Klöckner Pentaplast launches lightest-in-class MAP tray - kp Elite® Nova

#Klöckner Pentaplast (kp), a global leader in rigid and #flexiblepackaging and specialty film solutions, has announced the launch of kp Elite® Nova, a next generation modified atmosphere packaging (MAP) tray that is the lightest in its class.

The tray uses a unique ribbed design to add strength in critical areas, while keeping weight and material use to a minimum, making it around 10% lighter than any other tray in its category - without compromising on barrier performance, sealing integrity, or mechanical strength. Developed using finite element analysis, kp Elite® Nova is ideal for high-speed automated protein packing lines and represents a step forward in sustainable food packaging.

We’re proud to reveal kp Elite® Nova; a breakthrough tray that reflects over 60 years of packaging innovation and technical excellence,” said Paul Rawlings, Launch Manager at kp Food Packaging. “With kp Elite® Nova, food producers no longer need to compromise between sustainability and performance.

This solution delivers both. The design is endorsed for recyclability by the Tray Circularity Evaluation Platform (TCEP) and is aligned with European Design for Recycling (D4R) guidelines, while still offering remarkable sealing and shelf-life performance.

kp Elite® Nova is made with up to 100% recycled PET, including material from kp’s revolutionary Tray2Tray® initiative, which creates a closed recycling loop for food trays. It is available in a variety of sizes and depths and designed with the realities of food production and logistics in mind.

At kp, we’re committed to improving access to circular solutions, by removing barriers that might prevent customers from making the switch,” Paul added. “In a market where EPR fees are taking effect, every gramme of packaging material counts. kp Elite® Nova is leading the protein industry’s lightweight, recyclable pathway to a more sustainable future. It’s a tray that’s built for today but is ready for tomorrow.

source : Klöckner Pentaplast

Today's KNOWLEDGE Share : Toray makes breakthrough in photosensitive polyimide

Today's KNOWLEDGE Share

Toray makes breakthrough in photosensitive polyimide

#Toray Industries has developed the STF-2000, a photosensitive polyimide solution that enables high-aspect-ratio fine patterning with 30-micrometer line widths in films up to 200 micrometers thick.

 

This breakthrough came from applying advanced high-sensitivity negative-tone formulation and proprietary photoresist design technology, which controls curing stress.

High-performing and sustainable

 STF-2000 retains the inherent advantages of a polyimide structure. These include excellent resistance to heat and chemicals, mechanical strength, insulation, and X-ray durability. At the same time, it enables fine microfabrication with aspect ratios of up to 7.

 

Sustainability is also in the engineering of STF-2000. Toray formulated STF-2000 without PFAS and adopted an alkaline development process that avoids organic solvents. The new material is free of N-Methyl-2-pyrrolidone (NMP) and per- and polyfluoroalkyl substances (PFAS), helping to shrink the environmental footprints of electronic components, micro-electromechanical systems (MEMS) devices, and other applications.

 

Thick film sheet version available

 While the standard formulation of this material is as a solution, Toray is developing a thick-film sheet version. Customer evaluations are underway with a view to commercialization during fiscal 2025.

STF-2000 has overcome four key challenges for thick-film photosensitive materials, including deformation and cracking, incomplete ultraviolet curing, inadequate development, and foreign particles and interlayer delamination.

 

Thick film for electronics industry

Applying the new material to form thick films could enhance insulation of electronic components and support high-aspect-ratio wiring. In structural material applications, it will offer engineers greater design flexibility for microstructures using #photolithography so they can develop more advanced MEMS devices.

 

The material will simplify manufacturing by forming thick-film patterns through a single coating, exposure, and development step, thus boosting productivity and helping cut process costs.

This material also delivers high-resolution patterning with line/space ratios of 4 micrometers or less in the 10-30 micrometer film thickness range traditionally served by conventional polyimides.

source : Toray/Adsale Plastics Network

 

Today's KNOWLEDGE Share : innovative 3D-printed PEKK (poly-ether-ketone-ketone) technology for implants

Today's KNOWLEDGE Share

Medella Northwest:

We are thrilled to share a groundbreaking case recently performed in collaboration with Oxford Performance Materials (OPM), utilizing their innovative 3D-printed PEKK (poly-ether-ketone-ketone) technology. This case marks an advancement in orthopedic care, showcasing the remarkable benefits of PEKK implants over traditional metal implants.

Our commitment to cutting-edge solutions led us to partner with OPM to deliver a patient-specific PEKK implant tailored to address a complex orthopedic challenge.

