
friendly floor mats.
Sommer Needlepunch, Baisieux, France, is specialised
in floor covering solutions: carpet for events,
domestic and contract use and more recently artificial
grass. Its more than 50 years of know-how and experience
is recognised throughout the world.
The care for the environment has always been an
important consideration for the company, especially for
the issues related to the consumption of raw materials
and energy and the development of new products. During
the last five years they proved to be a trendsetter in
the development of sustainable eco-friendly solutions,
believing strongly that economy and ecology can go
together.
An important investment program made it possible for
Sommer Needlepunch to switch almost completely to the
use of biobased and recycled raw materials and the plan
to supply energy from wind turbines is scheduled to be in
place by 2010.
The launch of Ecopunch ® , the first carpet collection made
from 100% PLA fibres derived from NatureWorks‘Ingeo
is a result of the important R&D efforts made in the area
of the development of biodegradable products. “Ecopunch
is a real natural alternative to the conventional oilbased
products that offers the same performance and
quality,“ says a press release of Sommer Needlepunch.
“This new product is an environmentally friendly carpet
as its process reduces the CO 2
emissions by up to 60 %
compared to the traditional PP and PA products and
extends the economical life time of the raw materials.“- MT
www.sommernp.com
www.natureworksllc.com
bioplastics MAGAZINE [05/09] Vol. 4 11
Fiber Applications
Innovative Tea-Bag
Material Made From
PLA Fibres
Ahlstrom Corporation, headquartered in Helsinki, Finland is a global
leader in the development and manufacture of high performance fiber-based
materials. Last June the company presented its innovative,
biodegradable nonwoven for infusion applications at the Tea & Coffee World
Cup exhibition in Seville, Spain.
Thanks to an innovative, ahead of the curve investment at the Chirnside,
Scotland operations, Ahlstrom introduced a world premier to the infusion
market: a lightweight, fine filament web based on NatureWorks‘ Ingeo
PLA. It is designed to deliver functional benefits to converters and consumers
of tea-bags, while featuring unique environmental characteristics. Now
commercially available, it was presented for the first time at a European
exhibition.
“The raw material and the fine filament webs are fully biodegradable and
compostable. An independent LCA (life cycle assessment) carried out to
ISO 14040 standards demonstrated that these webs have a lower carbon
footprint compared to similar products made of oil-based polymers“ says
Mike Black, Ahlstrom‘s General Manager, Food Nonwovens. The principal
ingredient is PLA. This also means that the raw material for this product is
based on 100% annually renewable resources.
While responding to the growing demand for sustainable food packaging
solutions, the new product also delivers remarkable functional benefits.
The extra fine webs highlight the contents while maintaining shape and
easily accommodating tea-bag strings and tags. The resulting tea-bags
look different and feel different to the touch: they represent the ideal choice
for brand owners wanting to highlight quality infusions and to differentiate
their premium blends, the fastest growing segment in the market.
Suitable for conversion on tea-packing machines that use ultrasonic
sealing technology, the new materials complement Ahlstrom‘s wide
range of traditional heatsealable and non-heatsealable filter webs for tea
and coffee. Ahlstrom now offers the broadest range of beverage filtration
materials available on the market, with manufacturing both in Europe and
North America.
Ahlstrom infusion materials are part of the company‘s Advanced
Nonwovens business area and can be found worldwide in numerous
everyday applications. These include tea-bag materials manufactured
primarily in the UK and USA and used by leading tea packers such as Tetley,
Typhoo or Unilever. The products are sold globally through the Ahlstrom
sales network. - MT
www.ahlstrom.com
12 bioplastics MAGAZINE [05/09] Vol. 4
Fiber Applications
Plant-Based Materials
for Automobile Interiors
Toray Industries, Inc. with headquarters in Chuo-ku, Tokyo,
Japan has started full-fledged mass production of
its environment-friendly fiber materials based on PLA
and plant-derived polyesters for automobile applications.
Toray has already been supplying the materials for the trunk
and floor carpeting to Toyota Motor Corp. in its latest hybrid
model of Lexus, the HS 250h, launched in July this year. At
the same time, Toray is promoting the products to other automakers.
Toray aims to have annual sales of 200 tons for the
first year for products including ceiling upholstery and door
trim materials, and expects them to grow to 5,000 tons per
year by 2015.
Materials to be used in different automobile interior parts
have to clear tough and varied physical property requirements.
Generally, environment-friendly materials such as PLA used
to be believed to lack in heat and wear resistance properties
in comparison to regular polyester. Though various efforts
were being made to address those weaknesses, the adoption
of such materials in automobile applications had so far been
limited to a few models due to a number of shortcomings.
This time Toray developed various technologies for
compounding environment-friendly materials with
petroleum-based products, including a proprietary hydrolysis
control technology to modify polymer and techniques for
compounding using polymer alloys and in the process of
fiber spinning as well as mixed fiber compounding during
higher processing. By making full use of these technologies,
Toray succeeded in achieving the significantly high levels of
durability sought by automobile interior applications, enabling
actual adoption by mass-produced vehicles.
Having cleared the tough physical property benchmarks
for automobile interiors, Toray will focus on further
development of materials with higher plant-derived biomass
percentage and expand the materials’ applications into wideranging
applications such as general apparel and industrial
materials.
In this age of growing importance for environmentconsciousness,
automobile manufacturers are striving to
develop advanced technologies and aiming for a motorized
society that can co-exist with the environment. The companies
are actively considering a shift from the existing petroleumbased
materials to products made from plant-derived
materials for interior components which make up about 5
to 10% of a vehicle’s body weight. The use of plant-derived
materials is expected to explode in the future, given the fact
that it has low CO 2 emissions in its lifecycle from production
to disposal and it helps in curbing the use of the limited fossil
fuel resources.
Under its Innovation by Chemistry slogan, Toray is actively
pursuing the development of environment-friendly products
and aims to contribute to the development of a sustainable,
recycling-oriented society through its sales of environmentfriendly
automobile parts.
www.toray.com
Photos: Lexus / Toyota
bioplastics MAGAZINE [05/09] Vol. 4 13
Fiber Applications
Fibers of PTT Receive
New U.S. Generic, ‘Triexta’
Article contributed by
Dawson E. Winch
Global Brand Manager
DuPont Applied BioSciences
Wilmington, Delaware, USA
This year is a significant year in fiber history for several reasons.
Seventy years ago, at the 1939 World’s Fair, nylon was introduced
and women began wearing stockings made with nylon
from DuPont. In 1959, 50 years ago this year, the Textile Identification
Act was passed to create standards for fiber identification in apparel,
carpet and other fiber markets. And most recently, in March of 2009,
the U.S. Federal Trade Commission (FTC) issued a new subgeneric
– ‘triexta’ – for fibers made from PTT (polytrimethylene terephthalate)
polymer. Sorona ® is the brand name for renewably sourced PTT polymer
from DuPont.
In addition to its legacy of fiber innovation, DuPont has also led in
the establishment of environmental goals. DuPont established its first
environmental goals more than 19 years ago and as recently as 2006,
set aggressive sustainability goals to meet or exceed by 2015. In addition
to the operational goals of reducing its environmental footprint, for the
first time DuPont established market facing goals. Sorona addresses
one of these goals in particular, to reduce dependency on depletable
(petrochemical) resources. DuPont Sorona ® renewably sourced
polymer was created at the intersection where sustainability and fiber
innovation meet.
Sorona is just one product that utilizes Bio-PDO, the key and
‘green’ ingredient made using a fermentation process. And it is only
one of many products in the DuPont Renewable Materials Program
(DRSM). DRSM was developed to help DuPont customers identify
those products that perform as well as or better than traditional
petrochemical-based products AND contain a minimum of 20%
renewably sourced ingredients by weight.
By creating base monomers or building block molecules like Bio-
PDO, using renewable resources instead of petrochemicals, DuPont
has introduced a variety of materials for diverse markets and end
uses from personal care products to industrial antifreeze to fibers for
textiles and carpet. It is in these last two categories – textiles and
carpet – where Sorona can be found.
Apparel as well as residential and commercial interior markets can
enjoy and benefit from the unique combination of attributes provided
by Sorona, that led to the new generic, ‘triexta.’
APPAREL
The versatility and adaptability of fibers made with Sorona
compliment the needs by a wide variety of apparel applications. Since
it can easily be blended with other fibers, both synthetic and natural,
14 bioplastics MAGAZINE [05/09] Vol. 4
fibers from Sorona, with its features and benefits, allows
designers to take designs to new heights.
The benefits of Sorona compliment the demands of
swimwear manufacturers and consumers. Swimwear
remains looking newer longer due to the chlorine and
UV resistance, meaning prints and colors won’t fade or
wash out due to repeated exposure to bright sun and
harsh chlorine. And one swimsuit will last the whole
season (at least) since it resists pilling. Speedo has
adopted Sorona for swimwear in the United Kingdom.
Intimate apparel designers and consumers appreciate
the exceptional and luxurious softness and flattering
drape provided by Sorona. Unlike other synthetics, these
-fibers reach a bright white and a deep, rich black –
both very popular colors in the intimate apparel market.
And, due to its colorfastness and fade resistance blacks
and whites won’t fade or yellow over time. Best of all
for consumers is the easy care attribute of Sorona - no
special washing instructions to follow.
Activewear also benefits from the unique attributes
and benefits of Sorona. As a polymer, it can be extruded
in an odd cross section to increase the wicking ability of
the fiber. Moisture management is enhanced with these
fibers since the moisture transporting channels remain
more clearly defined. And, fleece takes on a new level of
softness since a microdenier feel can be obtained with
fibers of greater than one denier. And, fiber and fabric
is fade resistant from repeated washings, activewear
colors remain bold and vivid through many work-outs
and adventures.
In blended fabrics popular in ready to wear, Sorona
continues to provide wonderful benefits. Wool/Sorona
blends offer softness and drape along with resistance
to wrinkles – perfect for the business traveler who
goes from plane to meeting. Cotton/Sorona blends
offer softness and a comfort stretch and recovery to
provide freedom of movement through the shoulders
and elbows where consumers need it most. And, baggy,
saggy knees and elbows are virtually eliminated since
it also provides permanent recovery. This stretch and
recovery leads to freedom of movement improving
comfort and wearability in clothing. In other words,
such blends enhance and maximize the fabric’s benefits.
Spun Bamboo ® has incorporated blends of Sorona
and bamboo into it’s lines of t-shirts and polo shirts.
Timberland and Izod have also adopted Sorona into a
line of fishing shirts and polo shirts respectively.
Designers and apparel manufacturers appreciate the
easy dyability of fibers made with Sorona since it reaches
full color absorption at the boiling point of water. Unlike
some other synthetic fibers, it doesn’t require additional
heat, pressure or chemical carriers to dye. Fabrics print
beautifully too – and prints remain sharp, vivid and
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The unique book represents an important and comprehensive
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Definition of biopolymers
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bioplastics MAGAZINE [05/09] Vol. 4 15
Fiber Applications
crisp since fabrics are fade resistant from both sunlight and
repeated washings.
The most unique attribute of Sorona, however, lies in the
fact that this fiber is also an environmentally smart choice
for textile and carpet markets. The performance of Sorona
contributes to the overall sustainability since the performance
keeps products look newer longer.
Since one of the ingredients is made with renewable
resources instead of petrochemicals, Sorona is 37% renewably
sourced by weight. Energy savings and reduced greenhouse
gas emissions are added to the environmental benefits
since the production requires 30% less energy and reduces
CO 2 emissions 63% over nylon 6 on a pound for pound basis.
Durability and performance also contribute to the sustainable
aspects since products perform and look better, longer.
CARPET
The ‘Performance PLUS Environmental‘ story of Sorona
continues in carpet fibers for both residential and commercial
applications. In carpeting, it offers a unique combination
of benefits that customers’ value. In addition to providing
durability and crush resistance, carpets with Sorona are
permanently, naturally stain resistance. Since the stain
resistance is an inherent attribute of the fiber, it will never
wash or wear off and therefore never has to be reapplied.
Triexta, the new generic, also pertains to Sorona as a fiber for
residential and commercial carpets. In test after test, carpets
with Sorona outperformed both premium stain treated nylon
and polyester carpet in both durability and stain resistance.
And the energy equivalent of 1 gallon of gasoline is saved for
approximately every 7 square yards (1 liter per 1.55 m²) of
residential carpet. Leaders in the carpet industry state that
Sorona is the newest innovation to positively impact the carpet
industry in over 20 years.
The benefits of Sorona in commercial carpet continue in
green building design for commercial interiors. It’s permanent
natural stain resistance and durability attributes delight both
building residents and maintenance teams alike. Architects
and designers appreciate the three ways that carpeting with
Sorona can contribute to LEED’s points: 1) As a ‘Rapidly
Renewable Material’ MR Credit 6; 2) as a ‘Regional Material’
MR Credit 5; and 3) ‘Low-Emitting Materials,’ IEQ Credit
3. The LEED program was established by the U. S. Green
Building Council as guidelines for the design and construction
industries.
