innobioplast 2013 presentation dwa coffee cup development
TRANSCRIPT
Presenting to:
How to tailor your material for
customer needs –
PLA coffee cup case study
Derek Atkinson - PuracFrançois de Bie – Purac Sicco de Vos - PuracKarin Molenveld – WURGerald Schennink - WUR
2
Outline
Origin of the project
Project partners
Material development
Results from composting study
Next steps & Summary
3
Market pull - Origin of the project In 2009 Wageningen University defines a
“ Sustainable business policy” Objective is to reduce the ecological footprint of the university
and encourage sustainable business practises
Formation of working group: “Bioplastics in catering” Wageningen UR
Facility service & Food and Biobased Research (FBR) Province of Gelderland Douwe Egberts Albron (catering) Other stakeholders
The working group evaluates the possibilities & benefits of introducing biobased materials in catering applications – focus on coffee cups
Wageningen university uses 2.5Million PS cups/year
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What is the most environmentally friendly coffee cup ?
Carbon footprint: cradle to gate vs cradle to grave-> Impact of end of life options ?
Technical requirements Consumer experience
-> Multiuse vs single use ?-> Separate collection system ?
PS PLA Paper/PLA Porcelain
5
Technology push - Origin of the project
In 2008 Purac and Wageningen UR* start a project.
PLLA/PDLA homopolymers
Objectives:Develop high heat injection moulding compounds in PLA
*) Wageningen University & Research centre, Food & Biobased Research
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PLA coffee cup project kickoff
Develop a PLA coffee cup that:
- Can withstand hot coffee / 93oC
- Can be produced on existing PS coffee cup production lines
- Can reach the same thermoforming speed as PS today
Technology push Market pull
Industrial Partner
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Feasibility study Several material formulations created High heat PLA concept of Purac based on PLLA/PDLA Compounding and sheet extrusion at Wageningen UR Thermoforming using industrial equipment and moulds
Conclusions Processing conditions are of major importance (hot mould)
Crystallisation speed of PLA homopolymers is sufficient
Short cycle times (1-2 seconds) are possible
See Table on next slide
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Results feasibility study on thermoformed prototype cups
Conclusion:Even at short cooling rates, PLA homopolymers can reach a high level of crystallinity
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Results feasibility study
Processing speed is OK .. BUT .. cup stiffness, when filled with hot coffee (93°C), is NOT sufficient.
50 100 150
E-
modu
lus
MPa
Temperature oC
Amorphous PLASemi-crystalline PLATarget stiffness
93
How to increase stiffness at 93°C ?
Calcium Carbonate (chalk) Cheap Limited effect on stiffness No influence on crystallisation
speed
Talc More expensive High effect on stiffness Strong influence on crystallization
speed
Combine PLA homopolymers with fillers: Fillers increase the stiffness Fillers can introduce brittleness Fillers can impact crystallization behaviour
Conclusion:PLA homopolymers, in combination with a filler, have an acceptable stiffness over the required temperature range. ( see chart on next page )
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DMTA - effect of fillers & crystallinity
1,E+04
1,E+05
1,E+06
1,E+07
1,E+08
1,E+09
1,E+10
0 50 100 150 200
E’ (───
) [P
a]
Temperature [°C]
PLA 6400
0x
7x at 115C
Unfilled PLA - amporhousFilled PLLA homopolymers – high crystallinity
Conclusion:PLA homopolymers, in combination with a filler, have an acceptable stiffness over the required temperature range.
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Results reformulations with fillers
Promising formulations tested at pilot scale PLLA and PDLA homopolymers from Synbra/Purac Compounding done by Wageningen FBR Sheet production and thermoforming at industrial partner
Various formulations with following ingredients:1) PLLA Homopolymer
2) PDLA Homopolymer
3) PLA
4) Filler
5) Nucleating agent
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Results semi-industrial trialsPLL
A h
om
opoly
mers
PLA
co
poly
mers
Conclusion:The best results could be obtained with combination of PLLA and PDLA homopolymers
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Main conclusions on thermoformed PLA hot drink cup
Thermoforming of high heat PLA is finding a balance between formability and crystallization speed
The best results could be obtained with combination of PLLA and PDLA
Fillers are necessary to provide sufficient stiffness above the Tg of PLA
Replacement of amorphous PS cups is possible
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Biodegradation of the PLA cup
Cups were submitted to Organic Waste Systems (OWS)
to evaluate the compostability.
Qualitative disintegration is part of EN13432 and is
considered to be the most significant hurdle for
obtaining the compostability according EN13432.
Only the qualitative disintegration test was performed.
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Results from composting tests
Test conditions: The samples were added to a bin with compostable waste @ OWS.
Conclusion:Does not meet EN13432 standard.Significant degradation, fungal growth, size of left over’s 1 x 3 cm.
Start 1 week 3 weeks 12 weeks
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Next steps and actions Finalize large scale industrial production run Commercial roll out of PLA cups Complete bio-based certification Evaluate options for end of life recycling
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Summary – key learnings Replacing traditional plastics in “high volume”
applications takes time & effort. Working closely with expert partners that have
knowhow in different areas of the process increases the rate of success.
PLA homopolymers can replace PS in hot coffee cups.
Many thanks to all partners that contributed to this project:
Industrial Partner
19Questions ? For info please contact [email protected]
2020
For more information, contact:Derek AtkinsonBusiness Development DirectorPLA AsiaM +65 9093 [email protected]
No representation or warranty is made as to the truth or accuracy of any data, information or opinions contained herein or as to their suitability for any purpose, condition or application. None of the data, information or opinions herein may be relied upon for any purpose or reason. Purac disclaims any liability, damages, losses or other consequences suffered or incurred in connection with the use of the data, information or opinions contained herein. In addition, nothing contained herein shall be taken as an inducement or recommendation to manufacture or use any of the described materials or processes in violation of existing or future patent of Purac or any party.