CARBIOS’ Enzymatic Solution for PLA Biodegradation Gets Food Contact Approval by FDA

CARBIOS announced that CARBIOS Active, its enzymatic solution for the biodegradation of PLA, is included in the U.S. FDA Inventory of Effective Food Contact Substances (FCS) with the assigned Food Contact Notification (FCN) 2325, effective since February 29, 2024.

With this milestone, CARBIOS Active can be used to make packaging materials that are sold in the United States. It can be used in food contact applications, including rigid and flexible packaging and other applications.

Produces PLA that is 100% Compostable at Room Temperature:

Integrated directly into plastic conversion processes, CARBIOS Active enables the creation of a new generation of PLA (polylactic acid). This PLA is 100% compostable, even at ambient temperature, without leaving toxic residues or microplastics. PLA made using this unique enzymatic solution is certified for industrial and home composting. CARBIOS Active was recently certified by the Biodegradable Products Institute (BPI), North America’s leading authority on compostable products and packaging. Food Contact Notification and BPI certification ensure the quality of CARBIOS Active. It provides brand owners and industrial composters with a reliable solution for designing and marketing fully biodegradable packaging, aligning with circularity commitments.

"For CARBIOS, product safety is a top priority and we consider FCN from the FDA as the gold standard. The US is a key market for CARBIOS’ biodegradation solution and we expect the FCN clearance to drive significant additional demand in North America in 2024. Well done to the teams from our biodegradation division for their relentless efforts," said Emmanuel Ladent, CEO of CARBIOS.

"CARBIOS is strategically forging commercial partnerships for its biodegradation solution with a specific focus on the US market. The consumer growing willingness to pay for green combined to increasing EPR regulations are putting pressure on brands and packaging industries to market more sustainable products, and CARBIOS Active answers their needs for improved circularity," said Stuart MacDonald, senior advisor for CARBIOS Biodegradation Division, North America.

Source: Carbios/omnexus.specialchem.com

Storage compartment demonstrates lightweight potential of sandwich construction

ENGEL Austria GmbH, ThermHex Waben GmbH, Edevis GmbH and the Fraunhofer Institute for Microstructure of Materials and Systems IMWS have produced a storage compartment flap for a truck interior in sandwich construction in a recently completed project. The flap, made from thermoplastic sandwich semi-finished products, demonstrates the enormous potential for saving weight with thermoplastic sandwich molding technology and its suitability both for molded components and for use in large-scale production.

The use of fibre composite materials and in particular the sandwich construction method offer particularly great potential for lightweight construction applications in commercial vehicles. Such sandwich structures consist of highly rigid and strong cover layers and a lightweight core. In addition to high material efficiency, this combination also enables very high weight-specific bending and buckling stiffness. The sandwich architecture is therefore also suitable for heavy-duty structural components, for example in aircraft and vehicle applications. It enables potential weight savings of up to 70 percent compared to monolithic structures, with a load-bearing capacity of the components that corresponds to or even exceeds that of (significantly heavier) metallic components.

One challenge to date has been that these components can hardly be manufactured in large-scale production processes. The use of thermoplastic fibre composite sandwich semi-finished products can be the solution here. These can be produced efficiently in continuous processes and turned into components in automated manufacturing processes. The participants in the joint “HyWaSand” project, which has now been successfully completed, have shown what is possible with this.

A flap for a storage compartment in a truck cabin was produced as a demonstrator. “We wanted to prove that the sandwich construction method with continuously produced thermoplastic sandwich semi-finished products is possible for such applications. Together with our partners, we succeeded,” says Dr. Ralf Schlimper, who led the project at the Fraunhofer IMWS.

The thermoplastic sandwich molding technology developed at the institute proved to be particularly valuable in achieving this goal. This is based on a new type of thermoforming process and was developed specifically for the fully automated production of continuous fiber-reinforced sandwich components with a thermoplastic matrix in large series. Thermoplastic sandwich semi-finished products, consisting of a thermoplastic honeycomb core and cover layers of fibre-reinforced thermoplastic UD tape laminates, are heated in an infrared oven and, after automated transfer to the molding tool, 3D thermoformed and functionalized by means of injection molding.

