Biomass products and the bioplastics research area in VTT

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1 Biomass products and the bioplastics research area in VTT Katariina Torvinen, Research manager VTT VTT beyond the obvious 1

2 VTT impact from excellence VTT is one of the leading research and technology organisations in Europe. We use our scientific and technological excellence to provide innovation services for our domestic and international customers and partners. Our vision A brighter future is created through science-based innovations. Established in M Net turnover and other operating income (VTT Group 2016) 2,414 Total of personnel (VTT Group 2016) Our mission Customers and society grow and renew through applied research. Strategy Impact through scientific and technological excellence. Owned by Ministry of Economic Affairs and Employment 33% from abroad (VTT Group 2016) 28% Doctorates and Licentiates (VTT 2016) 05/10/2018 2

3 #1 FORESTED COUNTRY IN EUROPE 75% OF THE LAND COVERED IN FORESTS 17 BILLION TREES SUSTAINABLE AND COMPREHENSIVE UTILIZATION THE NORDIC ENVIRONMENT HAS GIVEN FINNISH WOOD SOME SPECIAL FEATURES Slowly grown wood is very strong Beautiful wood for further processing

4 Source: :Arasto, Antti; Koljonen, Tiina; Similä Lassi ( eds) Growth by integrating integrating bioeconomy and low-carbon carboneconomy-scenarios for Finland until VTT Visions 13

5 Strategic focus areas and offering to the industry Web based fibre products Foam forming of paper and board, moldable web Use of NFC in paper and board Foam coating NFC films and membranes Barriers Biobased hybrid structures Reactive extrusion of polymers and cellulose Wood plastic composites by extrusion High bulk fibre products Nanocellulose as dispergant / emulsifier Polymer foams

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7 Challenge 1. Recyclability EU s plastic strategy: plastic packaging's has to be recyclable by 2030 In practice recycling of plastics and exploitation of recycled fractions are complicated combination Development of collecting and sorting techniques Development of commercially profitable applications for recycled plastics Improve the quality of recycled materials The end of life taken into account already in design of the packaging's (recycled or compostable) Needs simultaneous development in all stages of the value chain VTT beyond the obvious 7

8 Challenge 2. Minimize the use of petroleum based material CELLULOSE Supermaterial of the future

9 Nanocellulose (Hefcel) Dry food packaging Nuts Coffee Chocolate Muesli Pet food Oxygen barrier Potential for moist foods as well Increased shelf life for food Compostable Printable

10 Thermoplastic cellulose -new properties! Cellulose can be made thermoformable by modifying molecular mass (cellulose esters) Processable with existing plastic converting equipment Moisture and water vapor resistant Heat-sealable 100% bio-based Comes in granulate and filament form VTT beyond the obvious 10

11 Ellen MacArthur Circular materials challenge winner 2018 M&S Ecopackaging Challenge winner % RENEWABLE CUSTOMIZABLE HEAT SEALABLE 3 layer barrier film structure Moisture & water vapour barrier Thermoplastic cellulose Nanocellulose film Thermoplastic cellulose Oxygen, gas & grease barrier Accepts MULTIPLE BIOBASED RAW MATERIALS use of local resources Processable with EXISTING MACHINERY

12 Biomaterial products Expertise from idea generation to market-ready applications Our competence areas are Biopolymer and fibre foams High-performance fibre composites Tailoring of fibres and biopolymers Biomaterial process development Bio- and circular economy materials 05/10/

13 VTT Foam Forming Pilots SAMPO Pilot-scale research environment for nonpressed materials Foam Forming Technology Vertical headbox Horizontal geometry Impingement and TAD dryers D=600 mm, max speed 200 m/min Start-up 2017 SUORA Pilot-scale research environment for papermaking board manufacturing processes and product development Water-laid and Foam-laid webs Stratified foam forming Small amounts of raw material <100 kg abs dry D=300 mm, max speed 2000 m/min Built 2006, rebuild 2010, foam start-up 2013

14 Foam forming as a manufacturing platform for future fiber products Packaging and cushioning Lightweight, mouldable board Replacement for plastic bags Sound insulation Nonwovens Construction Growth media

15 New opportunities with 3D printing Wood-based cellulosic 3D-printing materials offer a sustainable bio-based alternative to plastics. Cellulose is lightweight, non-allergenic material that can be processed into multiple forms (filament, powder or paste) to suit a wide range of different applications, including textiles, spare parts, decorative items, and low-volume consumer goods etc. Another advantage of native cellulose is its biocompatibility, which makes it suitable for medical applications VTT beyond the obvious 15

16 Plastics processing Thermo-Haake MiniLab, Micro Compounder Tandem Extrusion Foaming Line Injection moulding Berstorff Compounding Line Micro-scale melt processing Small scale processing Pilot scale processing Pre- and Post-processing Injection moulding Extrusion Extrusion foaming Pre- and Post-processing

