Biome Bioplastics to Explore Bio-based Alternative for Organic Chemicals Used to Produce Bioplastics

The UK's innovation agency, the Technology Strategy Board, has awarded a grant to a consortium led by Biome Technologies; to investigate a bio-based alternative for the oil derived organic chemicals used in the manufacturing of bioplastics.

The research will be undertaken by the group's bioplastic division Biome Bioplastics, one of the UK's leading developers of natural plastics, in conjunction with the University of Warwick's Centre for Biotechnology and Biorefining.

The £150,000 grant is part of the Technology Strategy Board's 'Sustainable high value chemical manufacture through industrial biotechnology' technical feasibility competition, which funds projects that apply sustainable bio-based feedstocks and biocatalytic processes in the production of chemicals.

The Technology Strategy Board has identified the potential of industrial biotechnology to help the chemical industry move away from a dependency on fossil resources to a bioeconomy based on renewable and biological compounds.

Although bioplastics are often based on natural materials, some oil-based chemicals are widely used in their manufacture to convey properties including mechanical strength, tear resistance and durability. Deriving these chemicals from a plentiful, natural source could significantly reduce costs, expand functionality and increase performance in bioplastics, enhancing their ability to compete with, and ultimately replace, conventional oil-based plastics.

One of the most interesting sources of these bio-based chemicals is lignin, the complex hydrocarbon that helps to provide structural support in plants. As a waste product of the pulp and paper industry, lignin is a potentially abundant feedstock that could provide the foundation for a new generation of bioplastics.

Biome has partnered with the University of Warwick's Centre for Biotechnology and Biorefining that is pioneering academic research into lignin degrading bacteria. Biome is working with the Warwick team to develop methods to control the lignin breakdown process to determine whether these chemicals can be extracted in significant quantities.

"The environmental and social concerns surrounding the use of fossil fuels and food crops make lignin a compelling target as a source of chemicals", explains Professor Tim Bugg, Director of the Centre. "Often considered a waste product, it may provide a sustainable source of building blocks for aromatic chemicals that can be used in bioplastics".

The government-backed Technology Strategy Board's grant will support an initial feasibility project to isolate a chemical from lignin to replace the oil-derived equivalent currently used in polyester that conveys strength and flexibility in some of Biome's products. The production of such bio-based polyester would reduce the cost and further enhance the sustainability of these products.

If the initial feasibility assessment is successful, building on this work, Biome will explore the possibilities for deriving a wide selection of bio-based aromatic chemicals from lignin, further reducing cost and expanding bioplastic functionality.

"The bioplastics market remains small compared to that of fossil-based polymers", comments Biome Bioplastics CEO Paul Mines. "Growth is restricted by the price of bioplastic resins being 2-4 times that of their petrochemical counterparts. We anticipate that the availability of a high performance polymer, manufactured economically from renewable sources would considerably increase the market".

Industrial biotechnology is firmly supported by the UK government as a means of opening up new, emerging and established markets to develop less carbon intensive products and processes. It poses a significant opportunity for the UK's chemical sector to maintain and increase its competitiveness through the development of efficient and sustainable ways of satisfying our chemical and material needs. The total value to the UK of using industrial biotechnology is estimated to be between £4bn and £12bn by 2025.

Source: Biome Technologies

Evonik's VESTAMELT® X1333-P1 GFR PA 6 Replaces Metal in Mercedes' Hybrid Component

Effectively immediately, Mercedes, a leader worldwide in the manufacture of automobiles, will be using the adhesion promoter from Evonik Industries in several of its mass-produced models. Although it is used inside the vehicle and thus concealed from view, the VESTAMELT®-based hybrid component performs an important job. The aluminum tubing connects both A-pillars together and supports the entire dashboard — from the steering wheel to the glove compartment.

These elements used to be welded or screwed together with metal connecting plates, a stable solution, but one that involves more weight. By contrast, VESTAMELT® X1333-P1, a co-polyamide, covers the aluminum tubing and joins the holding brackets made of fiberglass-reinforced polyamide 6 of the individual components to the tubing by means of an injection molding process based on melt-bonding. When this adhesion promoter is used, component weight can be dramatically reduced by up to 20% compared to conventional solutions.

"Together with automobile manufacturers, we're developing even more applications worldwide for VESTAMELT®," says Martin Risthaus, the global business manager for Lightweight Design at Evonik. "Structural components or doors, for example, still have considerable weight-saving potential." Machine construction and the construction industry are also examples of segments in which the VESTAMELT® concept can be applied to hybrid machine parts.