Sorona is evidence of the innovation that results from
intersections – the intersection of biology, chemistry and
polymer science as well as the intersection of performance
and environmental benefits.
www.sorona.dupont.com
www.renewable.dupont.com
16 bioplastics MAGAZINE [05/09] Vol. 4
Processing
Twin-Screw Extruders for
Biopolymer Compounding
ENTEK Manufacturing, Inc., headquartered in Lebanon,
Oregon, USA, the leading U.S. based manufacturer
of twin-screw extruders and replacement wear
parts, recently introduced customized twin-screw extruders
specifically designed for bio-based compounding.
At NPE in Chicago in June, ENTEK showed a specially
outfitted E-MAX 27mm twin-screw extruder designed for
processing bio-based blends. It includes two dry feeders and
a liquid feeder for processing a combination of thermoplastics
and a bioresin or starch material.
The use of ENTEK twin-screw extruders for biopolymer
processing is not new; in fact, the company’s machinery is
currently being used by several processors worldwide in
commercially successful bio-based applications. However,
because of the ever-increasing number of biopolymer
materials, additives and fillers being used in the industry,
ENTEK has developed new machine configurations
specifically designed for compounding materials in the
following three areas:
• Reactive bio-based materials (starch-based materials
and plasticizers)
• Bioresin materials (PLA, PHA, PSM, etc.)
• Bio-based blends (Bioresins or Starches blended with
Thermoplastics)
“Our development lab has seen a real spike in the
number of bio-based material and product trials,” said John
Effmann, ENTEK Director of Sales and Marketing. “The
experience we’ve gained from these trials, as well as our
in-field bio experience, has helped us understand what’s
needed to successfully compound the many types of biobased
materials on the market.”
ENTEK 27mm, 40mm, and 53mm twin-screw extruders
are the most popular models for bio-based applications, but
larger models such as the 73mm and 103mm machines are
also in use for commercial applications. “Typically a customer
will use our in-house development lab for material trials,
then start with a 27mm or 40mm machine,” said Effmann.
“Once the bio-based compound makes it to market, the
customer ramps up for production by purchasing our larger
machines,” he said.
ENTEK was an early participant in biopolymer processing.
Back in 2004, Australian customer Plantic, a pioneer in
biopolymer compounding, successfully processed their
patented packaging products on ENTEK machinery before
the term ‘biopolymers’ was common in the industry. The first
Plantic products got their start in the ENTEK lab in Lebanon,
Oregon, and the two companies continue a strong business
relationship today.
While still a young industry, today biopolymers are a fastgrowing
field. In 2008, bio-based material trials made up
36% of all trials run in ENTEK’s in-house development lab.
Several new players have emerged in the industry in
this area, and ENTEK is working with many of them. New
materials of all types are arriving at the company weekly,
and ENTEK welcomes the opportunity to lend its lab and
processing expertise for the next breakthrough biopolymer
application.
www.next-step.com
bioplastics MAGAZINE [05/09] Vol. 4 17
Paper Coating
Improved
Paper
Coatings
Article contributed by
John T. Moore,
Vice President- Business Development,
DaniMer Scientific, Bainbridge, Georgia,
USA
Many companies are building the value of their brands
and growing their business by investing in development
of product offerings that utilize renewable-based
biopolymer materials. DaniMer Scientific, LLC is enabling brand
owners and converters who focus on environmental stewardship
to grow their market share by offering biopolymers for extrusion
coating of paper and paperboard. Extrusion coating is an excellent
application for biopolymers, and there is no current opposition
concerning contamination of the existing recycle stream for
paper articles when biopolymers are present. Further enhancing
its appeal, DaniMer’s extrusion coating resin provides additional
value by enabling coated articles to be repulpable. DaniMer’s advances
in the use of biopolymers led to the introduction in 2006
of the world’s first commercial extrusion coating resin that meets
global standards for compostability while utilizing renewable resources.
This new DaniMer technology enabled International Paper
to launch the Ecotainer product in a partnership with Green
Mountain Coffee. Since that launch, DaniMer’s extrusion coating
product has continued to enjoy the market’s embrace and
steady growth. In fact, International Paper recently announced it
has crossed the one billion cup milestone and is expanding their
product line to include cold cups for a certain large global brand
owner; further demonstrating that biopolymer coated paper substrates
are more than just a fad. DaniMer has expanded its customer
base and is working with key customers on a global basis
in various stages of commercialization for new products.
DaniMer’s proprietary extrusion coating resin is based on
NatureWorks Ingeo Biopolymer. Ingeo biopolymer is an excellent
material, but requires modification for melt strength, melt curtain
stability, and adhesion to paper in extrusion coating applications.
In most cases, DaniMer’s extrusion coating resin can be run on
existing equipment with minimal adjustments relative to the
18 bioplastics MAGAZINE [05/09] Vol. 4
Paper Coating
setup typically used for low density polyethylene. One challenge
encountered with the use of biopolymers is the need to process the
material at lower moisture content than that typically acceptable
for polyethylene. Like PET and other polyesters, biopolymers (which
are typically bio-polyesters) can gain moisture when exposed to
ambient conditions. Moisture management is often a new area
of focus to most converters of LDPE. Another difference often
noted with biopolymer materials such as the DaniMer extrusion
coating resin is the lower processing temperatures than those
used when processing traditional polyolefin materials such as
LDPE. The ability to process at much lower temperatures enables
an additional cost savings when using biopolymers. With proper
training and instruction, most processing changes are recognized
as minor and require only slight adjustment in procedure.
The market success that DaniMer has enabled its customers to
experience with the first generation renewable-based, compostable
extrusion coating biopolymer has led to development of a second
generation formulation. Development of this second generation
material is in the final stages of commercial-scale validation with
cost reduction and broader operating parameters as the primary
new characteristics. Increased efficiencies in manufacturing
of the next generation material will translate into cost savings,
which along with broader processing and converting parameters
are expected to enable converters and brand owners to gain and
retain greater market share for coated paper articles that are
intended for single-use and short-term-use applications.
In response to requests from key market leaders, DaniMer has
recently developed a wax replacement coating. This proprietary
material is also made from renewable resources and is both
compostable and repulpable. Traditional wax coatings are
losing favor with paper companies and converters, due to large
fluctuations in consistency and price. Utilizing their Seluma
technology platform, the Danimer R&D staff has developed a
wax replacement material using renewable based monomers to
create a coating resin that can be used as a ‘drop in’ for existing
wax coatings of paper and other substrates. Early customer
evaluations confirmed that because the DaniMer material has
a higher stiffness vs. wax, a reduction in part weight or paper
thickness is possible resulting in significant overall package
savings.
Photos: International Paper
DaniMer continues to focus on cost-effective innovation in order
to serve brand owners and converters with a broad product portfolio
of biopolymer materials. DaniMer recently acquired the Procter &
Gamble intellectual property portfolio for a new type of biopolymer
known as polyhydroxyalcanoate (PHA) and is commercializing the
technology via a new company identified as Meredian, Inc. It is
expected that Meredina PHA (scheduled for commercial-scale
production in 2010) will provide additional innovations in the area
of biopolymer technologies suitable for paper and paperboard
coatings as well as for other unique combinations of biopolymers
that will be offered through Meredian’s sister company DaniMer
Scientific.
www.danimer.com
bioplastics MAGAZINE [05/09] Vol. 4 19
Paper Coating
Sustainable Cups
from Georgia-Pacific
Article contributed by
John Mulcahy
Vice President – Category
Georgia-Pacific Professional
Food Services Solutions
Atlanta, Georgia, USA
In August, Georgia-Pacific Professional Food Services Solutions
launched a complete line of Dixie beverage solutions, which are
part of the company’s EcoSmart product line that demonstrates
the company’s commitment to innovative products that support
sustainability goals.
The EcoSmart products includes two collections: A PLA-lined
single wall paper hot cups made from at least 95 percent renewable
resources; and the Insulair ® line of insulated cups, available in 12
and 25 percent post-consumer recycled fiber.
The products are designed to allow operators to enhance their
environmental stewardship position. These EcoSmart products can
be processed successfully in commercial composting operations,
where they exist. The PLA hot cup is 100 percent compostable
because both the fiber portion and the coating are fully compostable.
This coating is supplied by NatureWorks. The Insulair collection
contains a fiber portion which is fully compostable in commercial
facilities. While the Insulair coating is not inherently compostable, it
will separate from the fibers and can be screened out at the end of
the composting operation.
“This is a tremendous step forward in the approach we take to
responsible manufacturing,” notes John Mulcahy, vice president
– category, Georgia-Pacific Professional Food Services Solutions.
“The EcoSmart line represents some of the most groundbreaking
products available to operators and is just one example of our
dedication to providing sustainable solutions that create a positive
impact on the world around us.”
New from Georgia-Pacific Food Services Solutions, the PLA
coated cup collection is printed with a green foliage stock design,
Viridian, and available immediately in 8-, 10-, 12-, 16- and 20-
ounce sizes.
The Insulair insulated hot cup collection features 12 and 25 percent
post-consumer recycled fiber options. Both feature triple-wall
construction and an insulative middle layer that keeps beverages
hot while staying cool to the touch. The corrugated middle layer is
comprised of 99 percent post-consumer recycled fiber.
Insulair is available in attractive stock designs, including Viridian,
Aroma and Interlude, and in 8-, 12-, 16-, 20- and 24-ounce
sizes. The cup also boasts custom graphic capabilities with sharp
resolution and rich colors, which have won Bronze, Silver and Gold
at the 2008 Flexography Awards international design competition.
www.gppro.com
20 bioplastics MAGAZINE [05/09] Vol. 4
Polylactic Acid
Uhde Inventa-Fischer extended its portfolio to technology and production plants for PLA,
based on its long-term experience with PA and PET. The feedstock for our PLA process is lactic acid
which can be produced from local agricultural products containing starch or sugar.
The application range is similar to that of polymers based on fossil resources. Physical properties of
PLA can be tailored to meet the requirements of packaging, textile and other applications.
Think. Invest. Earn.
Uhde Inventa-Fischer GmbH
Holzhauser Strasse 157–159
13509 Berlin
Germany
Tel. +49 30 43 567 5
Fax +49 30 43 567 699
Uhde Inventa-Fischer AG
Reichenauerstrasse
7013 Domat/Ems
Switzerland
Tel. +41 81 632 63 11
Fax +41 81 632 74 03
www.uhde-inventa-fischer.com
Uhde Inventa-Fischer
A company of ThyssenKrupp Technologies
Application-News
In conjunction with the new 62N BioTAK contact adhesive,
German company Herma is offering a unique adhesive
material that is 100 % biodegradable. Located in Filderstadt
near Stuttgart, Herma GmbH is a leading European specialist
in self-adhesive technology. The new contact adhesive
satisfies the European standard DIN EN 13432 which certifies
products made from compostable materials. A white, lightweight
coated paper and three different films are available as
the label material. The patented 62N BioTAK contact adhesive
is used on all of them. “Biodegradable materials based on
renewable raw materials have already had a huge impact on
the packaging materials sector,“ explains Herma managing
director Dr. Thomas Baumgärtner. “Consumers are already
showing a growing interest in where packagings come from,
and whether they can be reused; natural cosmetics, fruit and
vegetable packagings and all the products in the burgeoning
organic sector are good examples of this trend.“
Fully Compostable
Self-Adhesive Labels
HERMAnaturefilms – films made from wood
In the certification procedure, the HERMAnaturefilms
widely exceeded the requirements. To comply with EN
13432, 90 % of the material must have biodegraded after 45
days. The HERMAnaturefilms achieved this value after only
31 days and were fully degraded after 39 days. The special
films are obtained from cellulose supplied by FSC-certified
companies (from sustainable forestry). The films can be
printed using solvent-free and water and UV-based inks by
all conventional printing methods; they are antistatic and
repel oil and grease. Paper converters also benefit from the
high moisture and oxygen barrier. “The film is already used
as a packaging material by a large number of major food
manufacturers and packaging companies. With labels made
from our HERMAnaturefilms, these packaging materials are
now fully compostable,“ stresses Baumgärtner. Thanks to the
high gloss level, they even meet the sophisticated needs of
cosmetics packagings.
Labels using BioTAK adhesive
(Photo: courtesy BioTAK)
The biodegradable adhesive material is a further addition
to HERMA‘s ‘GreenLine’ product range. Just recently the
company included PEFC-certified paper adhesives and label
papers in its offering. “In this way label manufacturers will
now be able to take even greater advantage of the growing
demand for environmentally friendly packagings and marking
systems,“ states Baumgärtner.
