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Codex-UK ´Gebrauchsgegenstände´
3. Juni 2008 / BMGFJ
Biobased packaging
Renewable vs. Biodegradable
New materials for packaging
technology
Michael Pitzl ofi – Department Packaging
Titelformat bearbeiten Austrian Research Institute for Chemistry and Technology - ofi www.ofi.at
CROPACK 2010
Denico Green Products Environment is our engagement
Blancefloerlaan 179 E
2050 Antwerpen
Belgium
tel.: +32.(0)3.540.09.10
fax: +32.(0)3.540.09.19
www.denico.eu
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Recycled and recyclable
materials
Examples
Paper and cardboard made from recycled
fibre or moulded pulp
Recycled and recyclable plastics like HDPE
and PET
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Design for reuse
Examples
Reusable and
recyclable crates and
pallets
Re-sealable plastic
containers
Return system for
customer refills
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Design for recycling
Examples
Packaging made from
a single material
(including labels and
closure system)
Packaging made from
materials that are
commonly collected for
recycling
Packaging with
prominent recycling
symbols
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No toxic inks, paints or
adhesives
Examples
Print with inks that do not
contain toxic compounds
(volatile organic compounds
– VOCs)
Use paints and inks that do
not contain heavy metals or
other toxic compounds
Use adhesives that do not
contain toxic compounds
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No secondary packaging
Example
Use only
primary
packaging
and transit
packaging
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Reduced material volume
Examples
Inflatable pouches to
fill package voids
Refills in pouches
Lightweight bottles
and cans
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With the support of the
European Commission
Definition for “Biodegradable” :
“ A material or product is called biodegradable under specific environmental conditions if it is able to undergo within a given time a certian degradation process that is caused by biological activity and can be measured by a standarised test method.”
Definition for “Biodegradable” :
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With the support of the
European Commission
Biodegradation after 1 – 2 – 4 weeks
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With the support of the
European Commission
OK Compost
Temperature : 50 - 60 °C
Biodegradation : after 6 weeks 90 %
Desintegration : after 12 weeks 90 %,
2 mm
Ecotoxicity
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With the support of the
European Commission
OK Compost HOME
Temperature : 20 - 23 °C
Biodegradation: after 9 weeks 90
%
Desintegration : after 16 weeks 90
%, 2 mm
Ecotoxicity
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Worldwide logo’s
With the support of the European Commission
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Compostable materials are similar to biodegradable materials, as
they are both intended to return to the earth safely. However,
compostable materials go one step further by providing the earth
with nutrients once the material has completely broken down.
These materials are added to compost piles, which are designated
sites with specific conditions dependent on wind, sunlight,
drainage and other factors. While biodegradable materials are
designed to break down within landfills, compostable materials
require special composting conditions. Compostable packaging
materials include starch-based packing peanuts - an alternative to
Styrofoam loose fill packaging that can be dissolved in water and
added to composts for safe disposal.
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With the support of the
European Commission
Labelling
Validity certificate : 5 years
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With the support of the
European Commission
Objectives and advantages of product labeling :
Product identification by the
users/consumers
Product quality assurance (EN 13432
criteria)
Facilitating proper sorting in waste
collection and recovery
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Development of the market
Capacity 2009 400.000 t worldwide
Small market, but high growth rates up to 10 %
Source: www.european-bioplastics.org 2010-02-17
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Solution – Bioplastics?
Recent headlines:
Coca-Cola Co announced the selective global roll-out of
its new PET bottle made from up to 30 per cent plant
materials such as sugar and molasses.
Bioserie iPhone® Case is really green!