“The TS molding technology proved to be very efficient in our project. We were able to show that it enables the efficient production of 3D-molded and functionalized lightweight components in sandwich construction in the injection molding cycle, i.e. with cycle times of around one minute. This shows the potential for further fields of application, such as the car body sector,” says Schlimper.

In the project, ThermHex Waben GmbH focused primarily on the development of hybrid sandwich semi-finished products with a small cell width and functional polymer and metal foils to improve the surface quality. In addition, the new development of continuously manufactured semi-finished sandwich products with even lower material usage was driven forward. In conjunction with the necessary adaptation of the manufacturing process to make it suitable for series production, it was possible to achieve a further reduction in costs and weight compared to the previous standard configurations and non-recyclable material alternatives from reaction injection molding (RIM) processes. At the semi-finished product level, 30 to 45 percent of the weight can be saved with the same material thickness or up to 22 percent of the weight with comparable mechanical performance and greater material thickness. This improved resource efficiency in the use of materials also has a proportionally positive effect on material costs and CO2 emissions.

In test structures, the project was able to demonstrate that components with Class A surfaces, which are particularly important for the automotive industry, can also be manufactured from thermoplastic semi-finished products in sandwich construction. Progress was also made for metal-plastic hybrid sandwich materials as part of the “HyWaSand” project, for example the lamination of test structures with metallic cover layers within the TS molding process.

“There are still open research questions here that we want to continue working on. This makes it all the more valuable that we have made great progress in the project in providing virtual engineering methods for process and component development and have also developed feasible test tools for various common component design features. The new possibilities for inline inspection and for suitable non-destructive testing methods to ensure component quality also enable us to rapidly bring the technology even closer to application in various cost- and weight-sensitive areas,” says Schlimper.

“We are currently investigating the transferability of the results to customer development projects in order to facilitate entry into new market segments,” says Matthias Biegerl, who led the project at ElringKlinger. “The potential is huge. By manufacturing the components in large series, cost-efficient lightweight structures for interior and body components can be produced.”

The demonstration at JEC World 2024 has already generated a lot of interest. The project partners will also present the component and the technology at the Composite Sandwich Conference on April 24-25, 2024 in Halle (Saale).

source:www.thermhex.com/www.jeccomposites.com

Today's KNOWLEDGE Share:Microbial decomposition of biodegradable plastics on the deep-sea floor:

Today's KNOWLEDGE Share

Microbial decomposition of biodegradable plastics on the deep-sea floor:

Microbes can decompose biodegradable plastics on land, rivers and seashore. However, it is unclear whether deep-sea microbes can degrade biodegradable plastics in the extreme environmental conditions of the seafloor. Here, we report microbial decomposition of representative biodegradable plastics (polyhydroxyalkanoates, biodegradable polyesters, and polysaccharide esters) at diverse deep-sea floor locations ranging in depth from 757 to 5552 m. The degradation of samples was evaluated in terms of weight loss, reduction in material thickness, and surface morphological changes. Poly(L-lactic acid) did not degrade at either shore or deep-sea sites, while other biodegradable polyesters, polyhydroxyalkanoates, and polysaccharide esters were degraded.

Biodegradation at the deep-sea floor:

We investigated the decomposition of representative biodegradable plastics (PHA, biodegradable polyesters, and polysaccharide esters) at the above-described five deep-sea floor locations. Injection-molded samples and films were placed in custom-made sample holders and mesh bags, respectively, and were placed on the deep-sea floor in a condition that prevented physical deformation [samples were placed in polyethylene terephthalate (PET) containers with holes, protected by tennis nets. Installation in the deep-sea and recovery of the samples were performed aboard the Shinkai 6500 human-occupied vehicle (HOV) using a robotic arm. The seafloor soil immediately below the samples was also recovered using a custom-made core and used for microbiological analysis.