22 bioplastics MAGAZINE [05/09] Vol. 4
Biobased and
Compostable
Shrink Film
Application News
Sustainable and compostable, metallised NatureFlex NM
wraps Dr Vie Inc’s nutritional products
Nutritional Canadian
Products
Canadian company, Dr Vie Inc, is wrapping its entire range
of nutritional ‘superfood’ products in metalized NatureFlex
NM film from Innovia Films, Wigton, Cumbria, UK.
Based in Montréal, Québec, Dr Vie Inc is a family-owned
business managed by a mother and daughter team. A family
history of ill health inspired their mission to create powerful
low-allergenic superfoods that stimulate wellness, enhance
a feeling of well-being and prevent illness.
The company’s 100% all-natural products are lowglycemic,
high in antioxidants, essential omegas and fatty
acids. The product line includes a variety of pure cacao
products, antioxidant-rich goji berry and acai berry raw
chocolate bars, sports nutrition bars and frozen desserts.
Dr Vie Inc has recently partnered with a global team of
elite sports, IronMan and Olympic team coaches and their
products are now available worldwide online to athletes, in
addition to Canadian health food, sports, wellness centres
and speciality stores.
Dr Vie Inc individually cuts and shapes the roll of
NatureFlex film to wrap each product at their factory.
According to company founder, Dr Vie, NatureFlex is an
ideal packaging choice: “Our company’s goal is to promote
wellness, optimise individual performance and protect the
planet in the process. NatureFlex is fully sustainable and
aligns beautifully with our core values”.
The high barrier against water vapour (WVTR
Application News
Green Packaging Line
A new ‘Green Packaging Line‘ of products has been
recently developed by Smurfit Kappa, Orsenigo, Italy, a
leading company specialised in the sector of innovative
cardboard based packaging.
It has adopted a new technology offered by Novamont,
Italy and Iggesund Paperboard, a leading company active
in the sector of high quality coated boards, headquartered
in Iggesund, Sweden.
World’s First
Bioplastic Eyeglasses
Japanese Companies Teijin Limited and Teijin Chemicals
Limited announced the development of eyeglass frames
made from plant-based, heat-resistant PLA BIOFRONT,
the world’s first bioplastic to be used for all plastic parts
of eyeglass frames, including the temples. The frames
were developed in collaboration with Tanaka Foresight
Inc., Higashi-Sabae City, Japan, which manufactures and
sells approximately 60% of all plastic eyeglass parts in
Japan.
The new Biofront frames will be exhibited at the Tanaka
Foresight booth during the International Optical Fair
Tokyo (IOFT 2009) at Tokyo Big Sight from October 27 to
29. Tanaka Foresight eventually expects to sell between
50,000 and 100,000 pairs of PLA eyeglasses per year.
Although acetate is commonly used for the plastic
parts of eyeglasses, contact with cosmetics or hairstyling
products can result in bleaching. Acetate also
tends to warp under high heat and can cause skin rashes.
PLA (polylactide) has been used for eyeglass nose pads
because its antibacterial properties help to avoid rashes,
but conventional PLA has not been used for other parts
such as frames and temples because of insufficient heat
resistance.
Biofront, however, is an advanced polylactide that offers
enhanced heat resistance. Its melting point of 210 °C puts
it on par with PBT, a leading engineering plastic. Biofront
also is highly resistant to bleaching and bacteria, making
it ideal for the plastic parts of eyeglasses.
This new rigid packaging line, which comprises trays,
punnets and containers for fresh and frozen food, bakery,
confectionary and others, is based on the virgin fibre
paperboard Invercote, coated through extrusion coating
technology with a compostable Mater-Bi polymer.
This special coating brings various technical properties
to the cardboard, like an excellent sealability, good thermal
stability and water, oil and fat protection.
Given these properties, Smurfit Kappa Orsenigo is able
to supply a wide range of products for cold and hot, dry and
wet food packaging applications, in the retail, catering and
Ho.Re.Ca. (=Hotel/Restaurant/Café) areas, like:
Deep frozen packaging, trays and punnets for ready cut
salad or fresh fruits or vegetables, ready meals and take
away containers, fresh cheese and dairy products, sweets,
chocolate, bakery.
Moreover, several non food applications can be taken
into consideration, like agro-floricultural ones, customised
gifts, wear packaging.
Besides being food contact approved, biodegradable and
compostable (according to EN13432), the ‘Green Packaging
Line’ products may also be disposed in the paper stream,
because the Mater-Bi coating has been designed as
well in order to meet the paper and cardboard recycling
requirements.
The result is an extremely versatile and sustainable range
of products, because of its multiple end of life options.
www.smurfitkappa.it
www.novamont.com
www.iggesund.com
www.teijin.co.jp
24 bioplastics MAGAZINE [05/09] Vol. 4
The ‘Green‘ Shaver
Application News
Established in 1945, the Société BIC is a Clichy, France based, well
recognized one-time-use products manufacturer. The company specialises in
ballpoint pens, cigarette lighters, razors and many more such products. The
BIC Group is committed to a pragmatic approach when it comes to materials
which have a better environment performance: to experiment them. This is
why the company started to implement different material alternatives in their
products and packaging recycled or coming from renewable resources.
This is the case for example for the new BIC ECOLUTIONS triple blade shaver
with its bioplastic handle and its 100% recycled cardboard packaging. After
5 years of research, BIC succeeded to develop a handle made with Ingeo T
PLA and other additives that resists to the constraints of shaving. In addition
bio-pigments of vegetable origin give this shaver a distinct green color and
the recycled pack is printed with bio inks made of vegetable based pigments
(soy).
Consumers usually perceive ‘green‘ products as expensive. However with
a suggested retail price of €3.20 per pack of four shavers, BIC ® ecolutions
remains affordable to everyone. - MT
www.bicecolutions.com
Eco-Conscious
Parenting Solutions
Dorel Juvenile Group, Inc, Columbus, Indiana, USA, the
largest juvenile products manufacturer in the USA, recently
launched its Safety 1st ® Nature Next collection as part of its
ongoing initiative to focus on the environment. The special
collection addresses a growing concern among parents
who want to provide quality products for their children that
incorporate eco-conscious materials.
“We recognize the need – and our customers’ desire – to
make products that help keep children safe and healthy,“
said Vinnie D’Alleva, EVP Business Development at Dorel,
“but with a view to maximizing the environmental benefits.
We are also pleased to bring the collection to retail at an
accessible price point that all parents can appreciate.”
The Nature Next collection features the following ecoconscious
materials, such as bamboo, a quick-growing
and renewable resource. It is able to rapidly replenish
itself, making it a great alternative to traditional woods. In
addition, bamboo can thrive with little water and does not
require the use of fertilizers or pesticides, further reducing
its environmental impact.Bioplastics: The starches used in
the Nature Next collection’s items are all plant byproducts,
not crops that could otherwise be used as a food source.
Dorel also applies recycled plastics.
The line currently includes a Bamboo Booster Seat (photo),
Bamboo Gate, Bio-Plastic Infant-to-Toddler Bathtub, Bio-
Plastic Booster and Bio-Plastic 3-in-1 Potty.
http://naturenext.safety1st.com
bioplastics MAGAZINE [05/09] Vol. 4 25
Materials
Biobased
Engineering
Castor beans
Plastic
www.dsm.com
DSM Engineering Plastics from Sittard, The Netherlands,
has expanded further its Green Portfolio with
the introduction of EcoPaXX, a bio-based, high
performance engineering plastic. The new material, which
is based on polyamide (PA) 410 (or PA 4.10), has been developed
by DSM in recent years, and is now set to be commercialized.
High performance
Polyamide 410 is a ‘long-chain polyamide’. Thus EcoPaXX
is a high-performance polyamide with excellent mechanical
properties. It combines typical long-chain polyamide
properties such as low moisture absorption with high
melting point of 250°C (the highest of all bio-plastics) and
high crystallization rate enabling short cycle times and
thus high productivity. The material has excellent chemical
and hydrolysis resistance, which makes it highly suitable
for various demanding applications, for instance in the
automotive and electrical markets. A good example is its
very good resistance to salts, such as calcium chloride.
Because of its low moisture absorption, EcoPaXX will also
keep good strength and stiffness after conditioning.
Zero carbon footprint
Newly-introduced EcoPaXX is a green, bio-based
material: The polyamide 4.10 consists of the ‘4‘-component
(fossil oil based diaminobutane) and the ‘10‘-component
(approximately 70% of the polymer) derived from castor
oil as a renewable resource. Castor oil is a unique natural
material and is obtained from the Ricinus Communis plant,
which grows in tropical regions. It is grown in relatively poor
soil conditions, and its production does not compete with the
food-chain.
As not all carbon of the castor beans (or even of the castor
plants) is being used for making the building blocks of the
PA 4.10 there is still a certain amount of carbon sequestered
by the castor plant that is being used as an energy source
for the PA production or as fertilizer. Thus EcoPaXX can be
seen as to be 100 % carbon neutral from cradle to gate, as
per DSM, which means that the carbon dioxide which is
generated during the production process of the polymer, is
fully compensated by the amount of carbon dioxide absorbed
in the growth phase of the castor beans. According to Kees
Tintel, project manager EcoPaXX “the carbon footprint
of plastics is rapidly becoming a hot issue for Customers,
therefore they really appreciate EcoPaXX being carbon
neutral!”
Market introduction phase
“DSM Engineering Plastics is proud to have EcoPaXX,
the ‘Green Performer’ , in a market introduction phase.
Combining unique DSM knowledge with the skills of Mother
Nature allows our Customers to benefit from a new step
towards a more sustainable world” says Roelof Westerbeek,
President of DSM Engineering Plastics. - MT
Castor plants
26 bioplastics MAGAZINE [05/09] Vol. 4
Materials
Injection
Moldable High
Temperature
Bioplastic
Launched in March 2009 by Colombes (France) based
Arkema, Rilsan ® HT for extrusion is the first flexible
high-temperature thermoplastic to replace metal in
high-temperature applications. Now, the company unveiled
Rilsan HT injection resins. The Rilsan HT range is now the
first complete polyphtalamide (PPA)-based product line
suitable for all process technologies, ranging from extrusion
to blow or injection molding. Rilsan HT resins are up to 70%
bio-based (according to ASTM D6866-06, biobased carbon)
and match the increasing environmental commitment of
many industries.
PPA-based injection resins in automotive applications
have increasingly replaced metal parts as a way to optimize
costs, reduce emissions and weight, improve fuel economy
and extend car life. Until now, PPA-based injection resins
were more difficult and costly to process when compared to
aliphatic high-performance polyamides.
According to Arkema, Rilsan HT is the only PPA-based
injection resin that offers processing characteristics similar
to those of aliphatic high-performance polyamides. With
mold temperatures close to those of PA12 and PA11, it
can be easily processed on standard injection-molding
equipment using conventional water-cooled temperature
control. Moreover, the material can be processed in injection
molds designed for PA12 and PA11 thanks to similar mold
shrinkage properties.
Unlike conventional PPA-based resins, Rilsan HT has very
low moisture uptake, which provides multiple benefits in
manufacture and applications. Low moisture pickup means
that the resin is easily stored and requires no supplemental
steps before processing. Low moisture absorption makes
the resin easy to process and handle, and imparts reliable
uniformity to the finished parts’ properties, which avoids
further downstream processing and limits waste. The
finished parts exhibit excellent dimensional stability.
Rilsan HT injection grades have exceptional ductility not
found in typical semi-aromatic injection resins. Thus the
resins deliver a designer-friendly balance of toughness,
strength and elongation and reduce the risk of failures that
can occur with brittle plastics, such as conventional PPAbased
injection materials or PPS.
Conductivity combined with ductility make it the first
conductive PPA-based injection resin that perfectly balances
high temperature resistance and excellent mechanical
properties with conductivity – making it well suited for
fuel system applications where conductivity is specifically
required, as it is for example in the North American market.
As stated by Arkema, this new PPA-based injection resin
is the only one that can be easily spin-welded with aliphatic
high performance polyamides, a completely new processing
feature for this material group. This offers further component
integration and addresses the enhanced safety and emission
standards of pipe connections in fuel-conducting systems.
Rilsan HT injection grades - glass-fiber reinforced or
formulated for conductivity - are ideally suited for metal
replacement in fuel system applications requiring low
permeation, low swelling and high thermal resistance. And
the suitability of the injection grade for quick-connectors
and other temperature resistant parts extends to powertrain
components including those integrated with Rilsan HT
flexible tubing.