Advertising slogan:
Packaging without the guilt? Bioplastics
Source: www.plasticsnews.com 2010-02-17 www.ubergizmo.com 2010-02-22
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Bioplastic
Source/base: renewable or not renewable Material: biodegradable or not biodegradable
Plastics: 265 M tons (2010) – Plastics Europe Bioplastics: 0.724 M tons biodegradable (non renewable resources) 428 000
t plastics from renewable resources 296 000 t
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Development of bioplastics through history
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Research > Development > Pilot Plant > Commercialization > World-scale Plant > Industrial production
State of development
Source: bioplastics Magazine 03/2007
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With the support of the
European Commission
Renewable Raw Materials
Fibers Bioplastics
Sugarcane
Bamboo
Palm Leef
…
Starch (Materbi)
PLA
Cellulose
…
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Fibres Life Cycle Analysis of Sugar Cane Packaging
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Production Sugarcane => Bagasse
With the support of the European Commission
Pulp Moulding Technique
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With the support of the
European Commission
Fibers
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With the support of the
European Commission
Bamboo Palm leef
Coloured sugarcane
Other Fiber products
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With the support of the
European Commission
Biodegradation Fibres
• 100 % Biodegradable & Home compostable
Before composting After 4 weeks of incubation After 8 weeks of
incubation
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With the support of the
European Commission
Properties Fibres
• Food Contact Approved
• Flexible shapes & size
• Suitable for thermal applications
Microwave/oven + 225°C
Freezer - 20°C
Water + 100 °C
Oil + 150 °C
• Acid resistance – no discoloration
• HACCP – ISO – SGS – FDA
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BIOPLASTICS
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Definition Bioplastics = environmentally friendly plastics processed by plastic
processing technologies :
• Film extrusion => flow pack
• Thermoforming => Food containers
• Blow moulding => bottles
• Fibres => clothing
And that are :
1.Biodegradable or/and compostable according to
relevant standards
2.Based (at least in parts) on renewable raw materials
(RRM)
With the support of the
European Commission
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Relevant standards : EN13432, EN114995, ISO 17088, ASTM D-6400
With the support of the
European Commission
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With the support of the
European Commission
Green waste bags
Shopping/carrier
bags
Dog waste
bags
Starch-based ( Materbi®) films and bioplastics
Wrapping film
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Waste bags
Width
mm
Length
mm
Tickness
micron
350 420 13
420 420 13
450 500 15
500 700 18
700 1100 20
950 1200 22
Standard sizes
With the support of the
European Commission
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Shopping bags
With the support of the
European Commission
Standard sizes or custom-made
Different thicknesses
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With the support of the
European Commission
Biofilm Should not be removed after harvest
Degrades completely
No residues in the soil
Can be applied with existing machinery
Huge savings on labour cost
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Biodegradation
With the support of the
European Commission
100 % Home
compostable
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With the support of the
European Commission
Applications - starch
Advantages: • Abundantly available
• Printable
• Home compostable (bags to 120 µm : 10 to 45 days )
• Gasbarrier: - low CO2 permeability
- high (water)vapour permeability
• Our bag complies with EU requirements for
packaging in the food industry
• Our bag "breathes" and reduces the weight of its
contents by up to 25% in five days.
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Air-Cushioning / Loose fill
Optimum protection for your
product
Loose Fill :
• made from vegetable starch
• 100% biodegradable
• 100 %water soluble
With the support of the
European Commission
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Cutlery
100% biodegradable
Made of PLA/Starch
blends
Better rigidity than
plastic cutlery
Heat resistance up to 85
°C
With the support of the
European Commission
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European Commission
PLA film and bioplastics
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With the support of the
European Commission
Production PLA resin ( Polylactic Acid)
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With the support of the
European Commission
Application - PLA
PLA (Poly Lactic Acid)
(sheet)extrusion:
• Film extrusion -> flow pack
• Thermoforming -> Food containers
• Blow moulding -> bottles
• Fibres -> clothing