17 Sustainable film solutions with VTT VTT provides easy-access material development, piloting and demonstration facilities with world class material experts and unlimited material possibilities, including biopolymers, biocomposites and multilayer structures. Film processing services include: Pilot-scale roll-to-roll cast film processing and extrusion coating Laboratory-scale thick cast film processing Blown-film processing (1-layer) Biaxial orientation of thick plastic sheets Thermoforming Clean room facilities Experience in versatile materials and applications

18 Updated film extrusion pilot line at VTT Roll-to-roll cast film processing and extrusion coating Line width 600 mm, 5-layer die (ABCBA) 550 mm effective width 500 mm Two 35 mm single-screw extruders and a 25 mm twin-screw extruder Online-compounding option with the twin-screw extruder, unique set-up Pre-treatment / adhesion promoting: Corona upcoming Post-treatments: Machine-direction orientation equipment (1:1 1:10, max 200 ºC) spray coating, drying (IR, convection oven), UV-curing available for 300 mm line width

19 VTT facilities for thermoformable solutions Material compounding with twin-screw extruders from lab- to pilot scale Cast film production from lab- to pilot scale Lab-scale cast film extrusion: 10 cm wide cast film, material need >2 kg Pilot-scale mono- and multilayer films: roll-to-roll film extrusion and extrusion coating. Effective width 500 mm, 5-layer films, online compounding option, machine-direction orientation option Thermoforming: Thermal press with contact and IR heating, sample size 100x300 mm or 300x300 mm Materials & processes Melt compounding Melt compounding Melt compounding Film extrusion Film extrusion Vacuum Vacuum forming Vacuum Thermoforming Cellulose fibres Side stream forming Natural fibres Side stream+ + Additives Additives + Additives Thermoformed Granulates Granulates Granulates biocomposite Thermoplastic Thermoplastic Thermoplastic polymer polymer Biobased Biobased honeycomb honeycomb products polymer structure structure (bioplastic or with improved with improved stiffness stiffness conventional)

20 Polymer and biocomposite foaming at VTT POSSIBILITIES AT VTT Extrusion foams: Foam extrusion with kg of polymers Chemical or physical blowing agent Particle foams: Twin screw extrusion with high pressure underwater micropelletizer Hot steam moulding 05/10/

21 Modular mixer for e.g bulky and heterogeneous waste materials (patent pending) With VTT s modular mixer benefits compared to traditional compounding technology include: Large feeding zone without increasing the length or throughput Conversion of various materials, including bulky and heterogeneous waste materials New application fields for extrusion technology Lower investment costs Bulky waste or side stream Traditional process Pelletizer Improved mixing with short screw length Compact reduce floor space Simplified maintenance with decreased costs Allows transferable treatment units Waste treatment on-site Alternative processing solution provided by VTT s modular mixer Bulky waste or side stream Scredder / Mill / Grinder Ground waste or side stream Pelletized waste or side stream Homogenous material for product processing Homogenous material for product processing 05/10/2018 Compounding and extruding by twin screw extrusion Compacting and compounding by modular mixer 21

22 Research Examples

23 RESEARCH CASE Sustainable light-weight materials Conventional thermoplastic foams are produced from fossil-based materials. Biopolymers and biocomposites are mainly used in unfoamed solutions. 50% lighter VTT has focused on development of light-weight solutions based on bio-based plastics and cellulose fibre reinforced biocomposites. Sustainability by replacing fossil-based plastics Up to 100% bio-based compositions Light-weight, insulation properties Applications in packaging, construction and transport

24 RESEARCH CASE Light-weight PLA foam development Extrusion foamed and expanded PLA Sustainability by replacing oil-based components Light-weight, high insulation 100% bio-based Applications in e.g. packaging, construction and transport

25 RESEARCH CASE Bio-based packaging film Customer: Welmu International Oy New bio-based and/or renewable material to replace plastics and to produce clear and biodegradable films in packaging applications. Development of novel material with great opportunities on packaging film markets. Decrease amount of plastic waste with non-plastic wrapping film. VTT designed material combinations which were tested in pilot environment. A set of prototype films with alternative properties were manufactured. We chose the unconventional way to do R&D and outsourced it entirely to VTT. It has turned out to be a great decision as we are now on the brink of commercializing our new, revolutionary film material. Jaakko Kaminen CEO Welmu International Oy. Our wood based biowrap is the future of packaging 05/10/

26 RESEARCH CASE PIHI Sustainable polymer film solutions ERDF project, 3 years, 1 M. Contributors: VTT Oy, TAMK, Ekokumppanit Oy Funding: ERDF, self-funding, 9 companies from Tampere area throughout the value chain EU Plastic strategy, increasing plastic waste and microplastic amounts, increasing environmental awareness, need to detach from fossil-derived raw materials Ecological and recyclable plastic film solutions commercially available. Head start to international markets graving for sustainable plastic solutions: growth and competitiveness through bioeconomy business areas. Bio-based, compostable, recycled and easier recyclable plastic film solutions and applicable R&D facilities. Strengthening of collaboration throughout the value chain and creation of new knowledge cluster for sustainable solutions. 05/10/

27 Thank You! Katariina Torvinen Phone: /5/2018 VTT beyond the obvious 27