Extended shelf-life biopolymers for sustainable and multifunctional food packaging

Transcription

1 Extended shelf-life biopolymers for sustainable and multifunctional food packaging Åge Larsen, SINTEF Materials and Chemistry PACE Amsterdam, February 9-11, 2016

2 Outline NanoBarrier background challenges for sustainable packaging Biomaterials for food packaging NanoBarrier nanotechnology platform Barrier promoters Sensor development Demonstrator product cases Environmental and safety aspects 2

3 To succeed with EU proposals: Reply to a specific call! Program FP7 NMP Duration Budget Coordinator Partners 9.9 M, including 7.2 M from the European Commission SINTEF Materials and Chemistry, Norway 15 partners from 10 countries

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5 Packaging development - Main role to provide information about product - Designed to function discretely - Consumers not aware of improved performance Barrier: Base materials, coatings, fillers, scavengers Sensors: Capsules, prints, labels NanoBarrier Objective: Multifunctional food packaging from CO₂ neutral, renewable resources Barrier: not visible Sensors: how shall signals be read? 5

6 Biopolymers a field in development Base materials of demonstrators: - polylactic acid (PLA) or polyethylene terephthalate from bioresources (Bio-PET). PLA: mostly by fermentation of carbohydrates by bacteria - biotechnology Bio-PET: monomers from bioresources biorefinery Initial focuse of NanoBarrier: biodegradation Included with bio-pet: recycling NanoBarrier proof-of-concept: PLA-SPI-PLA based film laminate. Promising OTR! Silica-based humidity barrier on boards 6

7 NanoBarrier - Nanotechnology platform Barrier promoters from renewable resources: Inorganic-organic hybrid polymers: O 2 (IOHP) Microfibrillated cellulose: humidity, O 2 (MFC) Hydroxyl-decorated organic nanoparticles; O 2 (HDNP) Layered double hydroxides: humidity in board (LDH) Oxygen scavenger HDNP Sensors: Local ph changes: hydrogel-based nanocapsules and mesoporous nanocontainers; LDH; HDNP Temperature changes: nanocapsules; thermo-ink labels with visible colour change (TTi) Humidity: LDH LDH Addition of the sensor increases the demonstrator cost by % of barrier promoters increase demonstrator cost by

8 Demonstrator safety analysis Migration Migration tests of all materials using set of food stimulants according to specific EU protocols UV-VIS SERS Calibration curves and detection limits for all elements Toxicity Cytotoxicity of nanoparticles on: -cell viability assay and internalization in cells -oxidative stress and the effect on cell cycle -cell morphology and blood cells hemolysis Absorbance HDNPs 100%-50% Etoh Wavelength (nm) 2 days 3 days 7 days 10 days 16 days 36 days UV-Vis spectra of the food simulant liquid after migration tests on PLA with nanoparticles Low toxicity of all materials! Immunofluorescence staining as means to display cell morphology 8

9 Demonstrator products D1. Thermoformed 3 layer film for oxygen sensitive food Sliced meat. PLA-MFC-PLA. Oxygen barrier from modified MFC ph sensorized by LDHs. Benchmark: thermoformed tray PE/PA/PE. Up to 3X reduced OTR. MFC D2. Blow moulded bottle for oxygen sensitive produce Bottle of ketchup. Base material bio-pet. IOHP coating, LDHs and oxygen scavengers. Benchmark : Uncoated PET Up to 3x reduced OTR 9

10 Demonstrator products D3. Injection moulded jar for sea food Packaged crab meat. Base material PLA. Oxygen barrier with MFC and IOHP coating. Closure with the PLA/MFC/PLA film. Benchmark: monomaterial polypropylene jar. 4X reduced OTR D4. Blown three-layer film for meat packaging Packaged beef. Base material is PLA. Mid-layer of PLA with MFC. TTi temperature sensor. Benchmark: multilayer film of PLA. 25 % reduced OTR 10

11 Environmental impact assessment - LCA Comparative LCAs between benchmarks and demonstrators D1 thermoformed tray PLA/MFC/PLA benchmark thermoformed tray PE/PA/PE

12 Environmental impact - ecodesign, waste management Ecodesign Actions focused on: Material replacement, Thickness reduction and weight optimization Energy reduction Use of compostable materials. Use of recycled materials Sensors: ph, TTi The environmental improvements through CO₂ footprint compared with benchmarks: Demonstrator 1-40% lower, Demonstrator 2-5% lower Demonstrator 4-20% lower Demonstrator 3-1% increase Waste management D1, D3 and D4 are compostable D2 is recyclable Optical sorting relevant for all demonstrators. Particular waste streams to be identified 12

13 Summary Biomaterials Fast developing field "Old" polymers from bioresources Biodegradation versus recycling! NanoBarrier nanothechnology platform New concepts for barrier promoters and sensor elements Demonstrators Improved oxygen barrier compared to benchmarks Environmental impact Significantly reduced CO₂ footprints compared to benchmarks Health and safety All tested materials exhibit low toxicity evaluated in cell cultures 13

14 Thank you for your attention 14