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With the support of the
European Commission
Properties - PLA
• 100 % Biodegradable
• Industrial compostable (50°C - 65 °C)
• Printable
• High Stiffness
• Tensile strength
• Higher transparency than conventional plastic
• Chemical resistance against greases, fats and oils
• Excellent barrier ( aroma / flavour)
• High water vapour transmission rate
• FDA approval for Food Contact
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Applications - PLA
Disadvantages:
• Not “Home Compostable => industrial
composting facility
• Low temperature resistance (0°C - 40°C)
=> solved with “blends” of other RRM (
starch, cellulose,…)
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Material Properties
Apet
Mapet
1
CPET
1
CO-PP
(Co-Polymer)
5
Ho-PP
(Homo-Polymer)
5
PS
6
PLA
7
Min. Temperature - 40°C* - 40°C* - 40°C* + 2°C* - 40°C*² 0°C*
Max. Temperature + 70°C + 220°C + 121°C** + 121°C + 85°C + 40°C
Sealing with film + + + + + +
Sealing with board + + + + + +
Fat resistant + + + + + +
Transparent + - + by contact + + by contact +
Many colour variants + + + + + -
Density 1.35 1.35 0.91 0.91 1.05 1.25
Material rigidity 2,200
N/mm²
2,900
N/mm²
1,350
N/mm²
1,700
N/mm²
1,900-2,500
N/mm²
3,500
N/mm²
* Handle with care at low temperatures
** Some colours have a maximum temperature limit of + 40°C
² Clear PS withstands only -20°C
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PLA cups
100 % Biodegradable
Cold drinks & smoothies (
up to 40 °C)
Easy printable
All sizes available from
2 oz (60 ml) – 20 oz (600
ml)
Suitable flat & Dome lids
Straws (transparent or
coloured)
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Other PLA products
Available in all
sizes and shapes
• Salad bowls
• Food packaging
• Egg boxes
• Sandwich
wedges
• Wrapping film
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Biocups Suitable for drinks to 80° C
Heat resistant biodegradable lid (75 °
C)
Made using laminated cellulose or
from PLA
Can be branded using natural inks
Wide range of sizes available :
4 oz 120 ml
6 oz 180 ml
8 oz 240 ml
10 oz 300 ml
12 oz 360 ml
16 oz 480 ml
20 oz 600 ml
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Biodegradable materials
In general 4 materials commercially available
• Starch-based polymers
• Polylactic acid
• Polyhydroxyalkanoates
• Cellulose derivates
Chitosan?
Polymer blends and
composites
Source: www.basf.com 2008-09-12 YU L. et al. 2006
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Maize and/or potatoe starch in blend with
polycaprolactones and other biodegradable
esters
Europeas most common bioplastic
Starch-based polymers Mater-Bi®
Source: www.novamont.com 2009-12-01
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Plantic®
Starch from maize and hydroxypropyl, Plantic
Technologies (AUS)
Solanyl® Starch from potatoes, Rodenburg Biopolymers
(NL)
Bioplast® Starch blend, Biotec (DE)
Biopar® Starch from potatoes and blends, Biop AG (D)
Similar to PE (converting)
Limited applications!
Starch-based polymers Others
Source: www.plantic.com.au 2009-04-01
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Polylactic acid
Main producer: NatureWorks (US)
Other Producers: Hycail (FI), Toyota (J) and
Uhde Inventa (D)
Glucose from maize or lactose from whey
Source: LIM L.-T. et al. 2008
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Ecovio®
45 % PLA + Ecoflex®, BASF (D)
Ecovio® L-Foam
75 % PLA + Ecoflex®, BASF (D)
Bio-Flex®
PLA + Copolyester, FKuR (D)
Similar to PET and/or PS (converting)
Sensitive to temperature!
Polylactic acid blends
Source: www.basf.com 2008-09-12 YU L. et al. 2006
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Mirel™ Metabolix (US)
Biomer™ Biomer (D)
Fermentation of starch, rape, plant residues, etc.
Only Injection Moulding!
PHB, PHV, PHBV, ...
Polyhydroxyalkanoates
Source: www.metabolix.com 2008-09-12
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NatureFlex™
Innovia (UK)
Cellulose derivates
Source: www.innoviafilms.com 2008-09-12
Barrier coatings!
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Thermal properties: Melting temperature
Biopolymers comparable with conventional plastics
Source: WEBER C. J. 2000
Comparision
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Oxygen transmission rate
Biopolymers in the midfield
Source: WEBER C. J. 2000
Comparision
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Water vapour transmission rate
Biopolymers in the midfield
Source: WEBER C. J. 2000
Comparision
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Transmission of UV-light
Comparision
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Food safety packaging material
Nearly all starting substances are listed
Migration values are below legal limits
No significant difference in microbial growth
on packaging material
No desintegration during shelf life
Migrants from PLA are safe
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End of life
Composting?
Source: WEBER C. J. 2000
End of life
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End of life
Compsoting?
Source: ENDRES H.-J. 2009
End of life