Largely derived from renewable non-food-crop
vegetable feedstock, the polyamide material is a
durable high-temperature thermoplastic containing
up to 70% renewable carbon. It offers a significant
reduction in CO 2 emissions compared to conventional
petroleum-based high-temperature plastics, a reduced
dependence on oil resources and a perfect fit with the
eco-design concepts of many vehicle manufacturers.
www.arkema.com
bioplastics MAGAZINE [05/09] Vol. 4 27
Materials
Composite Technical Services Inc. (CTS), based in Kettering (Dayton),
Ohio, USA, have recently established manufacturing and
research and development operations. Combining innovation
with environmental sustainability, CTS is providing high performance,
cost effective materials and technology that include unique bio-resins
and flame retardant additives. Housed in the National Composite Center
(NCC), CTS is initially targeting the composites and plastics industries.
Versatile Precursor
Made From Cashew Nuts
Cardanol from Cashew
One versatile precursor for a variety of polymers is cardanol, a phenol
derivative having a C15 unsaturated hydrocarbon chain with one to three
double bonds in meta position. It has interesting structural features for
chemical modification and polymerization. Cardanol can be obtained
from anarcadic acid, the main component of Cashew (Anacardium
occidentale L.) Nut Shell Liquid (CNSL) by double vaccum destillation.
CNSL is a renewable natural resource obtained as a by-product of the
mechanical processes used to render the cashew kernel edible. Its total
production approaches one million tons annually. If not used as a widely
available and low cost renewable raw material, CNSL would represent a
dangerous pollutant source.
Cardanol-phenol resins were developed in the 1920s by a student of
the Columbia University (New York) named Mortimer T. Harvey.
The name ‘cardanol‘ comes from the word Anarcadium, which includes
the cashew tree, Anarcadium occidentale. The name Anarcadium itself is
based on the Greek word for heart.
Cardanol-based resins
Based on this, CTS is currently working on a breakthrough brand called
Exaphen. Exaphen products use a process that extracts (exa) phenolic
(phen) resins from agricultural by-products such as CNSL while retaining
the special properties nature has already engineered. A unique chemical
structure gives phenolic-type resins the capability to fight fire and delay
the spread of flames combined while providing resistance to aggressive
environments.
28 bioplastics MAGAZINE [05/09] Vol. 4
Photo: Barnabà
Materials
CTS offers a series of products based on the phenolic structure derived
from cashew nut shells.
• Cardanol-based phenolic resins (novolacs) as curing agents of
commercial epoxy resins;
• Cardanol-based polyols (POLYCARD XFN) for the preparation of
polyurethanes;
• Cardanol-based epoxy-novolacs (NOVOCARD XFN);
• Saturated and unsaturated polyester resins prepared using cardanol
derivatives;
• Cardanol-based aminoalcohols to be used in polymeric matrices with
a polyurea scaffold;
• Cardanol-based acrylic and methacrylic monomers as additives for
coating or varnishes;
• Cardanol-based benzoxazines as either coupling agents for glass and
natural fibres or as reticulating agents for epoxy resins.
Cardanol based polyols for poluyrethanes
Polycard XFN product line is a family of earth-friendly polyols derived
from cardanol for the formulation of both high and low density rigid
polyurethane foams, flexible polyurethane foams for use in insulating
foams, mattresses and couches, elastomers and coatings. The high
percentage of primary hydroxyl groups give these polyols a relatively
high rate of reactivity with isocyanates. In addition to classic polyols an
aminolachol monomer, AMINOLCARD XFN-AM120, is available.
Cardanol based epoxy hardeners
Novocard XFN products are liquid cardanol/formaldehyde novolacs
designed to be used as curing agent in formulating heat cured bisphenol-
A and bisphenol-F epoxy resins. Their long alkenyl side chains impart
flexibility in cured epoxy resins. The intrinsic properties of the phenolic
structure are chemical resistance, heat and flame resistance. Novocard
XFN can also be used as polyols for polyurethane formulations.
Cardanol based epoxy monomer and resins
Epocard XFN are epoxy monomers and resins suitable for composite
manufacture and coating applications which are available in a wide range
of viscosities. The alkyl side chain of the phenolic ring enhances the
final product flexibility, while the phenolic structure enhances chemical
resistance, heat and flame durability. Epoxy Equivalent Weight and their
formulation can be tailored for any end-use. - MT
References:
CTS-Materials Divison Brochure
wikipedia
Tullo, Alexander H.: (September 8,
2008). „A Nutty Chemical“. Chemical and
Engineering News 86 (36): 26–27.
Senning, Alexander: (2006). Elsevier‘s
Dictionary of Chemoetymology. Elsevier.
ISBN 0444522395
Ikeda, Ryohei et. al.: (2000). „A new
crosslinkable polyphenol from a
renewable resource“. Macromolecular
Rapid Communications 21 (8): 496–499.
www.ctsusa.us
bioplastics MAGAZINE [05/09] Vol. 4 29
End of Life
Finished
product
producers
PLA
pellets
Sales
Partners
-
PLA
producers
E nd users End users
Lactic
acid
CCollection
Loopla
Patented
technology
Partners
S
Sorting
orting &
recovery
recovery
entities
entities
Loopla
Shipment of
used PLA lot
A new Cradle-to-Cradle
Galactic is a Belgian company involved in the world of
green chemistry with its lactic acid being produced
by fermentation of a biomass such as beet or cane
sugar. Lactic acid is used in different applications such as
foodstuffs, cosmetics and pharmaceuticals, as well as in industrial
applications.
Lactic acid is also used as the starting material for
the production of polylactic acid or PLA, an eco-friendly,
renewable biopolymer with attractive characteristics for
packaging and other convenience applications.
Introduction to LOOPLA ®
Although PLA is derived from renewable resources,
Galactic has conceived the LOOPLA process to provide the
best ‘end-of-life‘ option for PLA waste and contribute to the
development of a sustainable environment.
The LOOPLA concept is a closed loop where the used
PLA is recovered and recycled back into its original form:
lactic acid. This lactic acid can easily be polymerised again
to make PLA with exactly the same characteristics as the
original material.
Carbon footprint
The patented technology is a chemical recycling process
that goes back from PLA to lactic acid by depolymerisation
through hydrolysis. The process does not need harmful
chemicals and is optimised to create a minimum CO 2
footprint.
Currently there are several ‘end-of-life‘ options available:
mechanical recycling, incineration, composting, anaerobic
digestion and land filling.
All energy and raw materials invested in the original PLA
are recovered as the recycling rate with LOOPLA is close to
100% and provides a low carbon footprint.
Chemical Recycling vs. other ‘end-of-life‘ options
With this concept, GALACTIC is proud to contribute to a
more sustainable solution for the ‘end-of-life‘ management
of PLA waste:
• Less energy consumption
• Low chemicals needed
• Recycling rate close to 100%
• Recycling process is endless
• Less agricultural land needed
• shorter recycling loop means:
- lower CO 2 foot-print
- Cheaper process
End-users
The success of LOOPLA is related to the contribution of
the different parties involved in the recycling process.
The sorting and recovery of the used PLA is key in the
efficiency of the process:
PLA is used in a wide range of applications including food
packaging, beverage containers, cars, electronic, housing
etc. Two types of material are identified: the nearly 100%
PLA, and material combinations such as blends, compounds
and composites. LOOPLA not only recovers close to 100% of
the lactic acid used for the production of PLA, it also takes
care of possible contamination of the used PLA.
All PLA waste can be put into one of three different
categories:
• ‘Post-industrial‘ waste or production waste that consists
of out-of-specification material or objects produced
during trial runs, production start-up procedures or as
trimmings or runners and sprue in injection moulding.
30 bioplastics MAGAZINE [05/09] Vol. 4
ECO-Benefits (points)
End of Life
200
180
160
160
140
120
100
80
60
40
20
3
10
20
0
Composting Incineration Anaerobic digestion LOOPLA
Approach for PLA
Article contributed by
Johnathan Willocq,
Project Engineer Developments
n.v. Galactic s.a.,
Escanaffles, Belgium
The material flow is generally very clean and does not
need specific sorting.
• ‘Short-loop‘ or ‚closed-loop‘ waste that is locally generated
during a defined period: cups during a music-festival,
catering in aeroplanes etc… and even non-woven carpets,
combining a wide range of colours and patterns as used
during an exhibition, can be sorted out and recycled.
Indeed, the flow of waste generally does contain other
materials. A creative effort has to be realised in order
optimise the process and efficiently sort PLA from other
materials.
• And finally, ‘post-consumer‘ waste. The process for this
kind of waste is the most complex one. For example,
bottles made of PLA and PET are mixed together. It is
important to sort PLA from PET to avoid a negative impact
on the recycling of PET (yield and quality) and also to be
able to recover a single stream of PLA in order to recycle it.
Technical solutions are available on the market, including
NIR installations or a green chemical treatment able to
separate PLA (more than 99%) from PET.
LOOPLA technology
According to the origin of the used PLA, the process will
be adjusted: the treatment is not the same if the stream
is clean or dirty, pure or contaminated. The contamination
can arise from a problem of sorting or when the product is
made from different materials. In case of contamination,
the process can be easily adjusted in order to remove the
contaminant(s) with no consequence on the quality of the
final lactic acid.
At the end of the cycle, the lactic acid obtained by
depolymerisation will be purified according to the targeted
applications (industrial applications or polymer production).
A little chemistry
Lactic acid is a chiral molecule and has two optical
isomers. One is known as L-(+)-lactic acid and the other,
its mirror image, is D-(−)-Lactic. L-(+)-Lactic acid is the
biologically important isomer.
During the polymerisation and the production of the
original product, the treatments generate a racemization of
the lactic acid. If PLA is made of L-(+)-Lactic acid, only a
small quantity of D-(−)-Lactic will remain in the final product.
Then, lactic acid coming from the LOOPLA technology
contains a low amount of D-(−)-Lactic but the production of
PLA is feasible.
The research and development team has developed a
process in order to reach a high L polymer grade of lactic
acid.
Galactic has acquired a deep knowledge of the PLA
market with its involvement in Futerro, a joint venture
created between Total Petrochemicals and Galactic. The
project entails the construction of a demonstration plant
able to produce 1,500 tonnes of PLA per year using a clean,
innovative and competitive technology, developed by both
partners.
Thanks to the LOOPLA concept, PLA can be then
depolymerised back into lactic acid which also could be the
raw material for a wide range of products including solvents,
detergents, textiles, food and beverages containers...
PLA is a renewable and sustainable resource with
countless possibilities!
www.loopla.lactic.com
bioplastics MAGAZINE [05/09] Vol. 4 31
Report
In a new series bioplastics MAGAZINE plans to introduce, in no
particular order, research institutes that work on bioplastics,
whether it be the synthesis, the analysis, processing or application
of bioplastics. The first article introduces the Fraunhofer
Institut für Angewandte Polymerforschung in Potsdam-Golm,
Germany
The Fraunhofer Institut für Angewandte Polymerforschung IAP
(The Fraunhofer Institute for Applied Polymer Research) is one
of about 60 Institutes within the Fraunhofer Gesellschaft e.V.,
a non-profit organization headquartered in Munich, Germany.
The institute‘s budget in 2008 was about € 12 million, 30% of
which was government funded and 70% acquired from other
sources (35% by way of publicly funded research projects and
35% directly from industry projects)
Fraunhofer
IAP
Bead cellulose with porous and smooth surface
In the preface to the institute‘s 2008 Annual Report, Professor
Hans Peter Fink, director of the institute writes: “We are living in
the age of plastics. Polymers are everywhere, found in plastics
and in many other applications like fibers and films, foam plastics,
synthetic rubber products, varnishes, adhesives, and additives
for construction materials, paper, detergents, cosmetic and
pharmaceutical industries. In addition to innovative developments
in polymer functional materials, research is now focusing on the
sustainability of the polymer industry. Environmentally friendly
and energy efficient production processes and the utilisation of
bio-based resources, which are not dependent on petroleum,
are playing a vital role. The Fraunhofer IAP is well positioned in
this regard with its unique competencies in the area of synthetic
and bio-based polymers…“
PLA
In the area of biopolymers, the Fraunhofer IAP is active in
particular in the field of synthesis and material development of
bio-based polylactide (PLA) in connection with the establishment
of production facilities in Guben (on the German/Polish border).
A biopolymer application center is being planned at the site
in collaboration with the investor Pyramid Bioplastics Guben
GmbH. Here, a project group from IAP will develop PLA grades,
blends and composites for different fields of application such
as films, fibers, bottles, injection moulded or extruded products
and many more. The research and development of blends and
copolymers of L- and D-lactides is also part of the planned
activities.
Further research activities concentrate on naturally
synthesized polysaccharides such as cellulose, hemicellulose,
starch and chitin, which are available in almost unlimited
quantities.
The opportunities for using cellulose and starch biopolymers,
which have been available in almost unlimited quantities for a
long time, are far from being exhausted. One focus of the research
and development at the Fraunhofer IAP is on these versatile
raw materials. New products and environmentally friendly
production methods are being developed at the IAP thanks to
the growing amount of knowledge concerning the exploration,
characterization and modification of these polymers.
