Innovative value chain development for sustainable plastics in Central Europe

Transcription

1 Work Package 3: Developing a roadmap for action from science to innovation in the value chain Goal: To elaborate a transnational roadmap for technology transfer in biodegradable plastics industry STAGE II WORKSHOP I

2 Agenda Welcoming - Marek Kowalczuk, WP3 leader Workshop session 1 - Presentation of the case studies Break Each partner presents the activities and final outcomes of the case studies (9 case studies x 10 minutes) Evaluation and recommendations concerning the preparation of the report on the case studies Discussion - Moderator: Luk Palmen 11:30 Workshop session 2 Preparation of the Roadmap Presentation of the main activities for the period November 2012 March 2013 and March-June 2013 Structure of the roadmap Role of the WP3 partners in preparing the Roadmap Discussion - Moderator: Luk Palmen Other items: planning the date for the third workshop in March :45 Closing of the workshop

3 PLASTiCE Value Chain development European Directives on waste management Governmental institutions National Information Points National laws on waste management Certification system Information campaign Joint R&D Scheme Joint Advisory Scheme Information package Research Institute Producers of basic components Producers of sustainable plastics End-users Food sector Pharmaceutical sector Cosmetic sector Distributors Retailers Consumers Roadmap for research and commercialization of new sustainable polymers

4 Main goals of the second workshop To assess the case study outcomes against the prior expectations and the transnational R&D scheme structure To formulate recommendations for the final transnational R&D scheme structure To agree upon the structure of the roadmap, including the information on international trends and on the case studies that will be included in the roadmap To define the action plan for the period November 2012 June 2013 and to verify the budget

5 Nr. case study 1A 1B 2A 2B A 6B R&D institutions involved LP PP11 PP12 PP13 LP PP11 PP12 PP13 LP PP11 PP5 PP6 PP5 PP6 LP PP11 PP8 Name of the case study Main key-words 10-minute presentations Development of markers for biodegradable materials that would enable easy separation / identification of biodegradable plastics Systemic approach for sustainable production of bioplastics Pilot production, end of life treatment Anaerobic digestion and composting Plastic tampon applicators Biodegradable packaging for hygiene products Production of packaging for eggs made from BDPs Masterbatches for biodegradable films Transformation process Introduction of biodegradable materials in production processes

6 Content Starting point: evaluation reports Additional information: ex-post assessment of the process Pictures Make sure you are allowed to publicize this information (agreement from the company) Case study report Structure for the description of the case studies in the evaluation report Title Key-words Research areas covered (in line with the R&D scheme) Problem definition Main goal Planned activities (step by step) Description of the activities Results Recommendations for the future (young scientific missions) Roadmap Selected information from the case study evaluation report will be used in the roadmap

7 Case study report Content Starting point: evaluation reports Additional information: ex-post assessment of the process Pictures Time table Make sure you are allowed to publicize this information (agreement from the company) 20 November: you will receive the case study template for the final report by Structure for the description of the case studies in the evaluation report Title 30 November: Key-words all filled in templates to be sent to WP3 leader Research areas covered (in line with the R&D scheme) 10 December: case study evaluation report prepared by WP3 leader Problem definition Main goal Planned activities (step by step) Description of the activities Results Recommendations for the future (young scientific missions) Roadmap Selected information from the case study evaluation report will be used in the roadmap

8 Young scientific missions Scientific mission 1 Main partner responsible for organising the workshop Scientific mission 2 Main partner responsible for organising the workshop Selection of polymer materials for twine production PP8: University of Bologna, Department of Chemistry G. Ciamician Mariastella Scandola (Professor, head of Polymer Science Group) Processing of biodegradable polymers PP5: Polymer Institute of the Slovak Academy of Sciences Ivan Chodak (Senior scientist, professor) PP6: Slovak University of Technology in Bratislava Dušan Bakoš (professor) Scientific mission 3 Main partner responsible for organising the workshop Compostability of biodegradable polymers, testing procedures PP13: Polish Packaging Research and Development Centre Hanna Żakowska (Deputy Director for Research)