Biodegradation of biodegradable polyesters at the deep-sea floor:

The picture shows the overall shapes and morphology of poly[(R)−3-hydroxybutyrate-co-(R)−3-hydroxyhexanoate] (PHBH) injection-molded samples placed on shore (PJM12) and off Hatsushima Island (BHT14) and Minamitorishima Island (AMN13) for approximately 1 year. The PHBH sample shown as an example is one in which degradation had progressed relatively well compared with other samples. The photographs taken from the top and the end after ultrasonic washing and drying, revealed that no physical deformation had occurred. Furthermore, it was confirmed by X-ray diffraction that the crystal structure of samples remained unchanged during the submersion periods at the deep-sea floor and experimental processing. Scanning electron microscopy (SEM) images show the surface profiles after removal of microorganisms from the surface. Whereas the surface morphology before degradation (original) was very smooth, the surfaces of the samples after placement on the shore or the deep-sea floor were observed to be uneven, and degradation was in progress.

source:https://www.nature.com/articles/s41467-023-44368-8

Today's KNOWLEDGE Share:Carbon fibre Catamaran

Today's KNOWLEDGE Share

Cure Marine’s new 70-foot all-carbon fibre catamaran has embarked on her maiden journey

Australian Sunshine Coast boat building company Cure Marine has unveiled the ‘Cure Custom 70’, a 70-foot all-#carbonfiber catamaran, billed as ” the first of its kind built in Australia over the past five last years.”

The catamaran was crafted within Cure Marine’s state-of-the-art facility at Coolum Industrial Estate using high-tech equipment, including the southern hemisphere’s largest #3dprinter . The 3D printer provided by sister company, Zone RV, enabled Cure Marine to produce tooling and prototypes in a fraction of the time that the industry traditionally had seen.

Cure Marine CEO Carl Bird said the launch marked the beginning of a new era for the company. “The ‘Cure Custom 70’ is the largest sailing vessel ever launched by #CureMarine and indeed the first all-carbon sailing catamaran to be launched in Australia in the last five years”, Carl Bird said. “The launch not only reinforces Cure Marine’s commitment to innovation but also solidifies our position as a major player in the industry.”

Founded in 2005 by Sunshine Coast locals Dave Biggar and Ian McMahon, Cure Marine began as an ambitious project to create a leading composites facility and deliver high-end sailing vessels for the recreational market. Alongside sister companies Zone RV and One Composites, Cure Marine is dedicated to elevating the Australian Marine Industry with continuous innovation and quality craftsmanship.

source:www.curemarine.com.au/jeccomposites.com

Today's KNOWLEDGE Share: PyroWall™ technology

Today's KNOWLEDGE Share

Revolutionizing fire proof protection and sustainability for FRP products – PyroWall™ technology

The introduction of ALEC² PyroWall™ has revolutionized fire protection in the FRP manufacturing industry, ushering in a new era of safety. Since its launch, ALEC² PyroWall™ has driven a significant improvement in fire protection standards, prioritizing safety and raising the bar for the entire FRP industry.

This revolutionary fireproof material, unlike any FRP composite material on the market, offers remarkable protection for FRP products against heat and fire events. This fireproofing capability paves the way for a significantly safer and more sustainable future across diverse FRP applications and industries.

A game-changer for FRP products and applications

ALEC² PyroWall™ fundamentally transforms fire protection for FRP products by providing a fireproof barrier. This is particularly crucial for sectors like:

Infrastructure construction

ALEC² PyroWall™ enhances the fire safety of new infrastructure components like building panels and cladding.

Infrastructure repair

Professionals can use ALEC² PyroWall™ to provide fireproof protection for FRP used to retrofit existing infrastructures and augment long-term safety.

Unlike traditional fire-resistant FRP, ALEC² PyroWall™ boasts:

• Zero Burn Rate – Eliminates the risk of ignition or fire propagation even in extreme heat.

• Unmatched Safety – Safeguards people and assets from impacts of fire events.

• Enhanced Structural Integrity – Maintains its form and characteristics during extreme heat and fire events, preventing catastrophic failures of the FRP being protected.

• Stops Fire Damage – properly protected FRP structures and/or products will not experience any significant impact.

Composite circularity and sustainability redefined

Beyond its exceptional fireproof capabilities, ALEC² PyroWall™ also achieves a remarkable 100% circular lifecycle:

• Closed-Loop System – Enables infinite recycling and reuse, eliminating reliance on virgin materials and landfill waste.

• Recycled Content – Composed of ~85% recycled industrial waste, it maximizes waste recovery and reuse and minimizes environmental impact.

• 100% Reusable – At end of use PyroWall™ can be easily recycled and processed into new products.