32 bioplastics MAGAZINE [05/09] Vol. 4
Report
Cellulose
Cellulose is the most frequently occurring biopolymer, and
as dissolving pulp it is an important industrial raw material. It
is processed into regenerated cellulose products such as fibers,
non-wovens, films, sponges and membranes. It can also be
processed into versatile cellulose derivatives, thermoplastics,
fibers, cigarette filters, adhesives, building additives, bore oils,
hygiene products, pharmaceutical components, etc.
Composites
Cellulose-based man-made fibers (rayon tyre cord yarn)
are a serious alternative to short glass fibers for reinforcing
even biopolymers such as PLA or PHA. Rayon fibers have
advantages over short glass fibers in terms of their low density
and abrasiveness. Furthermore, they do not pierce the skin
as do glass fibers, which makes them much easier to handle.
When rayon fibers are combined with PLA, a completely biobased
and biodegradable material is formed. One of the crucial
disadvantages of PLA is its low impact strength. In composites,
rayon fibers can increase impact strength significantly, as they
act as impact modifiers.
By reinforcing a polyhydroxyalkonoate (PHA) polymer with
cellulose-based spun fibers, biogenic and biodegradable
composites were obtained with substantially improved (in
some cases double) mechanical properties as compared with
the unreinforced matrix material. bioplastics MAGAZINE will
publish more comprehensive articles about these findings in
future issues.
Starch
Starch is another indispensable resource with a long tradition.
The substance’s many functional properties make it suitable
for use in the food sector and for technical applications. Nonfood
applications include additives for paper manufacture,
construction materials, fiber sizes, adhesives, fermentation,
bioplastics, detergents, and cosmetic and pharmaceutical
products.
50
40
30
20
10
10
8
6
4
2
Charpy, un-notched [kJ/m²]
- 23 °C
- 18 °C
native 15%
25% 30%
Un-notched Charpy impact strenght of rayon
reinforced polylactic acid vs. fibert content.
Charpy, notched [kJ/m²]
- 23 °C
- 18 °C
native 15%
25% 30%
Notched Charpy impact strenght of rayon
reinforced polylactid vs. fiber content.
Fiber content
Fiber content
To further their aim of comprehensive utilization of biomass
for such materials, scientists at Fraunhofer IAP have developed
strong lignin competencies in recent years. They have also
investigated the use of sugar beet pulp for polyurethane
production.
The use and optimization of biotechnology with the aim of
directly applying the biomass by extraction and plant material
processing is a further focus of Fraunhofer IAP‘s biopolymer
research. With its comprehensive expertise in the field of
biopolymers and long-standing experience and knowledge of
polymer synthesis, the institute is highly qualified to develop
products and processes in various areas of biopolymers,
ranging from applied basic research in the laboratory to pilot
plant operation. - MT
SEM micrograph of a cellulose melt blown nonwoven
www.iap.fraunhofer.de
bioplastics MAGAZINE [05/09] Vol. 4 33
Basics
Raw materials and
required for
In the last issue of bioplastics MAGAZINE we looked at the basic principles of ‘Land use
for Bioplastics’. Following this general introduction we now put forward some more
concrete facts concerning the specific biopolymers. The following article is an edited
extract from the new book entitled ‘Technical Biopoymers’, written by Hans-Josef Endres
and Andrea Siebert-Raths. The book has already been published in German and will be
available in English at the beginning of next year (see also page 15).
To evaluate the land area required for biopolymer production the annual yield from
different renewable raw materials is illustrated below.
In Fig. 1 the raw materials have been grouped into sugars, starches, plant oils and
cellulose or fibrous materials to facilitate comparison. It can be seen that the sugars offer
the highest yield. Starches too deliver relatively high yields, whilst the yield from renewable
plant sources of oils or cellulose is, in comparison, significantly less. Among the oils it is
only palm oil and perhaps jatropha oil that offer yields approaching that of the starches.
In order to determine the annual amount of biopolymer that can be produced per unit
of land area (the biopolymer yield per area) it is also necessary to take into account the
data in Fig. 2, i.e. the various biobased percentage of each biopolymer. With the blends in
particular there is a wide range of bio-based content because petrochemical components
and additives are often also used in the blend.
Furthermore, consideration must be given to the efficiency of converting the biobased
materials listed, i.e. the initial amount of the raw material required to produce the
particular bio-based component.
Based on the respective percentage of bio-based material and the amount of renewable
raw material required for this, Fig. 3 shows the representative relationship of the amount
of bio-based input material to the total amount of material output. When ethanol is used
as an intermediate step almost 0.5 tonnes of ethanol per tonne of sugar is output. But it
must be noted that almost no biopolymers are 100% bio-based. At times the bio-based
element of the material is below 25% by weight, i.e. in such a case 75 % of the weight of
the material is in no way to be considered when calculating the necessary amount of land
because it is not based on renewable raw materials. Basically the lower the percentage
of bio-based material the higher the relationship of the absolute quantity of bio-polymer
to the area under cultivation. This also shows the direct comparison of the data in figures
2 and 3, each of which represents a basically inverted proportionality. A statement of the
biopolymer output per unit of arable land without taking into consideration the percentage
of bio-based material in that polymer is therefore not sufficient.
When calculating the outputs of biopolymer materials and the input of renewable raw
material required, as shown in Fig. 3, the following assumptions were made:
1: Cellulose acetate (CA): Percentage of cellulose based material 40 – 50
percent by weight
Since even with partially biodegradable cellulose acetate at least about 2/3 of the
hydroxyl groups in the glucose element unit are replaced by acetal groups (for details
please see the respective section in the book), i.e. the degree of substitution is as a rule
greater than 2.0, and in addition non-bio-based softeners of up to a maximum of 30 %
by weight are used, for cellulose acetate an initial input amount of between 40 and 50 %
34 bioplastics MAGAZINE [05/09] Vol. 4
Basics
arable land
biopolymers
by weight is required. This means that under
certain circumstances up to 60 % of the material
is not cellulose at all but is based on acetic acid
(largely produced under pressure by catalytic
conversion of petrochemical methanol with carbon
monoxide), and other petrochemical softeners.
With an assumed minimum degree of substitution
of 2 the acetate content alone represents 30 and
the plasticizer 20 % by weight.
2: Cellulose regenerate: Percentage
of cellulose based material 90 - 99 percent
by weight
Cellulose regenerates are used in the biopolymer
sector mainly as coated film (e.g. with a barrier
coating or sealing layer). From the point of view
of the weight of the dominant material a cellulose
percentage of near enough 100 % can be assumed.
For the coating, a percentage by weight of at the
most 10 % is assumed. Normally the coating will
account for a much smaller percenatge.
3: Thermoplastic starch (TPS): Starch based
percentage of the material 70 - 80 percent
by weight
To optimise the performance of thermoplastic
starch in processing and use, native starches must
be modified and/or in particular be added with a
softener such as glycerine or sorbitol (for details
please see the respective section in the book).
To calculate the average starch content, a total
conversion of 100 % of the unmodified starch to a
biopolymer was assumed. For starch acetate on
the other hand, similar to cellulose acetate with a
high degree of substitution, a starch requirement
of only 600 kg per tonne is required. For the
remaining additives or softeners raw materials
of petrochemical origin were assumed. We can
therefore assume on average that thermoplastic
starch materials require an input of 70 to 80 % by
weight of starch itself.
4: Starch blends: Starch-based percentage
25 - 70 percent by weight
To optimise the properties in the processing and
use of thermoplastic processable starch polymers
it is necessary for native starch - as already
Raw material yield [t/(hectare*annum)]
The percentage of material in biopolymers
that is biobased, i.e. obtained from
renewable resources (% by weight)
Output: tonnes of biopolymer or bioethanol /
Input: tonnes of regenerating raw materials
25
20
15
10
5
0
100%
80%
60%
40%
20%
0%
6
5
4
3
2
1
0
Sugars Starches Plant oils Cellulose (fibres)
Sugar (cane)
Sugar (beet)
Maize starch
Potato starch
Wheat starch
Rice starch
Palm oil
Jatropha oil
Cocoa oil
Castor oil
Rapeseed oil
Sunflower oil
Soy oil
Wood fibres
Wheat straw
Hemp
Flax
Cotton
Fig 1: Absolute yield of various renewable raw materials
per hectare per annum
Cellulose regenerates 2
Cellulose acetates 1
Thermoplastic starches (TPS) 3
Starch blends 4
Polylactides (PLA) 5
Polylactide blends 6
Polyhydroxyalkcanoates (PHA) 7
Fig 2: Percentage of renewable raw materials
by weight in various biopolymers
Cellulose regenerates 2
Cellulose acetates 1
Thermoplastic starches (TPS) 3
Starch blends 4
Polylacticdes (PLA) 5
Polylactide blends 6
Polyhydroxyalkcanoates (PHA) 7
Bioenthanol 8
Bioenthanol 8
Fig 3: Total Biopolymer output in relation to the
input of renewable raw materials
Biopolyesters 9
Biopolyesters 9
Biopolyethylene (BIO-PE) 10
Biopolyethylene (BIO-PE) 10
bioplastics MAGAZINE [05/09] Vol. 4 35
Basics
[tonnes of bioplymer /(ha*annum)]
35
30
25
20
15
10
5
0
Cellulose regenerates 2
Cellulose acetates 1
Theoretical minimum and maximum biopolymer
yield per unit of land area
Thermoplastic starch (TPS) 3
Starch blends 4
Polylactic acid (PLA) 5
Polylactic acid blends 6
Polyhydroxyalkcanoates (PHA) 7
Fig 4: Minimum and maximum possible
biopolymer yields per hectare per annum
Bioenthanol 8
Biopolyesters 9
Biopolyethylene (BIO-PE) 10
explained - to be modified or blended with other
polymers. The second component of the blend
usually represents the continuous phase in the
resultant 2-phase blend (for details please see the
respective section in the book). The assumption is
made that in starch blends there is 30 to 85 % by
weight of material coming directly from the starch.
For this figure the values of thermoplastic starch
from the above assumption 3 have been used. For
the remaining 15 to 70 % of the starch blends it is
assumed that a petrochemical-based material is
used.
5: PLA: PLA-based percentage 90 - 97
percent by weight
With the PLA polymers produced from lactic
acid the assumption is made that only functional
additives (nucleating agents, colour batches,
stabilisers etc) in amounts from maximum 3 to 10 %
by weight, are added to the PLA. It is assumed
that maize starch is used as the raw material for
PLA. Around 0.7 tonnes of PLA are obtained from 1
tonne of maize starch.
6: PLA blends: PLA-based material
percentage 30 - 65 percent by weight
For these suitably ductile PLA blends, used
overwhelmingly for film applications, it can be
assumed a percentage of PLA-based material of
between a maximum of 65 % and a minimum of
30 % by weight. For the PLA components the PLA
values from the previous assumption 5 were used.
The second component of the blend is mainly a
bio-polyster. For the bio-polyester (30 to 65 % by
weight) the assumptions described under point 9
were made. Also, for PLA blends, the addition of
5 % by weight of a petrochemical-based additive
is assumed, for example processing aids or
components to improve the interaction of the two
basic materials.
7: Polyhydroxyalcanoate: PLA-based material
percentage 30 - 65 percent by weight
With the Polyhydroxyalcanoates (PHA), produced
by fermentation, there is a very small amount
of additive used and thus an average bio-based
material content of 90 to 98 % by weight can be
assumed. To produce one tonne of PHA about 4 to
5 tonnes of sugar are required.
8: Bioethanol
To produce bioethanol as an intermediate,
particularly for bio-polyethylene and various
bio-polyesters, it is assumed that 100% of the
bio-alcohol is sugar-based. In addition it can be
assumed that in the most favourable case about
1.7 (and in the least favourable case 2.7) tonnes of
sugar are required per tonne of bioethanol.
36 bioplastics MAGAZINE [05/09] Vol. 4
9: Bio-polyester: Bioalcohol content 30 - 40 percent by weight,
remainder based on petrochemical raw materials
With bio-polyesters a bioalcohol-based input of 30 - 40% was assumed to
calculate the conversion efficiency, i.e. viewed from the opposite perspective
60 - 70% of the so-called bio-polyester is not based on renewable raw
materials. For the bioalcohol content the raw material requirement for
bioethanol, as specified in point 8, is assumed.
10: Bio-polyethylene (bio-PE): Bioalcohol-based content 95 - 98
percent by weight
As with conventional PE, bio-polyethylene also requires between 2 and 5%
by weight of other additives, which means that a bioalcohol-based material
content of 95 to 98% by weight can be assumed. Furthermore it is assumed
that 2.3 - 2.5 tonnes of ethanol are required per tonne of polyethylene. For
the bioethanol content the same assumptions are made as in point 8.