An EU Regulation requires that the emissions values of all vehicle fleets be drastically reduced by 2015. Replacing metal with plastic is an especially promising way to reach this weight-saving goal. The less a vehicle weighs, the less fuel it consumes, and thus the less carbon dioxide it emits.

Source: Evonik

Metabolix & Tianjin GreenBio Sign Heat Shrink Film Distribution & PHA Biopolymer Supply Agreement

Metabolix, Inc., an innovation-driven bioscience company focused on delivering sustainable solutions for plastics, chemicals and energy, announced that it has entered into a distribution agreement with Tianjin GreenBio Materials Co., Ltd. ("GreenBio"), a biomaterials company based in Tianjin, China. Under the terms of the agreement, Metabolix will distribute GreenBio's SoGreen™ heat shrink film in Europe and will be the exclusive distributor in the Americas. In addition to a distribution relationship, Metabolix and GreenBio have also signed a supply agreement for PHA biopolymers. Under the arrangement, GreenBio will supply PHA resins to Metabolix, which will extend the range and availability of the Company's PHA products.

"Tianjin GreenBio has developed a heat shrink film based on PHA biopolymers. This product complements our product slate aimed at film and bag applications and we expect will be of interest to customers in the U.S. and Europe seeking biobased materials and biodegradable performance," said Bob Engle, vice president, business and commercial development, biopolymers, at Metabolix. "With products and technology that are complementary, the distribution and PHA supply agreements mark a first step toward potentially working with Tianjin to develop additional PHA biopolymer products."

Tianjin GreenBio offers two grades of heat shrink film that is used to bind together items for packaging, shipping, and storage. One SoGreen product is designed to replace non-compostable PVC film often used to package boxed goods, software and other non-edible products. The other is designed to replace softer polyethylene films, also not compostable and often used for wrapping multiple items, often bulky and irregular in shape, such as packs of bottled water. The SoGreen heat shrink film resins (2001 and 3001) are certified by DIN CERTCO to meet the EN 13432 standard for compostable plastics.

"We are excited to work with Metabolix to gain greater exposure for our products in the Americas and Europe," said Dr. Lu Weichuan, chairman and president of Tianjin GreenBio. "Metabolix has extensive experience in biopolymers, and we look forward to working together to build the market for PHA-based biopolymer products."


Source: Metabolix

Zoltek, TCG Co-develop & Enhance CF Thermoplastic Products for Optimized Automotive Components

Zoltek Corporation and Thermoplast Composite GmbH of Germany announced that they are working together to develop and improve carbon fiber thermoplastic tapes and other carbon fiber thermoplastic products, based on Zoltek fibers and using TCG innovative process technologies, for structural applications for automotive and other industries. Co-developed carbon fiber thermoplastic tapes produced by TCG were on display at this year's JEC Composites Show.

These thermoplastic tapes, manufactured with Zoltek's Panex® 35 carbon fiber and using TCG's patented process technology, have the ability to be used as the primary reinforcement in structural parts or as localized reinforcement for injection molding applications. Strategic placement in localized areas in combination with injection molding processes produce low cost, structurally optimized composite parts with the potential to be used for seat backs, front end carriers, bumpers, doors, and other automotive components with complex geometries and high structural requirements.

With increased interest from the automotive industry in carbon fiber thermoplastic materials, Zoltek and TCG will continue to develop and improve these products and processes for expanded applications.


Source: Zoltek Companies, Inc.

Teknor Apex at Interwire 2013: To Unveil Rubber-like Medical Grade TPE Wire & Cable Compounds

Three new thermoplastic elastomer (TPE) wire and cable compounds from Teknor Apex Company combine the rubber-like durability and flexibility valued by hospital and clinical professionals and the high degree of purity required for meeting stringent medical standards, the company recently announced. Teknor Apex will introduce the compounds at Interwire 2013, April 22-25, (Booth 406).

Medalist® 8421, 8431, and 8451 elastomers can be used for insulation, jacketing, and molded fittings and connectors. They have Shore A hardness levels of 92, 69, and 82, respectively, a flammability classification of HB (UL-94), and a maximum continuous operating temperature rating of 105 °C (UL-1581). The three compounds retain high levels of tensile strength, tensile modulus, and elongation after autoclave, gamma irradiation, and EtO sterilization. They are resistant to the cleaning solutions commonly used in medical facilities.

The new TPEs are analogs to specific Elexar® non-medical wire and cable compounds from Teknor Apex and provide comparable properties, but they are manufactured in an ISO-13485 facility dedicated to Medalist medical elastomers. Medalist® 8421, 8431, and 8451 compounds pass ISO-10993-5 cytotoxicity testing, are RoHS- and REACH- compliant, and are free of animal-derived materials, phthalates, and latex proteins.

