ZealaFoam A Functional Alternative to Polystyrene Foam

ZealaFoam A Functional Alternative to Polystyrene Foam

Outline Biopolymer Network Ltd The ZealaFoam process Fish box production and testing Scale up and current research

Biopolymer Network Limited

Biopolymer Network Limited New Zealand research company Established 2004 Research & Technology Focus NZ Natural Extracts & their Biopolymer Products plastics coatings cosmetics ultrafine starches and functional proteins tannin Non wood Natural Fibres & Biocomposites Thermoset Biobased Resins Biofoam Technologies

The ZealaFoam Process

The ZealaFoam Process Use commercial polylactic acid (PLA) beads Particle foam approach Drop in technology for polystyrene moulders CO 2 as a "green" blowing agent Patented US 8283389, also granted NZ, Australia, China and Japan. Pending Canada, Europe.

ZealaFoam Process Impregnated with CO 2 Pre foamed with heat Fused with heat

ZealaFoam Technology: Impregnation Commercial PLA beads Liquid CO 2 as a "green" blowing agent Low pressures / ambient temperatures Short impregnation time

ZealaFoam Technology: Pre foaming Impregnated PLA beads heat (steam, water, air) do not instantaneously foam short foaming time (size / density / temp dependant) do not need a second impregnation after being pre foamed

ZealaFoam Technology: Moulding Pre foamed PLA beads Rapid moulding Current density >24 g/l No additional chemicals/materials required

Our ZealaFoam technology: Final foam Fine cell structure

ZealaFoam : Molecular weight distribution Molecular weight of PLA not compromised during prefoaming or moulding PLA original PLA extruded PLA pre-foamed PLA moulded

Lab Scale Impregnated with CO 2 Pre foamed with heat Fused with heat

Pilot Plant CO 2 Impregnation Easy to use 1 tonne pallet of beads Colour for difference

Pilot Plant Impregnation Recycling of CO 2 critical for cost Adapted existing equipment to process Easy installation and operation Small footprint actual and environmental

Pilot Plant Pre foaming Density determined by pre foaming Impregnated beads Pre foamer Pre foamed beads

Pilot Plant Moulding Approx 43 L Fish Box 750 x 330 x 240 mm (L x W x H)

Fish Box Production and Testing

Export Simulation Trials Use current export packing methods Fresh fish packed directly on ice Simulate temperature profile (NZ Singapore 38 hours) Record temperatures both inside fish and internal box wall temp Compare ZealaFoam and EPS performance

Export Simulation Results Mean Air Temp at Surface of Boxes Mean EPS Internal Wall Temp Mean ZealaFoam Internal Wall Temp

Export Simulation Results Mean Air Temp at Surface of Boxes Mean EPS Fish Temp Mean ZealaFoam Fish Temp

Mechanical Testing Trials Industry driven property testing Lab testing based on industry standards Densities of EPS / ZealaFoam boxes differed

ZealaFoam Mechanical Properties At 25 g/l EPS ZealaFoam TM Shear modulus (MPa) 3.2 3.0 Shear strength (MPa) 0.12 0.11 Shear stress, maximum (MPa) 0.17 0.18 Cross-breaking strength (kpa) 327 418 Density (g/l) Thermal conductivity (W/m.k) EPS ~30 0.032 ZealaFoam TM ~30 0.032

Stack Test 18 kg of PLA inside Compression tested at 10 mm/min Buckling at maximum load Max load at ~12 kn GOOD AS 2582.3

Drop Test 25.3 kg of PLA inside Box put in freezer for 24 hours Box dropped 3 times from 500 mm (on corner, short edge and long edge) AS 2582.4 PASS

Puncture Test A 7 kg, 40 mm diameter dart was dropped from 100 mm onto a 150 mm diameter plastic disk Repeated on each surface and inspected for indentation PASS IATA Dangerous Goods Regulation 42 ed Paragraph 6.5.2

Scale up and Current Research

Commercial Scale up Challenges Beads may require resizing Impregnation required Looks like EPS, uses same equipment but Very different processing windows impregnation pre foam mould Different processing parameters temp / pressure Foam not as heat tolerant

Current Research Ongoing research program Use of additives to alter properties Addition of biomass

Use of Additives to Alter Properties Foaming increases HDT of PLA Modifying PLA can increase the HDT of PLA foam 0-0.5 Extension (mm) -1-1.5 PLA (4060D) 1.5mm PLA + Additive 1 PLA + Additive 2-2 Temperature (C)

Addition of Biomass Biomass can be added to PLA prior to impregnation Successful pre foam and mould Reduce cost and alter properties Further work on going

Acknowledgements