Finally, to define the annual output of various biopolymers per unit of land
area working from the bio-based material content of each of the biopolymers
(cf. Fig 2), the required input amount of renewable raw material for each
biopolymer (cf. Fig 3) and the related annual yield per unit of land area for
each of the renewable raw materials (cf. Fig 1) the theoretical achievable
annual amount of each of the biopolymers per unit of land area can be
calculated and is shown in Fig. 4.
Because of the wide range of yields from renewable resources, and the
possibility of using different renewable raw materials to produce the same
biopolymer (e.g. starch instead of sugar), plus the, at times, very different
bio-based material content, there is ultimately a very wide range of the
theoretical biopolymer yields per unit of arable land.
Because, in biopolymer manufacture, there is pressure on economic
grounds for maximum material usage and the maximum possible yield per
hectare, a comparison of the values detailed above is more representative of
the effective trends in biopolymer yield per hectare.
Accordingly to these considerations a bio-PE for example, despite the
high sugar yield available per hectare, exhibits the lowest land use efficiency
because of the high demand for sugar at the bioethanol stage and the high
ethanol demand for polymerisation of the polyethylene. The relatively low
land-use efficiency of the PHAs can, as with cellulose regenerates, also
be traced back to the high bio-based material input and the lack of a
petrochemical component not related to land use or to another bio-based
material.
By contrast the high percentage of non bio-based material components
in particular with bio-polyesters, starch blends, PLA blends and cellulose
acetate, leads to what seems to be a high land-use efficiency that is,
however, traced back to the addition of significant amounts of non landdependent
substances of petrochemical origin.
However, what is important at the end of the analysis is the fact that, in
comparison with bio-fuels, to achieve a perceptible share of the plastics
market biopolymers would require a significantly smaller land area in
absolute terms (see article on Land Use for Bioplastics in issue bM 04/2009),
as well as exhibiting a higher land use efficiency.
With a cautious estimate of the average yield per unit of land area of at
least 2.5 tonnes per hectare the current global biopolymer output (about 0.4
million tonnes per annum) would need only 0.01 % of the world‘s agricultural
land.
Basics
www.fakultaet2.fh-hannover.de
bioplastics MAGAZINE [05/09] Vol. 4 37
Basics
Position Paper
‘Oxo-Biodegradable‘
Plastics
In this issue bioplastics MAGAZINE publishes an extract of
the recently published Position Paper of European Bioplastics.
The complete document can be downloaded from
www.bioplasticsmagazine.de/200904.
Introduction
Bioplastics are either biobased or biodegradable or
both. European Bioplastics, as the industry association for
such materials is distancing itself from the so-called ‘oxobiodegradables‘
industry.
Terms such as ‘degradable‘, ‘biodegradable‘, ‘oxodegradable‘,
‘oxo-biodegradable‘ are used to promote
products made with traditional plastics supplemented with
specific additives.
Products made with this technology and available on
the market include film applications such as shopping
bags, agricultural mulch films and most recently certain
plastic bottles. There are serious concerns amongst many
plastics, composting and waste management experts that
these products do not meet their claimed environmental
promises.
In this position paper, European Bioplastics, the
international organisation representing the certified
Bioplastics and Biopolymer industries outlines the issues and
questions concerned in order to support consumers, retailers
and the plastics industry in identifying unsubstantiated and
misleading product claims.
Terminology
Producers of pro-oxidant additives use the term ‘oxobiodegradable’
for their products. This term suggests
that the products can undergo (complete) biodegradation.
However, main effect of oxidation is fragmentation into small
particles, which remain in the environment. Therefore the
term ‘oxo-fragmentation’ does better describe the typical
degradation process, which can occur to these products,
under some specific environmental conditions.
European Bioplastics considers the use of terms such as
biodegradable, oxo-biodegradable etc. without reference
to existing standards as misleading and as such not
reproducible and verifiable. Under these conditions the term
‘oxo-biodegradable‘ is free of substance. (...)
On the other hand, the terms ‘biodegradable and
compostable‘ enjoy a different status. There are
internationally established and acknowledged standards
that effectively substantiate claims on biodegradation and
compostability such as ISO 17088. (...) The specification of
time needed for the ultimate biodegradation is an essential
requirement for any serious claim on biodegradability.
Therefore, the U.S. Federal Trade Commission has
advised companies “that unqualified biodegradable claims
are acceptable only if they have scientific evidence that their
product will completely decompose within a reasonably
short period of time under customary methods of disposal”
[1]. (...)
The Degradation Process behind the So-called ‘Oxobiodegradable‘
Plastics
The ‘oxo-biodegradable‘ additives are typically incorporated
in conventional plastics (...) at the moment of conversion into
final products.
38 bioplastics MAGAZINE [05/09] Vol. 4
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These additives are based on chemical catalysts,
containing transition metals such as cobalt, manganese,
nickel, zinc, etc., which cause fragmentation as a
result of a chemical oxidation of the plastics’ polymer
chains triggered by UV irradiation or heat exposure. In
a second phase, the resulting fragments are claimed
to eventually undergo biodegradation. (...)
Fragmentation Is Not the Same as
Biodegradation
Fragmentation of ‘oxo-biodegradable‘ plastics is not
the result of a biodegradation process but rather the
result of a chemical reaction. The resulting fragments
will remain in the environment [2]. The fragmentation
is not a solution to the waste problem, but rather
the conversion of visible contaminants (the plastic
waste) into invisible contaminants (the fragments).
This is generally not considered as a feasible manner
of solving the problem of plastic waste, as the
behavioural problem of pollution by discarding waste
in the environment could be even stimulated by these
kinds of products.
An Answer to Littering or the Promotion of
Littering ?
Oxo-fragmentable plastic products have been
described as a solution to littering problems, whereby
they supposedly fragment in the natural environment.
In fact, such a concept risks increasing littering
instead of reducing it. (...)
Accumulation of Plastic Fragments Bears Risks
for the Environment
If oxo-fragmentable plastics are littered and end
up in the landscape they are supposed to start to
disintegrate due to the effect of the additives that
trigger breakdown. Consequently, plastic fragments
would be spread around the surrounding area. As
ultimate biodegradability has not been demonstrated
for these fragments [3], there is substantial risk of
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bioplastics MAGAZINE [05/09] Vol. 4 39
Basics
accumulation of persistent substances in the environment.
Through the impact of wind or precipitation the plastic
fragments can drift into aquatic or marine habitat where they
affect organisms and pose the risk of bioaccumulation. In
addition, studies, amongst others by the US National Oceanic
and Atmospheric Administration, have shown that degraded
plastics can accumulate toxic chemicals such as PCB, DDE and
others from the environment and act as transport medium in
marine environments [4]. Such persistant organic pollutants in
the marine environment were found to have negative effects on
marine resources [5].
Organic Recovery Is Not Feasible
Collection and recovery schemes for organic waste are liable
to suffer from the use of oxo-fragmentable materials, as these
materials are reported not to meet the requirements of organic
recovery [6].
Unfortunately, sometimes the oxo-fragmentable products
have been publicised as ‘biodegradable‘ and ‘compostable‘,
despite not meeting the standards of suitability for organic
recovery. Besides, the terms oxo-biodegradable, oxo-degradable
and the like can be taken by the consumers as synonym of
‘biodegradable and compostable‘ and erroneously recovered
via organic recovery. (...) Therefore, well-developed and broadly
accepted certification schemes according to EN 13432, EN 14995
or equivalent standards should be used invariably.
This is also why, in the interest of the best recovery of organic
fractions and biowaste, the involvement of ‘oxo-fragmentable’
materials in such recovery schemes should be avoided.
Plastic Recycling Schemes Are Disturbed
A further environmentally feasible option for the handling
of used plastics is that of recycling. Oxo-fragmentable
products can hamper recycling of post consumer plastics.
In practice, the ‚oxo-biodegradable‘ plastics are traditional
plastics. The only difference is that they incorporate additives
which affect their chemical stability. Thus, they are identified
and classified according to their chemical structure and
finish together with the other plastic waste in the recycling
streams. In this way, they bring their degradation additives
to the recyclate feedstock. As a consequence the recyclates
may be destabilised, which will hinder acceptance and lead to
reduced value. The European Plastics Recyclers Association
(EuPR) and the Association of Postconsumer Plastic Recyclers
(APR) therefore warn against oxo-degradable additives [7, 8].
www.european-bioplastics.org
References
[1] Federal Trade Commission Announces
Actions Against Kmart, Tender and Dyna-
E Alleging Deceptive ‚Biodegradable‘
Claims. www.ftc.gov/opa/2009/06/kmart.
shtm. Accessed on June 19, 2009
[2] Narayan, Ramani, Biodegradability
- Sorting Facts and Claims, in bioplastics
magazine, 01/2009, pp 29.
[3] Koutny et al. (2006)
[4] Moore C. (2008). Synthetic polymers
in the marine environment: A
rapidly increasing, long-term threat.
Environmental Research 108(2), pp.
131-139
[5] Yuki Mato et.al. (2001), Plastic Resin
pallets as a transport medium for toxic
chemicals in the Marine Environment,
Environmental Science and Technology,
35(2), pp. 318-324 .
[6] California State University, Chico
Research Foundation (2008).
Performance Evaluation of
Environmentally Degradable Plastic
Packaging and Disposable Food Service
Ware – Final Report. www.ciwmb.
ca.gov/Publications. Publication Date:
November, 8, 2008. Accessed on June
19, 2009
[7] Association of Postconsumer Plastic
Recyclers (APR) and the National
Association for Plastic Container
Resources (NAPCOR) express concerns
about degradable additives. www.
plasticsrecycling.org/article.asp?id=50.
Publication Date: February 12, 2009.
Accessed on June 19, 2009
[8] European Plastics Recyclers, OXO
degradables incompatibility with plastics
recycling. www.plasticsrecyclers.eu/
press. Publication Date: June 10, 2009.
Accessed on June 19, 2009
40 bioplastics MAGAZINE [05/09] Vol. 4
Basics
Basics of
Starch-Based Materials
Starch is a reserve of energy for plants and is widely
available in cereals, tubers and beans all over the
planet. The present annual production of starch
worldwide is about 44 million tonnes and comes mainly
from corn, where worldwide production is about 700 million
tonnes, as well as from wheat, tapioca, potatoes etc.. Today
the main uses of starch available annually from corn and
other crops, produced in excess of current market needs in
the United States and Europe, are in the pharmaceutical and
paper industries. Starch is totally biodegradable in a wide
variety of environments and can permit the development of
totally biodegradable products for specific market demands.
Biodegradation or incineration of starch products recycles
atmospheric CO 2 sequestered by starch-producing plants
and does not increase potential global warming.
All of these reasons aroused a renewed interest in
starch-based plastics over the last 20 years. Starch graft
copolymers, starch plastic composites, starch itself, and
starch derivatives have been proposed as plastic materials.
Starch consists of two major components: amylose (Fig. 1),
a mostly linear a-D-(1,4)-glucan; and amylopectine (Fig. 2), an
a-D-(1,4) glucan that has a-D-(1,6) linkages at the branch
point. The linear amylose molecules of starch have a
molecular weight of 0.2–2 million, while the branched
amylopectine molecules have molecular weights as high as
100–400 million.
In nature starch is found as crystalline beads of about
15–100 mm in diameter, in three crystalline design
modifications: A (cereal), B (tuber), and C (smooth pea and
various beans), all characterised by double helices - almost
perfect left-handed, six-fold structures, as elucidated by X-
ray-diffraction studies.
Starch as a filler
Crystalline starch beads can be used as a natural filler in
traditional plastics [1]; they have been used particularly in
polyolefines. When blended with starch beads, polyethylene
films biodeteriorate on exposure to a soil environment. The
microbial consumption of the starch component, in fact,
leads to increased porosity, void formation, and loss of
integrity of the plastic matrix. Generally, starch is added at
fairly low concentrations (6–15%); the overall disintegration
of these materials is obtained, however, by transition metal
compounds, soluble in the thermoplastic matrix, used as
pro-oxidant additives to catalyse the photo and thermooxidative
processes [2].
Starch-filled polyethylenes containing pro-oxidants have
been used in the past in agricultural mulch film, in bags,
and in six-pack yoke packaging. According to St. Lawrence
Starch Technology, regular cornstarch is treated with a
silane coupling agent to make it compatible with hydrophobic
polymers, and dried to less than 1% of water content. It is
then mixed with the other additives such as an unsaturated
fat or fatty-acid autoxidant to form a masterbatch that is
added to a commodity polymer.
The polymer can then be processed by convenient
methods, including film blowing, injection molding, and
blow molding. The non compliance of these materials with
the international standards of biodegradability in different
environments and the increasing concern for micropollution
that can be enhanced by their fragmentability, together with
the potential negative impact on recyclability of traditional
plastics, and their limited performances with time, have not
permitted serious consideration of this technology as a real
industrial and environmental option.