Why PEKK Outshines Metal Implants:

Bone-Like Mechanics: Unlike metal implants, which can be overly rigid and cause stress shielding, PEKK’s mechanical properties closely mimic cortical bone. This promotes natural load distribution, reducing the risk of bone resorption and enhancing long-term implant stability.

Enhanced Osseointegration: PEKK’s unique surface promotes protein adsorption, facilitating superior bone cell attachment and growth. This leads to faster, more complete bone ongrowth compared to metal, accelerating healing and improving outcomes.

Metal-Free Biocompatibility: PEKK eliminates risks associated with metal hypersensitivity offering a safer option for patients with sensitivities. It does not corrode or produce metallic debris, ensuring long-term safety.

Radiolucency for Better Imaging: PEKK’s radiolucency allows for clear post-operative imaging, enabling precise monitoring of bone healing without the interference often seen with metal implants.

Inherent Antibacterial Properties: Studies show PEKK significantly reduces bacterial colonization compared to metal, making it ideal for high-risk cases like joint revisions or trauma, minimizing infection risks.

Modifiable in the OR: Unlike rigid metal implants, PEKK implants can be adjusted during surgery, offering surgeons flexibility to achieve a perfect fit for each patient.

source: Medella Northwest

Today's KNOWLEDGE ShareEfficient circular economy: Plasma-based process for the recycling of GRP:

Today's KNOWLEDGE Share

Efficient circular economy: Plasma-based process for the recycling of GRP:

The Leibniz Institute for Plasma Science and Technology (INP) is developing an innovative method for the sustainable recycling of glass fibre reinforced plastics (GRP) as part of the PLAS4PLAS joint project. In cooperation with the Institute for Environment & Energy, Technology & Analytics e.V. (IUTA) and the TU Bergakademie Freiberg, the research team is working on an emission-free & residue-free recycling process based on thermal plasma. The project, which will run until 2029, is being funded by the Volkswagen Foundation with 1.37 million euros.

Challenge: Complex GRP waste

GRP is widely used in aviation, vehicle construction and wind turbines. Their composite of plastic and glass fibres makes recycling extremely difficult. Until now, major part of GRP waste has ended up in landfill sites or has been used as filler or fuel  with negative environmental consequences such as CO₂ emissions and the release of pollutants.

Sustainable solution through plasma technology:

The planned process is based on an allothermal gasification process in which thermal plasma is used. In this process, the working gas is heated to several thousand degrees Celsius & serves as an extremely hot medium that breaks down the plastic into its components. In contrast to conventional incineration, the required heat is supplied from the outside so that the plastic is gently converted into syngas, which serves as a raw material for the production of new plastics.

At the same time, the suitability of the remaining glass content for the manufacture of other products is being investigated, as well as the possibility of recovering other elements contained in the glass through process adjustments. In this way, we want to create a genuine circular economy that significantly reduces raw material consumption and CO₂ emissions.

Technical feasibility, scaling and acceptance:

A central goal of the project is to optimise thermal plasma technologies for the specific requirements of GRP waste. The recycling process will be evaluated both ecologically and economically in order to ensure its sustainability and efficiency. In addition, the technical basis for scaling up the process and developing a large-scale GRP gasification reactor is being developed.

In addition to the technical implementation, the project is also investigating the long-term effects of plasma technology on the supply of raw materials for fibre-reinforced plastics. The extent to which the process influences existing branches of industry such as the chemical industry, GRP production and metal processing is being analysed. At the same time, social acceptance plays a decisive role: the extent to which the recycling process is accepted by industry and society and what conditions need to be created for widespread implementation will be analysed.

source: Leibniz Institute for Plasma Science and Technology / idw nachrichten

Today's KNOWLEDGE Share : MIT, Freie Universität Berlin researchers develop mucus-inspired body glue

Today's KNOWLEDGE Share

MIT, Freie Universität Berlin researchers develop mucus-inspired body glue

Researchers from MIT and Freie Universität Berlin drew inspiration from mussels’ gluey plaque and human mucus to create a biomedical adhesive that combines both waterproof stickiness and germ-proof properties.A paper detailing the team’s results appeared in February in the Proceedings of the National Academy of Sciences. The MIT authors included George Degen, Corey Stevens, Gerardo Cárcamo-Oyarce, Jake Song, Katharina Ribbeck, and Gareth McKinley, along with Raju Bej, Peng Tang, and Rainer Haag of Freie Universität Berlin. The U.S. National Institutes of Health, the U.S. National Science Foundation, and the U.S. Army Research Office helped fund the research.