9 Young scientific missions Scientific mission 1 Selection of polymer materials for twine production PP8: University of Bologna, Department of Chemistry G. Ciamician Main partner Mariastella Scandola (Professor, head of Polymer Science Group) responsible for organising the workshop Time table 30 Scientific November: mission information 2 Processing on the of young biodegradable scientific polymers missions to be included in the case study evaluation template Main partner responsible for organising the workshop PP5: Polymer Institute of the Slovak Academy of Sciences Ivan Chodak (Senior scientist, professor) 10 December: case study evaluation report prepared by WP3 leader PP6: Slovak University of Technology in Bratislava Dušan Bakoš (professor) Scientific mission 3 Main partner responsible for organising the workshop Compostability of biodegradable polymers, testing procedures PP13: Polish Packaging Research and Development Centre Hanna Żakowska (Deputy Director for Research)

10 Agenda Welcoming - Marek Kowalczuk, WP3 leader Workshop session 1 - Presentation of the case studies Break Each partner presents the activities and final outcomes of the case studies (9 case studies x 10 minutes) Evaluation and recommendations concerning the preparation of the report on the case studies Discussion - Moderator: Luk Palmen 11:30 Workshop session 2 Preparation of the Roadmap Presentation of the main activities for the period November 2012 March 2013 and March-June 2013 Structure of the roadmap Role of the WP3 partners in preparing the Roadmap Discussion - Moderator: Luk Palmen Other items: planning the date for the third workshop in March :45 Closing of the workshop

11 PLASTiCE main project stages Month Month Dissemination activities by National Information Points Month 7-18 Refinement of tools, testing and evaluation Month 1-6 Tool development and first verification Methodology refinement and information gathering April 2011 October 2012 November 2012 March 2013 April July 2013

12 WP3 action 2: R&D scheme preparation and promotion translation of R&D scheme Feedback report ready Electronic version of R&D scheme on PP and NIP websites Min. 30 companies contacted(10 x 3) Report of activities

13 Area of interest Clear focus on environmental biodegradable plastics, that are in line with the following criteria: Compostable polymers (according EN13432/14995, ASTM D 6400, ISO16929) designed to be composted in municipal and industrial aerobic composting facilities Based on renewable and non renewable resources Applied in packaging, catering or agriculture Available on the market on a medium to large scale

14 Transnational R&D scheme Thanks to cooperation between the R&D institutions a full range of support services and R&D activities will be offered to companies in Central and Eastern Europe. The Joint R&D Scheme includes: Characterization of polymers available on the market, including: (1) Composition and molecular structure and (2) Solid-state properties Modification of polymer properties by chemical routes, including: (1) Modification (polymer modifiers) and (2) Functional polymers Modification of polymer properties by physical routes including: (1) Modification by additives, (2) Polymer blends and (3) Polymer composites including nanocomposites Processing, including: (1) Rheology, processing parameters and (2) Homogenization (by internal mixers, single screw, twin screw extruders) Industrial production, including: (1) films, (2) rigid packingm (3) flexible packaging, (4) mulch films, (5) foamed materials and (6) coated materials Application properties of polymer products, including: (1) aging properties of polymer materials, (2) barrier properties of polymer materials (gas permeation properties), (3) thermo-mechanical properties of polymer materials and (4) durability properties and shelf-life properties Biodegradation and compostability testing (according to EN, ASTM and ISO) including: (1) Under laboratory conditions and (2) At municipal and industrial aerobic composting facilities

15 Role of the WP3 Partners Area of research activities PLA, PHA Starch-based materials Other materials Characterization of polymers available on the market, including: LP, PP5, PP11, PP12 PP5, PP11, PP12 Composition and molecular structure PP5, PP6, PP12 PP5, PP6, PP12 Solid-state properties PP8, PP5, PP6, PP11 PP8, PP5, PP11 Modification of polymer properties by chemical routes, including: Modification (polymer modifiers) PP5, PP11, PP12 PP5, PP11, PP12 Functional polymers PP11, PP12 PP11, PP12 Modification of polymer properties by physical routes including: Modification by additives PP5, PP6, PP11 PP5, PP6, PP11 Polymer blends PP5, PP6, PP11, PP12 PP5, PP6, PP11, PP12 Polymer composites including nanocomposites PP5, PP6, PP11 PP5, PP6, PP11 Processing, including: Rheology, processing parameters PP5, PP6, PP11 PP5, PP6, PP11 Homogenization PP5, PP6, PP11 PP5, PP6, PP11