A safer and circular option for manufactured FRP composites used in diverse industries

The unique combination of fire proof safety and sustainability offered by the ALEC² PyroWall™ material empowers various industries to enhance their circular and sustainable composite materials goals:

Construction

From fireproofing building components and cladding to safer FRP infrastructure products, ALEC² PyroWall™ elevates fire safety to a new achievable standard in the built environment.

Manufacturing

Fireproofing FRP enclosures can significantly enhance people and asset safety in facilities.

source:www.alec2.com/jeccomposites

Today's KNOWLEDGE Share:Bio-circular Torayca carbon Fibre

Today's KNOWLEDGE Share

Toray Carbon Fibers Europe to supply bio-circular Torayca carbon fibre for HEAD’s prototype racquets

Toray Carbon Fibers Europe and HEAD are leaders in producing premium high-performance products and are committed to reducing the carbon footprint of their activities. The decision to build a partnership to develop new racquets was also based on Toray’s ability to provide bio-circular carbon fibre (mass balance approach) for this project. Toray Carbon Fibers Europe recently obtained ISCC PLUS certification in September 2023 and is able to supply bio-circular carbon fibre using the mass balance approach. Therefore, products manufactured with bio-circular carbon fibre will emit less CO2.

As an environmentally responsibly oriented sporting goods manufacturer, HEAD recognizes there is much more to be done to reduce harmful emissions and protect biodiversity. For HEAD, the goal is to achieve maximum sustainability in all its processes, from manufacturing to shipping. HEAD has initiated the development of prototype racquets using Toray’s bio-circular carbon fibre (mass balance approach) as part of the HEAD ReThink programme to create performance products designed to reduce their impact on the environment.

Part of the Toray Group’s Sustainability Vision for 2050 is to create a world where resources are sustainably managed. The Toray Group aims to build a new materials eco-system that harnesses bio-circular raw materials to make products that at the end of their lifecycle are able to be repurposed or recycled. In providing innovative materials, Toray is actively contributing to addressing global issues and is implementing its corporate philosophy to ‘contribute to society through the creation of new value with innovative ideas, technologies and products’.

‘Toray Carbon Fibers Europe is the European leader in premium carbon fibre and has a strong commitment to carbon neutrality. We are committed to consistently supplying our customers with the most advanced technology in a socially responsible way, thus providing value to society.

Pickleball is an indoor or outdoor game that is played on a level court with short-handled #paddles and a perforated #plasticball.

A mass balance approach is one in which raw materials with certain characteristics (an example being biomass-derived) are mixed with other raw materials (such as petroleum-derived ones) in the processing and distribution process, from raw materials through to finished products. Characteristics are assigned to part of a product in line with the input proportions of raw materials with those characteristics.

ISCC PLUS certification allows us to declare that Toray products are made from biomass or recycled raw materials in a mass balance approach.

‘Bio-circular’ means that the raw materials used to manufacture #carbonfiber are sourced from recycled and/or natural materials such as #sugarbeet waste.

source:www.toray-cfe.com/jeccomposites.com

Today's KNOWLEDGE Share:Max Shear Rate

Today's KNOWLEDGE Share

Sorry to disappoint some of you, but there is NO such a thing as Maximum admissible Shear Rate for a material in Injection Molding.

30+ years back, Colin Austin (Moldflow founder) wanted to put a recommendation in the code documentation and, having no clear answers from suppliers (including me at Solvay) he decided to list some values that were loosely based on a wild guess exercise. Actually an estimated typical shear rate (at some standard T) for a critical Shear Stress equal to an arbitrary fraction (abt 10%) of a Stress at break in the solid state. How wild is that ??

Shear rate does not destroy a polymer.

If chains break, that is due to Shear Stress, not shear rate. If they degrade thermally, it is the result of accumulated shear-heating along the flow. In both cases, shear rates alone CANNOT resolve the risk of damaging the material.

At low temperature (high viscosity hence higher stress) a lower shear rate can be more dangerous than a higher rate at a higher temperature (lower viscosity so potentially much lower stress).

So if you want to say something about the injection rate being too fast, check the stresses or the melt temperature increase. A high shear rate will be a warning signal, at best.

Source:Vito leo