Thermoplastic starch
There are two different conditions for loss of crystallinity
of starch: at high water volume fractions (>0.9) described
as gelatinization; and at low water volume, fractions (
Article contributed by
Catia Bastioli, CEO,
Novamont S.p.A.,
Novara, Italy
Fig. 3: Droplet-like structure of
thermoplastic starch / EVOH blend
above. It can show other forms of crystallinity, different from the
native ones, induced by the interaction of the amylose component with
specific molecules. These types of crystallinity are characterised by
single helical structures and are known as V complexes [7]. Moreover
thermoplastic starch is characterised by a melt viscosity comparable
with that of traditional polymers [8]. This aspect makes possible the
transformation of destructurised starch in finished products through
the use of traditional manufacturing technologies for plastics.
Thermoplastic starch alone can be processed as a traditional plastic;
its sensitivity to humidity, however, makes it unsuitable for most
applications.
Thermoplastic starch composites
Starch can be destructurised in combination with different synthetic
polymers to satisfy a broad spectrum of market needs. Thermoplastic
starch composites can reach starch contents higher than 50%.
EAA (ethylene-acrylic acid copolymer) /
thermoplastic starch composites
EAA/thermoplastic starch composites have been studied since 1977
[9]. The addition of ammonium hydroxide to EAA makes it compatible
with starch. The sensitivity to environmental changes and mainly the
susceptibility to tear propagation precluded their use in most of the
packaging applications; moreover, EAA is not at all biodegradable.
Starch / vinyl alcohol copolymers
Starch/vinyl alcohol copolymer systems, depending on the processing
conditions, starch type, and copolymer composition, can generate a
wide variety of morphologies and properties. Different microstructures
were observed: from a droplet-like (Fig. 3, 4) to a layered (Fig. 5) one
[10], as a function of different hydrophilicity of the synthetic copolymer.
Furthermore, for this type of composite, materials containing starch
with an amylose/amylopectine weight ratio of >20/80 do not dissolve
even under stirring in boiling water. Under these conditions a
microdispersion, constituted by microsphere aggregates, is produced,
whose individual particle diameter is
Basics
Fig.3: Mater-Bi technology: droplike structure
The products based on starch/EVOH show mechanical properties
good enough to meet the needs of specific industrial applications.
Their moldability in film blowing, injection molding, blow-molding,
thermoforming, foaming, etc is comparable with that of traditional
plastics such as PS, ABS, and LDPE [11]. The main limits of
these materials are in their high sensitivity to low humidities,
with consequent enbrittlement. The biodegradation of these
composites has been demonstrated in different environments [12].
A substantially different biodegradation mechanism for the two
components has been observed:
Fig. 5: Foamed loose fill
Bibliography
[1] G. J. L. Griffin, U.S. Pat. 4016117 (1977).
[2] G. Scott, U.K. Pat. 1,356,107 (1971).
[3] J. W. Donovan, Biopolymers 18, 263 (1979).
[4] P. Colonna and C. Mercier, Phytochemistry
24(8), 1667–1674 (1985).
[5] J. Silbiger, J. P. Sacchetto, and D. J. Lentz,
Eur. Pat. Appl. 0 404 728 (1990).
[6] C. Bastioli, V. Bellotti, and G. F. Del Tredici,
Eur. Pat. Appl. WO 91/02025 (1991).
[7] P. Le Bail, C. Rondeau, and A. Buléon,, Int.
Journal of Biological Macromolecules 35
(2005), 1-7
[8] J.L:Willett, B.K: Jasberg, C.L: Swanson,,
Polymer Engineering and Science 35 (2), 202-
210 (2004)
[9] F. H. Otey, U.S. Pat. 4133784 (1979).
[10] C. Bastioli, V. Bellotti, M. Camia, L. Del
Giudice, and A. Rallis “Biodegradable
Plastics and Polymers” in Y. Doi, K. Fukuda,
Ed., Elsevier, 1994, pp. 200–213.
[11] C. Bastioli, V. Bellotti, and A. Rallis,
“Microstructure and Melt Flow Behaviour of
a Starch-based Polymer,” Rheologica Acta
33, 307–316 (1994).
[12] C. Bastioli, V. Bellotti, L. Del Giudice, and
G. Gilli, J. Environ. Polym. Degradation 1(3),
181–191 (1993).
[13] C. Bastioli, V. Bellotti, G. F. Del Tredici, R.
Lombi, A. Montino, and R. Ponti, Internatl.
Pat. Appl. WO 92/19680, (1992).
• The natural component, even if significantly shielded by an
‘interpenetrated‘ structure of vinyl alcohol, seems, first,
hydrolysed by extracellular enzymes.
• The synthetic component seems biodegraded through a
superficial adsorption of micro-organisms, made easier by the
increase of available surface that occurred during the hydrolysis
of the natural component.
The degradation rate of 2–3 years in watery environments
remains too slow to consider these materials as compostable.
Aliphatic polyesters/thermoplastic starch
Starch can also be destructurised in the presence of more
hydrophobic polymers, totally incompatible with starch, such as
aliphatic polyesters [13].
It is known that aliphatic polyesters having a low melting point are
difficult to process by conventional techniques for thermoplastic
materials, such as film blowing and blow molding. It has been
found that the blending of starch with aliphatic polyesters allows
an improvement of their processability and their biodegradability.
Particularly suitable polyesters considered in the past have been
poly-e-caprolactone and its copolymers, or polymers at higher
melting point formed by the reaction of glycols as 1,4-butandiol
with succinic acid or with sebacic acid, adipic acid, azelaic acid,
dodecanoic acid, or brassilic acid. The presence of compatibilizers
between starch and aliphatic polyesters such as amylose/EVOH V-
type complexes [10], starch grafted polyesters, and chain extenders
such as diisocyanates, and epoxydes is preferred. Such materials
are characterised by excellent compostability, excellent mechanical
properties, and reduced sensitivity to water.
Thermoplastic starch can also be blended with polyolefines,
possibly in the presence of a compatibilizer. Starch/cellulose
derivative systems are also reported in the literature [12]. The
combination of starch with a soluble polymer such as polyvinyl
44 bioplastics MAGAZINE [05/09] Vol. 4
Fig.4: Mater-Bi technology: layered structure
alcohol (PVOH) and/or polyalkylene glycols has been widely considered
since 1970. In recent years the thermoplastic starch/PVOH system
has been studied, mainly for producing starch-based loose fillers as
a replacement for expanded polystyrene.
Micro- and Nanostructured Composites
The most important achievement of recent years in the sector of
starch technology is seen in the creation of micro and nanostructured
composites of starch with polyesters of different types and particularly
with aliphatic-aromatic polyesters and with rubber. This technology
has been developed and patented by Novamont. In these families
of products starch gives a technical contribution to the mechanical
performance of the finished products in terms of increased toughness
and excellent stability at different humidities and temperatures. With
this generation of products it is possible to cover a wide range of
demanding applications in the film sector and to meet the different
needs of end-of-life conditions up to home compostability and soil
biodegradation. Moreover, it is possible to obtain low hysteresis rubber
for low rolling-resistance treads in tyres. The last developments in
this sector have been achieved within the EU Biotyres project which
has led Goodyear to produce the tyres used in the new BMW 1-series
models.
The development of aliphatic and aliphatic-aromatic copolyesters
containing monomers from vegetable oils, covered by a new range
of Novamont’s patents, has further improved and widened the
performances of these products from an environmental and technical
point of view. Such development has justified the significant industrial
investment made by Novamont to build the first local biorefinery of
this type in Europe, which comprises plants for the production of
nanostructured starch and polyesters from vegetable oils. Moreover
new investments in monomers from vegetable oils from local crops
will permit a further up-stream integration of the biorefinery.
This family of tailor-made products has permitted Novamont to
work on many case studies aimed at demonstrating the opportunity
offered by biodegradable and bio-based plastics to rethink entire
application sectors, thereby affecting not only the manner in which
raw materials are produced, but also permitting verticalisation
of entire agro-industrial non-food chains, or which are synergistic
with food, and the way in which products are used and disposed of,
expanding the scope of experimentation to local areas. This is the
way Novamont believes bio-plastics may become a powerful, largescale
case study for sustainable development and cultural growth - a
real example of transition from a product-based to a system-based
economy.
Fig. 6: Biotyre
www.novamont.com
bioplastics MAGAZINE [05/09] Vol. 4 45
10
20
Suppliers Guide
1. Raw Materials
2. Additives /
Secondary raw materials
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
BASF SE
Global Business Management
Biodegradable Polymers
Carl-Bosch-Str. 38
67056 Ludwigshafen, Germany
Tel. +49-621 60 43 878
Fax +49-621 60 21 694
plas.com@basf.com
www.ecovio.com
www.basf.com/ecoflex
1.1 bio based monomers
Du Pont de Nemours International S.A.
2, Chemin du Pavillon, PO Box 50
CH 1218 Le Grand Saconnex,
Geneva, Switzerland
Tel. + 41 22 717 5428
Fax + 41 22 717 5500
jonathan.v.cohen@che.dupont.com
www.packaging.dupont.com
PURAC division
Arkelsedijk 46, P.O. Box 21
4200 AA Gorinchem -
The Netherlands
Tel.: +31 (0)183 695 695
Fax: +31 (0)183 695 604
www.purac.com
PLA@purac.com
1.2 compounds
BIOTEC Biologische
Naturverpackungen GmbH & Co. KG
Werner-Heisenberg-Straße 32
46446 Emmerich
Germany
Tel. +49 2822 92510
Fax +49 2822 51840
info@biotec.de
www.biotec.de
Cereplast Inc.
Tel: +1 310-676-5000 / Fax: -5003
pravera@cereplast.com
www.cereplast.com
European distributor A.Schulman :
Tel +49 (2273) 561 236
christophe_cario@de.aschulman.com
FKuR Kunststoff GmbH
Siemensring 79
D - 47 877 Willich
Tel. +49 2154 9251-0
Tel.: +49 2154 9251-51
sales@fkur.com
www.fkur.com
Natur-Tec ® - Northern Technologies
4201 Woodland Road
Circle Pines, MN 55014 USA
Tel. +1 763.225.6600
Fax +1 763.225.6645
info@natur-tec.com
www.natur-tec.com
Transmare Compounding B.V.
Ringweg 7, 6045 JL
Roermond, The Netherlands
Tel. +31 475 345 900
Fax +31 475 345 910
info@transmare.nl
www.compounding.nl
1.3 PLA
Division of A&O FilmPAC Ltd
7 Osier Way, Warrington Road
GB-Olney/Bucks.
MK46 5FP
Tel.: +44 844 335 0886
Fax: +44 1234 713 221
sales@aandofilmpac.com
www.bioresins.eu
1.4 starch-based bioplastics
BIOTEC Biologische
Naturverpackungen GmbH & Co. KG
Werner-Heisenberg-Straße 32
46446 Emmerich
Germany
Tel. +49 2822 92510
Fax +49 2822 51840
info@biotec.de
www.biotec.de
Limagrain Céréales Ingrédients
ZAC „Les Portes de Riom“ - BP 173
63204 Riom Cedex - France
Tel. +33 (0)4 73 67 17 00
Fax +33 (0)4 73 67 17 10
www.biolice.com
Plantic Technologies Limited
51 Burns Road
Altona VIC 3018 Australia
Tel. +61 3 9353 7900
Fax +61 3 9353 7901
info@plantic.com.au
www.plantic.com.au
PSM Bioplastic NA
Chicago, USA
www.psmna.com
+1-630-393-0012
1.5 PHA
Telles, Metabolix – ADM joint venture
650 Suffolk Street, Suite 100
Lowell, MA 01854 USA
Tel. +1-97 85 13 18 00
Fax +1-97 85 13 18 86
www.mirelplastics.com
Tianan Biologic
No. 68 Dagang 6th Rd,
Beilun, Ningbo, China, 315800
Tel. +86-57 48 68 62 50 2
Fax +86-57 48 68 77 98 0
enquiry@tianan-enmat.com
www.tianan-enmat.com
1.6 masterbatches
PolyOne
Avenue Melville Wilson, 2
Zoning de la Fagne
5330 Assesse
Belgium
Tel. + 32 83 660 211
info.color@polyone.com
www.polyone.com
Sukano Products Ltd.
Chaltenbodenstrasse 23
CH-8834 Schindellegi
Tel. +41 44 787 57 77
Fax +41 44 787 57 78
www.sukano.com
Du Pont de Nemours International S.A.