“The applications of our materials design approach will depend on the specific precursor materials,” George Degen, a postdoc in MIT’s Department of Mechanical Engineering, said in an MIT news release.

“For example, mucus-derived or mucus-inspired materials might be used as multifunctional biomedical adhesives that also prevent infections. Alternatively, applying our approach to keratin might enable the development of sustainable packaging materials.

The research group focused on a chemical motif that appears in mussel adhesives: a bond between two chemical groups known as “catechols” and “thiols.” In the mussel’s natural glue, or plaque, these groups combine to form catechol–thiol cross-links, and that’s what enables the cohesive strength of the plaque. In addition, the catechols enhance a mussel’s adhesion, binding to surfaces such as rocks and ship hulls.

Thiol groups are also prevalent in mucin proteins, which are the primary non-water component of human mucus. Degen and his colleagues wondered whether mussel-inspired polymers could link with mucin thiols, enabling the mucins to quickly turn from a liquid to a sticky gel.

To test the concept, they combined solutions of natural mucin proteins with synthetic mussel-inspired polymers and observed how the resulting mixture solidified and adhered to surfaces over time.

“It’s like a two-part epoxy. You combine two liquids together, and chemistry starts to occur so that the liquid solidifies while the substance is simultaneously gluing itself to the surface.

Added Degan’s colleague Rainer Haag at Freie Universität Berlin: “Depending on how much cross-linking you have, we can control the speed at which the liquids gelate and adhere. We can do this all on wet surfaces, at room temperature, and under very mild conditions. This is what is quite unique.”

The team deposited a range of compositions between two surfaces and found that the resulting adhesive held the surfaces together, with forces comparable to the commercial medical adhesives used for bonding tissue. In addition, they tested the adhesive’s bacteria-blocking properties by depositing it onto glass surfaces and incubating the glass with bacteria overnight.

“We found if we had a bare glass surface without our coating, the bacteria formed a thick biofilm, whereas with our coating, biofilms were largely prevented,” Degen said.

The research team concluded in their paper abstract: “The results highlight the potential of catechol–thiol cross-linking as a versatile platform for engineering multifunctional glycoprotein hydrogels with applications in wound repair and antimicrobial surface engineering.”

The team says that with some fine-tuning, they can further enhance the adhesive’s hold. The result could be a strong and protective alternative to existing medical adhesives.

“We are excited to have established a biomaterials design platform that gives us these desirable properties of gelation and adhesion, and as a starting point we’ve demonstrated some key biomedical applications,” Degen said. “We are now ready to expand into different synthetic and natural systems and target different applications.

source : MedicalDesign & Outsourcing

Hexion and Bloom Pioneer Industry-First Renewable Adhesive Technology

Hexion, a global leader in adhesives, systems, and AI technologies for wood panel manufacturing, today announced a partnership with Bloom Biorenewables, a Swiss startup that has developed a breakthrough method for preserving the natural adhesive properties of #lignin. Together, the companies aim to commercialize a renewable, high-performance alternative to synthetic #adhesives—once thought to be beyond the reach of modern science.

#Bloom has developed a unique and cost-effective process for extracting native lignin, a naturally occurring adhesive found in wood, while maintaining its chemical structure. This is a significant scientific achievement: traditional methods for isolating lignin typically cause it to condense, destroying the reactive groups responsible for its adhesive strength and rendering it unsuitable for industrial use. Bloom’s method uses low-cost aldehydes during the extraction process to protect these critical chemical groups. As a result, the company can recover high-quality, uncondensed lignin at commercial scale an industry first.

This innovation opens the door to a new class of 100% plant-based adhesives that combine strong bonding performance while also being environmentally friendly. Not only are these adhesives safer for people and the planet, but they also help manufacturers extract up to 80% more value from the same wood feedstock by using parts of the tree that would otherwise be wasted.

“For decades, the industry has operated under the assumption that strong performance and full renewability couldn’t coexist in wood adhesives. This partnership shatters that assumption,” said Michael Lefenfeld, President and CEO of Hexion. “By combining Bloom’s breakthrough in lignin science with Hexion’s industrial and AI-enhanced manufacturing expertise, we’re not just offering a new product—we’re opening a new chapter for our industry.”

The partnership between Hexion and Bloom is focused on one final critical step: enabling manufacturing-ready, adhesive-grade lignin through a scalable method that activates lignin’s evolved functionality without additional chemicals. This effort represents a transformative leap in bio-based manufacturing—replacing fossil-derived resins with sustainable, high-performance alternatives made entirely from wood.

