ALTERNATIVE PACKAGING BASED ON CELLULOSE NANOFIBERS DOUG BOUSFIELD, CALDER PROFESSOR PAPER DAYS APRIL 2018

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1 ALTERNATIVE PACKAGING BASED ON CELLULOSE NANOFIBERS DOUG BOUSFIELD, CALDER PROFESSOR PAPER DAYS APRIL 2018

2 GOAL TO PRODUCE A CELLULOSE BASED PACKAGING OPTION THAT CAN REPLACE THE COMMON SNACK PACKAGING. THE PACKAGE SHOULD BE ABLE TO BE RECYCLED WITH PAPER AND BREAK DOWN IN THE ENVIRONMENT IF LITTERED.

3 TEAM DOUG BOUSFIELD DIRECTOR PROF. MEHDI TAJVIDI, PROF. WILLIAM GRAMLICH, PROS BENNETT JINWU WANG, FOREST PRODUCTS LABORATORY YANFENG DU, VISITING SCIENTIST KENDRA FEIN, GRADUATE STUDENT YAPING ZHU, GRADUATE STUDENT THOALFAKAR ALSAADY, HONORS STUDENT SRI NARAYAN-SARATHY, SANDEEP KULKARNI, PEPSICO JOHN HOCKMAN MINERALS TECHNOLOGY BASF, OMNVOA, MICHELMAN, SUN CHEMICAL, AND OTHERS

4 THE PACKAGING CHALLENGE CAN WE GET BETTER AT TRANSPORTING, STORING, AND SELLING FOOD? FOOD WASTE IS A BIG PROBLEM. LITTER AND PLASTICS IN OCEANS IS ALSO A BIG PROBLEM. LANDFILL SPACE. 8 million tons of plastic dumped in ocean every year Flexible packaging market 2009 was $71 billion. 4

5 TYPICAL OPAQUE LAMINATED FILM Cross-Section Function EPB Copolymer Sealing Print Film Lamination Layer Polypropylene Print LDPE Metal Layer Clarity Graphics Inter-layer Adhesion Barrier Recycle? Decompose? Al layer, impact? Barrier Film Polypropylene Stiffness EPB Copolymer Sealing inside Flexible packaging is more complex than it appears.

6 CELLULOSE NANOFIBERS TO SAVE THE DAY. THOMPSON-REUTERS TOP 10 INNOVATIONS BY 2025 BIODEGRADABLE PACKING WILL BE THE NORM. PACKAGING WILL BE MADE OF CELLULOSE MATERIALS THAT ARE PLASTIC-LIKE BUT ACTUALLY MADE OF PLANT MATTER SO IT'S BIODEGRADABLE AND BETTER FOR THE ENVIRONMENT THAN THE PLASTIC BAGS WE CURRENTLY USE AT GROCERY STORES.

7 PATENTS ON NANOCELLULOSIC MATERIALS Rheology modifier Emulsifier Strength additive in paper/composites Aerogels Transparent nanopaper Cell growth matrix Membrane filter Barrier coatings/films SciFinder combined answer set: (microfibrillated cellulose, microfibrillar cellulose, cellulose microfibrils, nanocellulose, nanosized cellulose, nanofibrillated cellulose, nanofibrillar cellulose, cellulose nanofibrils, cellulose nanofibers, cellulose nanoparticles, nanoparticle cellulose, cellulose nanofillers, cellulose crystallites, cellulose microcrystals, cellulose nanocrystallites, cellulose nanocrystals, nanocrystalline cellulose, cellulose nanowhiskers, bacterial cellulose, bacterial nanocellulose). Document type: Patent Åbo Akademi University Domkyrkotorget Åbo

8 KEY IDEA: USE CELLULOSE NANOFIBERS TO DO WHAT THEY ARE GOOD AT OXYGEN AND GREASE BARRIER LAYER MANY HAVE REPORTED THE GOOD OXYGEN BARRIER PROPERTIES OF CELLULOSE NANOFIBERS (CNF) OR SIMILAR MECHANICALLY PRODUCED MATERIALS ALSO CALLED MICROFIBRILLATED CELLULOSE (MFC). O 2 BARRIER IS BETTER THAN MOST PLASTICS! GOOD GREASE BARRIER AS WELL. CNF PRODUCED WITH UMAINE METHOD IS LOW COST HOWEVER, CNF IS NOT A GOOD WATER VAPOR BARRIER. USE OTHER LAYERS FOR THIS. IF CNF IS 1% BY WEIGHT OF THE PACKAGE, AND 10% OF THE FLEXIBLE PACKAGING MARKET WAS REPLACED, THEN AT LEAST 35 MILLION TONS/YR OF CNF WOULD BE NEEDED. * * Assuming raw material costs are half the cost of packaging market and PP prices.

9 Nanocellulose Films Barrier Performance Maybe we can avoid Al layer!! Lavoine et al., Carbohydrate Polymers 2012, 90(2),

10 WE CAN APPLY CNF AS A COATING OR AS A TOP LAYER ON MACHINE. BLADE COATING, MOHAMMAD MAZHARI MOUSAVI, MEHDI TAJVIDI, DOUGLAS W. BOUSFIELD, 2017 TAPPI NANOTECHNOLOGY CONFERENCE. SLIDE DIE COATING, KUMAR, BOUSFIELD, TOIVAKKA, 2017 PAPERCON. ON TOP PAPER DURING FORMING. BILODEAU AND OTHERS Inlet Distribution Slot gap channel Schematic of slot die Substrate SWG Suspension feed Slot dye CNF Backing roll Slot die Adjustable rail

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12 SEM OF THE SURFACE OF COATED PAPER (CROSS SECTION) gcnf3%/cmc-coated paperboard at 2 different magnification Key point - CNF stays as a layer and does not sink into the paper sheet. Similar results to Kumar et al. (2017). Plastic like surface. 12

13 WVTR (g/m 2 day) WVTR (g/m 2 day) EXAMPLE RESULTS 350 Poor result from coat beading May not relate to polymer type CNF containing paper folded samples unfolded samples Light weight paper latex weight (g/m 2 ) 250 folded samples unfolded samples 200 Good results Paperboard latex weight (g/m 2 )

14 QUESTIONS? SUGGESTIONS? THANK YOU FOR YOUR ATTENTION