innobioplast 2013 presentation dwa coffee cup development

Presenting to:

How to tailor your material for

customer needs –

PLA coffee cup case study

Derek Atkinson - PuracFrançois de Bie – Purac Sicco de Vos - PuracKarin Molenveld – WURGerald Schennink - WUR

2

Outline

Origin of the project

Project partners

Material development

Results from composting study

Next steps & Summary

3

Market pull - Origin of the project In 2009 Wageningen University defines a

“ Sustainable business policy” Objective is to reduce the ecological footprint of the university

and encourage sustainable business practises

Formation of working group: “Bioplastics in catering” Wageningen UR

Facility service & Food and Biobased Research (FBR) Province of Gelderland Douwe Egberts Albron (catering) Other stakeholders

The working group evaluates the possibilities & benefits of introducing biobased materials in catering applications – focus on coffee cups

Wageningen university uses 2.5Million PS cups/year

4

What is the most environmentally friendly coffee cup ?

Carbon footprint: cradle to gate vs cradle to grave-> Impact of end of life options ?

Technical requirements Consumer experience

-> Multiuse vs single use ?-> Separate collection system ?

PS PLA Paper/PLA Porcelain

5

Technology push - Origin of the project

In 2008 Purac and Wageningen UR* start a project.

PLLA/PDLA homopolymers

Objectives:Develop high heat injection moulding compounds in PLA

*) Wageningen University & Research centre, Food & Biobased Research

6

PLA coffee cup project kickoff

Develop a PLA coffee cup that:

- Can withstand hot coffee / 93oC

- Can be produced on existing PS coffee cup production lines

- Can reach the same thermoforming speed as PS today

Technology push Market pull

Industrial Partner

7

Feasibility study Several material formulations created High heat PLA concept of Purac based on PLLA/PDLA Compounding and sheet extrusion at Wageningen UR Thermoforming using industrial equipment and moulds

Conclusions Processing conditions are of major importance (hot mould)

Crystallisation speed of PLA homopolymers is sufficient

Short cycle times (1-2 seconds) are possible

See Table on next slide

8

Results feasibility study on thermoformed prototype cups

Conclusion:Even at short cooling rates, PLA homopolymers can reach a high level of crystallinity

9

Results feasibility study

Processing speed is OK .. BUT .. cup stiffness, when filled with hot coffee (93°C), is NOT sufficient.

50 100 150

E-

modu

lus

MPa

Temperature oC

Amorphous PLASemi-crystalline PLATarget stiffness

93

How to increase stiffness at 93°C ?

Calcium Carbonate (chalk) Cheap Limited effect on stiffness No influence on crystallisation

speed

Talc More expensive High effect on stiffness Strong influence on crystallization

speed

Combine PLA homopolymers with fillers: Fillers increase the stiffness Fillers can introduce brittleness Fillers can impact crystallization behaviour

Conclusion:PLA homopolymers, in combination with a filler, have an acceptable stiffness over the required temperature range. ( see chart on next page )

11

DMTA - effect of fillers & crystallinity

1,E+04

1,E+05

1,E+06

1,E+07

1,E+08

1,E+09

1,E+10

0 50 100 150 200

E’ (───

) [P

a]

Temperature [°C]

PLA 6400

0x

7x at 115C

Unfilled PLA - amporhousFilled PLLA homopolymers – high crystallinity

Conclusion:PLA homopolymers, in combination with a filler, have an acceptable stiffness over the required temperature range.

12

Results reformulations with fillers

Promising formulations tested at pilot scale PLLA and PDLA homopolymers from Synbra/Purac Compounding done by Wageningen FBR Sheet production and thermoforming at industrial partner

Various formulations with following ingredients:1) PLLA Homopolymer

2) PDLA Homopolymer

3) PLA

4) Filler

5) Nucleating agent

13

Results semi-industrial trialsPLL

A h

om

opoly

mers

PLA

co

poly

mers

Conclusion:The best results could be obtained with combination of PLLA and PDLA homopolymers

14

Main conclusions on thermoformed PLA hot drink cup

Thermoforming of high heat PLA is finding a balance between formability and crystallization speed

The best results could be obtained with combination of PLLA and PDLA

Fillers are necessary to provide sufficient stiffness above the Tg of PLA

Replacement of amorphous PS cups is possible

15

Biodegradation of the PLA cup

Cups were submitted to Organic Waste Systems (OWS)

to evaluate the compostability.

Qualitative disintegration is part of EN13432 and is

considered to be the most significant hurdle for

obtaining the compostability according EN13432.

Only the qualitative disintegration test was performed.

16

Results from composting tests

Test conditions: The samples were added to a bin with compostable waste @ OWS.

Conclusion:Does not meet EN13432 standard.Significant degradation, fungal growth, size of left over’s 1 x 3 cm.

Start 1 week 3 weeks 12 weeks

17

Next steps and actions Finalize large scale industrial production run Commercial roll out of PLA cups Complete bio-based certification Evaluate options for end of life recycling

18

Summary – key learnings Replacing traditional plastics in “high volume”

applications takes time & effort. Working closely with expert partners that have

knowhow in different areas of the process increases the rate of success.

PLA homopolymers can replace PS in hot coffee cups.

Many thanks to all partners that contributed to this project:

Industrial Partner

19Questions ? For info please contact d.atkinson@purac.com

2020

For more information, contact:Derek AtkinsonBusiness Development DirectorPLA AsiaM +65 9093 9896d.atkinson@purac.com

No representation or warranty is made as to the truth or accuracy of any data, information or opinions contained herein or as to their suitability for any purpose, condition or application. None of the data, information or opinions herein may be relied upon for any purpose or reason. Purac disclaims any liability, damages, losses or other consequences suffered or incurred in connection with the use of the data, information or opinions contained herein. In addition, nothing contained herein shall be taken as an inducement or recommendation to manufacture or use any of the described materials or processes in violation of existing or future patent of Purac or any party.