"The new Medalist elastomers for wire and cable provide rubber-like toughness and elasticity and, unlike rubber, are readily recycled," said Keith Saunders, senior market manager for the Thermoplastic Elastomer Division of Teknor Apex. "As alternatives to PVC, Medalist compounds exhibit practical handling advantages in surgical or clinical settings, including superior 'drapability' for reduced cable clutter, better elastic memory in coil cords, and a softer, more supple feel."



Source: Teknor Apex

A*STAR Researchers Develop Process to Convert Biomass into PLA Feedstock for Biomedical Products

Powered by sunlight, microalgae are tiny biofuel generators that soak up carbon dioxide to produce energy-rich lipids, which are showing promise as a potential source of clean energy. Maximizing lipid production is the focus of many research efforts, but the material remaining after lipid extraction has caught the attention of Md. Mahabubur Rahman Talukder and his co-workers at the A*STAR Institute of Chemical and Engineering Sciences. Currently, this 'lipid-depleted biomass' is either burned for energy, or simply discarded as a waste product. Talukder and his team have developed a process that turns this material into a valuable chemical feedstock.

The researchers have pioneered a two-step biochemical process that converts lipid-depleted biomass into lactic acid. This substance is in increasing demand as a feedstock for polylactic acid (PLA), a biopolymer with numerous medical applications, ranging from surgical sutures to orthopedic implants. The high cost of raw materials used in the manufacture of lactic acid currently limits PLA use. Thus, producing an alternative source from algal lipid-extraction waste is proving attractive. Generating two valuable products from the algae, specifically the microalgae Nannochloropsis salina, would spread the costs of microalgae production, making the biofuel more cost-competitive with conventional fuels.

To produce both lipid and lactic acid from N. salina, Talukder and his co-workers first subjected the microalgae to an acid hydrolysis pre-treatment step. This process broke down the organisms' polysaccharide-based cell walls into simple sugars, while releasing the lipid for extraction. The researchers also systematically examined different acid concentrations, reaction times and temperatures. They identified that treatment for 1 hour at 120 °C maximizes sugar and lipid production.

When Talukder and his co-workers extracted the lipid at this point, the lipid-depleted biomass, now rich in sugars remained. They converted this material into lactic acid by fermentation. The team then added the bacterium Lactobacillus pentosus, which consumed the sugars over a 48-hour period, to generate the lactic acid.

The researchers found that, to maximize lactic acid production, they first had to remove metal ions from the mixture. Microalgae harvesting typically involves an iron chloride treatment, but the residual iron appeared to inhibit fermentation. "One of the next steps in our research will be to develop a chemical-free microalgae harvesting method so that fermentation will not be negatively affected," Talukder says. The researchers are also screening different bacterial strains for higher lactic acid productivity, and developing their current two-step process into a single-step operation.

The A*STAR-affiliated researchers contributing to this research are from the Institute of Chemical and Engineering Sciences


Source: A*STAR Research

Natureplast & Biopolynov Develop Customized Bioplastics Formulations from Seaweed

Natureplast, a French company specialized in bioplastics, has developed with its daughter company, Biopolynov, a brand new range of bioplastics made from non-food resources.

Established in late 2006, Natureplast is still the only company in Europe to supply European industries with bio plastics produced throughout the world. Natureplast's expansion led us to expand expertise with the creation of Biopolynov in 2010, the first research and development laboratory in Europe dedicated to bio plastics. This new division aims to modify and improve bio plastics' properties according to a functional book of specifications.

For more than ten years, the bio plastics market has been experiencing strong growth (20% per year). This growth comes from the continued development of new materials/additives and the creation of new production units throughout the World. However, today's bio plastics materials cannot always fulfill market demand.

To resolve this lack, Biopolynov develops customized formulations that meet processing and use constraints of the bio plastics produced for manufacturers (extruded wrap, injected/ thermoformed/ blowed parts.

Since 2010, in order to find alternatives to raw materials currently used (cereals/sugar...), Biopolynov has been developing new innovative bio plastics made from vegetative resources like seaweed or co-products of food-processing (olive seed powder??, resources that aren't in competition with food use. Biopolynov's formulation know-how has allowed developing bio based and bio degradable substitutes to conventional polymers like polypropylene for injection molding or thermoforming markets.

These new steps are intermediate stages while waiting for the second generation of bio plastics totally made from seaweed, cellulose, food waste and are scheduled to arrive on the market in 5 to 10 years' time.

Source: Natureplast