“This collaboration is a welcome disruption,” added Lorenz Manker, Chief Commercial Officer at Bloom #Biorenewables. “With #Hexion, we’re proving that it’s possible to build adhesives that are both powerful and 100% #biobased. What was once considered a scientific curiosity is now on the verge of changing how wood panels are made—forever.

source : Hexion

Today's KNOWLEDGE Share : Bagworm Silk: Forging a Path to the Future of Fibers

Today's KNOWLEDGE Share

Bagworm Silk: Forging a Path to the Future of Fibers

Fibers are utilized by society in diverse ways, from clothing to industrial applications. However, petroleum-based synthetic fibers raise environmental concerns associated with their disposal, including their contribution to microplastic pollution. A natural material developed in Japan not only promises to resolve such issues, but also possesses remarkable strength. The key lies in the bagworm—a tiny creature with heretofore hidden potential.

Until now, spider silk has laid claim to being the world’s strongest natural fiber. Its strength is four times that of steel, its elasticity rivals that of nylon, and it can withstand temperatures exceeding 300 degrees Celsius. However, spiders have cannibalistic tendencies that make large-scale breeding for commercial applications extremely difficult.

“Bagworm” is a general term for moth larvae of the order Lepidoptera, family Psychidae. Some 1,000 species exist worldwide, about 50 of which are found in Japan. The giant bagworm (Eumeta variegata) is the most well-known species in Japan. Bagworms spin their own silk to bind bits of leaves and twigs to form the nests they wrap themselves in, as well as to hang from branches for protection from predators and to move from place to place.

“Bagworm silk is made of protein, just like silkworm and spider silk. When we analyzed the amino acid sequences that make up the protein, we found that it has a highly ordered hierarchical structure, which is what provides its high strength,” says ASANUMA Akimune, Ph.D., Executive Officer and Senior Manager of the Future Business Development Office, Corporate Strategy Division at Kowa.

To commercialize this revolutionary natural fiber, Kowa established the Kowa Research Laboratories for Advanced Science in Tsukuba City, Ibaraki Prefecture, and began joint research with NARO on the artificial breeding of bagworms. With no bagworm specialists on hand, team members initially spent their days collecting, breeding, and observing bagworm behavior. The first step toward industrial application came with their discovery of a breeding method that leverages the characteristics of the bagworm lifecycle. Whereas silkworms spin silk only for two or three days just before pupation, bagworms begin spinning silk immediately after birth and continue throughout their larval stage. The team then developed indoor breeding methods and established a system for continuous silk collection.

Moreover, bagworms spin zigzag ladder-like silk threads and use them as scaffolding for their movement. Based on this “foothold silk,” Kowa successfully created ultra-thin nonwoven fabric-like sheets at a rate of up to 1,000 square meters annually.

In November 2024, Kowa successfully commercialized bagworm silk for the first time with the launch of its brand MINOLON.

The first product to utilize MINOLON was a new series of Ezone tennis rackets by sports equipment manufacturer Yonex Co., Ltd. MINOLON was used in the racket shaft by fusing it with advanced carbon materials. With MINOLON’s combination of strength and flexibility, the racket’s vibration damping performance improved by 5.8% compared to conventional products.

“Bagworm silk is made of protein and is biodegradable. Since it’s not derived from fossil fuels, there’s no risk of it turning into microplastics after disposal or negatively impacting ecosystems. We currently use it in composites with plastic, but if we can eventually produce composites with bioplastics, we should be able to develop products with even lower environmental impact,” says Asanuma about future prospects.

Kowa is pursuing low-volume, high-value-added applications that make use of the special properties of bagworm silk. The company anticipates the development of applications in unexplored fields such as aerospace where the fiber’s strength can be employed to maximum effect. Manufacturing that harnesses the hidden properties of living organisms like the bagworm is now opening up new possibilities for the future of fibers.

In 2018, the National Agriculture and Food Research Organization (NARO) and Kowa Company, Ltd., a manufacturer of pharmaceuticals and optical equipment that also imports and exports textiles and building materials, announced surprising joint research results.

They discovered that bagworm silk surpassed spider silk in all indicators of durability: approximately 2.3 times greater toughness (flexibility to withstand deformation without breaking) and about 1.8 times higher tensile strength (force that can be withstood before breaking when pulled). This research was published the following year in the international scientific journal Nature Communications.

source: The Government of Japan