FAIR-CT98-9715 Development of a low cost, environmentally friendly, starch-based packaging

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FAIR Area 1.2 - Green Chemicals and Polymers Chain : Packaging

	Contract No:	FAIR-CT98-9715
	Date Prepared:	February 2001
	Source:	Final Report Abstract & Executive Summary

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Final Report Abstract

The structure of the group of proposers is such that they form a supply chain capable of providing the technological solutions, and capable of forming a suitable vehicle for post project development, marketing and product support. The total consortium consists of 6 core SME proposers, 1 additional proposers and 3 RTD performers and involving 5 member nations. All the core skills required to deliver the proposed RTD are present in the selected performers. The industrial partnership covers all business activities relevant to the supply chain. It includes a starch supplier, a packaging equipment manufacturer, several manufacturers of EPS products and loose fill packaging, as well as an end user from the electronics industry.

Each year, as industry produces more and more packaged products, we, in turn, throw away more and more rubbish. Many packaging materials will only be used once, then thrown away as garbage where they will last forever. Polystyrene foam, for instance, represents a prime example. It seems appropriate that products of this nature, which are not supposed to be durable, could be made from biodegradable materials, so that they can be returned to the environment after use. In recent years, most packaging industries are being forced by different product manufacturers and end users to supply the market with biodegradable alternatives and to assume a more responsible approach to packaging. The goal of this project has been to develop a starch-based foam for industrial packaging applications, such as protective packaging for ceramics and small electronic equipment. Various parameters such as starch source, processing temperature, water content, presence of nucleating agents, production process and packaging requirements have been evaluated and optimised.

Two approaches for manufacturing starch foams were identified and experimental work has been carried out to prove their feasibility and define the technical risks involved in these processes. These approaches Were: (i) Injection moulding of starch granulate into foamed products, whereby starch is molten at high temperatures in an injection moulding machine, and expanded in a pre-designed mould; and (ii) Hot air blowing expansion of starch granulate, using a similar process to that used in the manufacture of expanded polystyrene.

Existing injection equipment and expandable polymer bead systems have been adapted for this proposed technology. Polystyrene and polyurethane foams used in packaging will have a more environmentally benign alternative. Practical applications have been validated for the ceramic industry and for low weight electronic devices.

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Final Report Executive Summary

Introduction

A great need exists for the development of new packaging alternatives, which satisfy all the essential environmental protection requirements, while at the same time do not incur disposal costs and related problems.

In nature starch is found as crystalline beads or grains, which can be used directly as fillers or can be transformed into thermoplastic starch. This can be processed alone or in combination with specific synthetic polymers. To make starch thermoplastic, its crystalline structure has to be destroyed by pressure, heat, mechanical work and plasticisers such as water, glycerine or other polyols.

The overall industrial objective of the project is to provide European SMEs with a low cost, environmentally friendly, starch based packaging that can be injection moulded or expanded in a similar process to EPS (expandable polystyrene), using destructured starch. Existing injection equipment and expandable polymer bead systems have been adapted for this proposed technology. Polystyrene and polyurethane foams used in packaging will have a more environmentally benign alternative.

Activities

Two pre-competitive processes have been developed, which will require further work before they are commercially available. Specifically the following results have been achieved:

• The successful development of injection moulding of starch granulate into foamed products, whereby starch is molten at high temperatures in an injection moulding machine, and expanded in a pre-designed mould. Densities and cushioning properties similar to EPS have been achieved
• The successful development of hot air blowing expansion of starch granulate, whereby a process similar to the one employed in the manufacture of expanded polystyrene is used. Densities and cushioning properties similar to EPS have been achieved.

The benefits of the project will include:

• a decrease in landfill usage
• an increase in energy efficiency by not having to recycle durable plastics
• reduction in the use of petroleum, which is a disappearing commodity
• increased employment in the manufacture of a more environmentally friendly packaging.

Achievements

Two approaches for manufacturing starch foams have been developed.

• Injection moulding of starch granulate into foamed products. Using this technique it has been possible to expand starch granulate into very homogeneous foams. The starch is expanded in a die by the abrupt pressure drop (ca. 600 bar), combined with a relatively high temperature of the material (ca. 1800C). The main developments in this field have been related to materials- the proper choice of the starch source, the composition of the granulate and the possibilities to adhere the foamed strands; and on the technology side- the temperature setting of the barrel, the development of a suitable runner and mould. Existing plastic injection moulding equipment has been used.
• Hot air blowing expansion of starch granulate. With the use of hot air it has been possible to expand starch granulate. EPS manufacturing can be mimicked using this technique. Innovation will be based on introducing starch to the process of moulding expandable polystyrene. The starch is expanded by the evaporation of water induced by the increase in temperature. Main developments achieved through research have been derived from the composition of the granulate and the adhesion of the expanded beads.

These developments have resulted in the production of samples with the following features:

• Parts produced by the injection moulding process resulted in thick walls (block like) and a hard layer in its surface which proved difficult to eliminate. This characteristic gave the final packaging product additional protection strength. In any case, automated cutting systems have been analysed in case this was to be considered a problem. The ceramics industry and the consumer electronic market, where standardised box type packaging could be applied could therefore benefit from these developments.
• Parts produced by the hot air blowing process resulted in thin walls (tray like). Lightweight electronics opens an enormous potential market for this application. Combined with starch based films which are available in the market, it would be possible to have a complete anti-static, load bearing, product safe and biodegradable packaging, based totally on renewable resources. A prototype packaging was prepared for an electronic chip.

Both the processes developed resulted in a rather peculiar characteristic that presents very interesting opportunities when it comes to the packaging of different items without the need for using different moulds. Due to the brittle nature of the foam, which can be controlled in such a way that it can be made more brittle at the centre of the foamed protective packaging part, it is possible to perfectly fit the item to be packed, by simply pressing it down into the foam. The structure of the protective packaging part is thus indented in the shape of the product to be packaged and a customised cushioning is obtained, thus allowing for safe transportation of the product in question.

Conclusion

It can be concluded that this project has indeed been very successful. The partners are excited about the exploitation potential, and they have the resources and facilities to bring the technology developed by this project to the market place.

Exploitation

Pre-competitive processes have been developed, which will require further work before they are commercially available.

JCB Electromeccinica S.L., Polisur and Com-Plas Packaging will lead the exploitation of the new technology, and together produce and market starch-based packaging throughout Europe. They have agreed to submit a proposal to the "Joint European Venture" scheme.

However, it is equally important that market pull is stimulated to complement the technology push generated by the Core Group Proposers. To assist in this, the demonstration facilities will be used to publicise the RTD's results to potential end users and potential licensors of the technology. This will involve partnerships with Trade Associations, as well as demonstrations and further development up to 12 months after completion of this activity.

The packaging manufacturers within the partnership will use this demonstration system to introduce the benefits of the technology to their existing and prospective customers.

The scientific achievement will be disseminated by the RTD Performers via papers in technical reviews, without revealing confidential information, and will require the approval of the consortium members beforehand. All dissemination of information will be restricted until a commercial advantage for the proposers is envisaged.

Collaboration

Collaboration is sought with companies willing to exploit the technology developed under a licence agreement.