2, Chemin du Pavillon, PO Box 50
CH 1218 Le Grand Saconnex,
Geneva, Switzerland
Tel. + 41(0) 22 717 5428
Fax + 41(0) 22 717 5500
jonathan.v.cohen@che.dupont.com
www.packaging.dupont.com
3. Semi finished products
3.1 films
Huhtamaki Forchheim
Herr Manfred Huberth
Zweibrückenstraße 15-25
91301 Forchheim
Tel. +49-9191 81305
Fax +49-9191 81244
Mobil +49-171 2439574
Maag GmbH
Leckingser Straße 12
58640 Iserlohn
Germany
Tel. + 49 2371 9779-30
Fax + 49 2371 9779-97
shonke@maag.de
www.maag.de
www.earthfirstpla.com
www.sidaplax.com
www.plasticsuppliers.com
Sidaplax UK : +44 (1) 604 76 66 99
Sidaplax Belgium: +32 9 210 80 10
Plastic Suppliers: +1 866 378 4178
3.1.1 cellulose based films
INNOVIA FILMS LTD
Wigton
Cumbria CA7 9BG
England
Contact: Andy Sweetman
Tel. +44 16973 41549
Fax +44 16973 41452
andy.sweetman@innoviafilms.com
www.innoviafilms.com
46 bioplastics MAGAZINE [05/09] Vol. 4
4. Bioplastics products
Suppliers Guide
alesco GmbH & Co. KG
Schönthaler Str. 55-59
D-52379 Langerwehe
Sales Germany: +49 2423 402 110
Sales Belgium: +32 9 2260 165
Sales Netherlands: +31 20 5037 710
info@alesco.net | www.alesco.net
Arkhe Will Co., Ltd.
19-1-5 Imaichi-cho, Fukui
918-8152 Fukui, Japan
Tel. +81-776 38 46 11
Fax +81-776 38 46 17
contactus@ecogooz.com
www.ecogooz.com
Postbus 26
7480 AA Haaksbergen
The Netherlands
Tel.: +31 616 121 843
info@bio4pack.com
www.bio4pack.com
Forapack S.r.l
Via Sodero, 43
66030 Poggiofi orito (Ch), Italy
Tel. +39-08 71 93 03 25
Fax +39-08 71 93 03 26
info@forapack.it
www.forapack.it
Minima Technology Co., Ltd.
Esmy Huang, Marketing Manager
No.33. Yichang E. Rd., Taipin City,
Taichung County
411, Taiwan (R.O.C.)
Tel. +886(4)2277 6888
Fax +883(4)2277 6989
Mobil +886(0)982-829988
esmy325@ms51.hinet.net
Skype esmy325
www.minima-tech.com
NOVAMONT S.p.A.
Via Fauser , 8
28100 Novara - ITALIA
Fax +39.0321.699.601
Tel. +39.0321.699.611
Info@novamont.com
Pland Paper ®
WEI MON INDUSTRY CO., LTD.
2F, No.57, Singjhong Rd.,
Neihu District,
Taipei City 114, Taiwan, R.O.C.
Tel. + 886 - 2 - 27953131
Fax + 886 - 2 - 27919966
sales@weimon.com.tw
www.plandpaper.com
President Packaging Ind., Corp.
PLA Paper Hot Cup manufacture
In Taiwan, www.ppi.com.tw
Tel.: +886-6-570-4066 ext.5531
Fax: +886-6-570-4077
sales@ppi.com.tw
Wiedmer AG - PLASTIC SOLUTIONS
8752 Näfels - Am Linthli 2
SWITZERLAND
Tel. +41 55 618 44 99
Fax +41 55 618 44 98
www.wiedmer-plastic.com
4.1 trays
5. Traders
5.1 wholesale
6. Equipment
6.1 Machinery & Molds
FAS Converting Machinery AB
O Zinkgatan 1/ Box 1503
27100 Ystad, Sweden
Tel.: +46 411 69260
www.fasconverting.com
MANN+HUMMEL ProTec GmbH
Stubenwald-Allee 9
64625 Bensheim, Deutschland
Tel. +49 6251 77061 0
Fax +49 6251 77061 510
info@mh-protec.com
www.mh-protec.com
6.2 Laboratory Equipment
MODA : Biodegradability Analyzer
Saida FDS Incorporated
3-6-6 Sakae-cho, Yaizu,
Shizuoka, Japan
Tel : +81-90-6803-4041
info@saidagroup.jp
www.saidagroup.jp
7. Plant engineering
Uhde Inventa-Fischer GmbH
Holzhauser Str. 157 - 159
13509 Berlin
Germany
Tel. +49 (0)30 43567 5
Fax +49 (0)30 43567 699
sales.de@thyssenkrupp.com
www.uhde-inventa-fischer.com
8. Ancillary equipment
9. Services
9. Services
Siemensring 79
47877 Willich, Germany
Tel.: +49 2154 9251-0 , Fax: -51
carmen.michels@umsicht.fhg.de
www.umsicht.fraunhofer.de
Bioplastics Consulting
Tel. +49 2161 664864
info@polymediaconsult.com
www.polymediaconsult.com
Marketing - Exhibition - Event
Tel. +49 2359-2996-0
info@teamburg.de
www.teamburg.de
10. Institutions
Simply contact:
Tel.: +49-2359-2996-0
suppguide@bioplasticsmagazine.com
Stay permanently listed in the
Suppliers Guide with your company
logo and contact information.
For only 6,– EUR per mm, per issue you
can be present among top suppliers in
the field of bioplastics.
For Example:
Polymedia Publisher GmbH
Dammer Str. 112
41066 Mönchengladbach
Germany
Tel. +49 2161 664864
Fax +49 2161 631045
info@bioplasticsmagazine.com
www.bioplasticsmagazine.com
Sample Charge:
35mm x 6,00 €
= 210,00 € per entry/per issue
Sample Charge for one year:
6 issues x 210,00 EUR = 1,260.00 €
The entry in our Suppliers Guide is
bookable for one year (6 issues) and
extends automatically if it’s not canceled
three month before expiry.
European Bioplastics e.V.
Marienstr. 19/20
10117 Berlin, Germany
Tel. +49 30 284 82 350
Fax +49 30 284 84 359
info@european-bioplastics.org
www.european-bioplastics.org
10.2 Universities
Michigan State University
Department of Chemical
Engineering & Materials Science
Professor Ramani Narayan
East Lansing MI 48824, USA
Tel. +1 517 719 7163
narayan@msu.edu
35 mm
10
20
30
35
10.1 Associations
natura Verpackungs GmbH
Industriestr. 55 - 57
48432 Rheine
Tel. +49 5975 303-57
Fax +49 5975 303-42
info@naturapackaging.com
www.naturapackagign.com
Molds, Change Parts and Turnkey
Solutions for the PET/Bioplastic
Container Industry
284 Pinebush Road
Cambridge Ontario
Canada N1T 1Z6
Tel. +1 519 624 9720
Fax +1 519 624 9721
info@hallink.com
www.hallink.com
BPI - The Biodegradable
Products Institute
331 West 57th Street, Suite 415
New York, NY 10019, USA
Tel. +1-888-274-5646
info@bpiworld.org
University of Applied Sciences
Faculty II, Department
of Bioprocess Engineering
Prof. Dr.-Ing. Hans-Josef Endres
Heisterbergallee 12
30453 Hannover, Germany
Tel. +49 (0)511-9296-2212
Fax +49 (0)511-9296-2210
hans-josef.endres@fh-hannover.de
www.fakultaet2.fh-hannover.de
bioplastics MAGAZINE [05/09] Vol. 4 47
Companies in this issue
Company Editorial Advert
A&O Filmpac 46
Ahlstrom Corporation 12
Alesco 23 47
Arkema 27
Arkhe Will 47
Bamboo 15
BASF 46
Biax-FiberFilm 10
BIC 25
BIO4PACK 5 47
bioplastics 24 39
BioTAK 22
Biotec 46
BPI 47
Centerplate 7
Cereplast 46
Composite technical Services 28
Dallas Convention Center 7
DaniMer 18
Dorel Juvenile 25
Dr Vie 23
DSM Engineering Plastics 26
DuPont 14 46
Entek 17
EPI 3
European Bioplastics 3, 5, 38 9, 47
Fachhochschule Hannover 5, 34 47
FAS Converting Machinery 47
FKuR 6 2, 46
Forapack 47
Fraunhofer IAP 32
Fraunhofer UMSICHT 47
Futerro 31
Gabriel Chemie 7
Galactic 30
Georgia Pacific 20
Green Mountain Coffee 18
Hallink 47
Herma Labels 22
Huhtamaki 46
Innovia Films 23 46
International Paper 18
Izod 15
Lexus 13
Limagrain 6 46
Company Editorial Advert
Maag 46
Mann + Hummel Protech 47
Michigan State University 47
Minima Technology 47
natura Verpackung 47
Naturally Iowa 8
NatureWorks 5, 10, 11, 12, 18, 20, 25
NaturTec 46
Nedupack 6
Neue Messe München (drinktec) 8
nova Institut 8
Novamont 6, 24, 42 47, 52
Plantic 16 46
Plastick2Pack 6
Plasticker 39
Polymediaconsult 47
Polyone 46
President Packaging 47
PSM 46
Purac 46
Pyramid Bioplastics 32
Saida 47
Sidaplax 46
Smurfit Kappa 24
Sommer Needlepunch 11
Speedo 15
Sukano 46
Symphony 3
Tanaka Foresight 24
Teijin 24
Telles 9 51, 46
Tetly 12
Tianan 46
Timberland 15
Toray 13
Total Petrochemicals 31
Toyota 11
Toyota 13
Transmare 46
Typhoo 12
Uhde Inventa-Fischer 21, 47
Unilever 12
University of Tennessee 10
Wei Mon 41, 47
Wiedmer 47
Next Issue
For the next issue of bioplastics MAGAZINE
(among others) the following subjects are scheduled:
Nov/Dec 30.11.2009
Editorial Focus:
Films / Flexibles / Bags
Consumer Electronics
Basics:
Anaerobic Digestion
Next issue:
Month Publ.-Date Editorial Focus (1) Editorial Focus (2) Basics Fair Specials
Jan/Feb 01.02.2010 Automotive Applications Foam Basics of Cellulosics
Mar/Apr 05.04.2010 Rigid Packaging Material Combinations Polyamides
May/June Injection Moulding Natural Fibre Composites t.b.d.
48 bioplastics MAGAZINE [04/09] Vol. 4
Events
Event Calender
October 06-07, 2009
3. BioKunststoffe
Technische Anwendungen biobasierter Werkstoffe
Duisburg, Germany
www.hanser-tagungen.de/biokunststoffe
October 7-10, 2009
Plastics Philippines
SMX Convention Center, Seashell Drive,
Mall of Asia Complex, Pasay City, Phillipines
www.globallinkph.com
October 22, 2009
Timeproof biopolymers: durability of biobased materials
PEP (Pôle Européen de Plasturgie)
Bellignat, Franceopéen de Plasturgie)
jt.pep@poleplasturgie.com
October 26-27, 2009
Biowerkstoff Kongress 2009
within framework of AVK and COMPOSITES EUROPE
Neue Messe Stuttgart, Germany
www.biowerkstoff-kongress.de
October 27-28, 2009
Biofoams 2009
Sheraton Fallsview Hotel & Conference Centre
Niagara Falls, Canada
http://mpml.mie.utoronto.ca/biofoams/
October 29, 2009
NVC Kurs Nachhaltige Verpackungsinnovationen
Hotel Novotel Düsseldorf City West
Düsseldorf, Germany
www.nvc.nl
November 10-11, 2009
4th European Bioplastics Conference
Ritz Carlton Hotel,
Berlin, Germany
www.european-bioplastics.org
December 2-3, 2009
Dritter Deutscher WPC-Kongress
Maritim Hotel, Cologne, Germany
www.wpc-kongress.de
March 16-17, 2010
EnviroPlas 2010
Brussels, Belgium
www.ismithers.net
June 22-23, 2010
8th Global WPC and Natural Fibre Composites
Congress an Exhibition
Fellbach (near Stuttgart), Germany
www.wpc-nfk.de
You can meet us!
Please contact us in advance by e-mail.
bioplastics MAGAZINE [05/09] Vol. 4 49
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50 bioplastics MAGAZINE [05/09] Vol. 3
EcoComunicazione.it
Salone del Gusto and Terra Madre 2008
Visitors of Salone del Gusto 180,000
Meals served at Terra Madre 26,000
Compost produced* kg 7,000
CO 2
saved kg 13,600
* data estimate – Novamont projection
The future,
with a different flavour:
sustainable
Mater-Bi® means biodegradable
and compostable plastics made
from renewable raw materials.
Slow Food, defending good things,
from food to land.
For the “Salone del Gusto” and “Terra Madre”, Slow Food
has chosen Mater-Bi® for bags, shoppers, cutlery,
cups and plates; showing that good food must also
get along with the environment.
Sustainable development is a necessity for everyone.
For Novamont and Slow Food, it is already a reality.
info@novamont.com
www.novamont.com
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