16 Role of the WP3 Partners Area of research activities PLA, PHA Starch-based materials Other materials Industrial production, including: films PP6, PP11, PP12 PP6, PP11, PP12 rigid packing PP6, PP11, PP12 PP6, PP11, PP12 flexible packaging PP6, PP12 PP6, PP12 mulch films PP6, PP12 PP6, PP12 foamed materials PP5 PP5 coated materials PP11, PP12 PP11, PP12 Application properties of polymer products, including: aging properties of polymer materials LP, PP5, PP12, PP13 LP, PP5, PP12, PP13 barrier properties of polymer materials (gas permeation PP5, PP12, PP13 PP5, PP12, PP13 properties) PP5, PP6, PP8, PP11, PP5, PP6, PP8, thermo-mechanical properties of polymer materials PP12, PP13 PP11, PP12, PP13 durability properties and shelf-life properties PP13 PP13 Biodegradation and compostability testing (according to EN, ASTM and ISO) including: Under laboratory conditions PP6*, PP11, PP12, PP13 PP6*, PP11, PP12, PP13 At municipal and industrial aerobic composting facilities PP12 PP12

17 Main research activities Area of research service Characterization of polymers available on the market Solid-state physical properties (thermal, mechanical, structure, morphology) Estimated price range Estimated service delivery time Analysis of thermal stability (degradation temperature) of single- or multicomponent material, by Thermogravimetric Analysis from RT to 900 C in inert atmosphere or in air) Analysis of thermal stability and Mass spectrometry of volatiles ( by TGA-MS from RT to 900 C in inert atmosphere) 150 per sample 250 per sample 3 working days (single sample) 1-2 weeks (up to 10 samples) 3 working days (single sample) 1-2 weeks (up to 10 samples) Description of the research activity Analysis of thermal transitions (glass transition, crystallization and melting, with determination of transition temperature, and of the respective specific heat increment, crystallization and melting enthalpies, by Differential Scanning Calorimetry. T-range explored -100 C-250 C, cooling with liquid Nitrogen). 2 scans per sample 200 per sample 160 per sample (3 samples or more) 2-4 weeks (depending on number of samples) Evaluation of mechanical properties at room temperature (Elastic modulus, stress and strain at yield and at break, by tensile testing with statistical analysis of the results on a minimum of 8 specimens) 400 per sample 2-5 weeks (depending on number of samples) Determination of the viscoelastic relaxations (by Dynamic-mechanical Analysis in single- or multi-frequency mode, T-range -150 C-250 C ) 200 per sample (single frequency) 300 per sample (multifrequency) 3-4 weeks Structural analysis of the crystal phase (by powder wide angle X-ray diffraction) 200 per sample 2 weeks Product the client receives Report on the physical properties of the analysed polymers

18 Main research activities Area of research service Characterization of polymers available on the market Composition and molecular structure Estimated price range Estimated service delivery time Determination of the solid state properties using infrared spectrometers FT-IR (Fourier Transform Infrared Spectroscopy) /sample 1-2 weeks Characterization of the material solubility and determination of the percentage of the polymer in the plastic (chemical analysis) /sample 1-3 weeks Description of the research activity Characterization of the polymer part in the plastic by way of NMR (Nuclear Magnetic Resonance Spectroscopy) Evaluation of the polymer molecular weight using GPC technique (Gel Permeation Chromatography) /sample 1-3 weeks /sample 1-3 weeks Analysis of the additives using mass spectrometer LCMS-IT-TOF (Hybrid mass spectrometer with both ability of an ion trap and the resolution and mass accuracy of a tandem mass spectrometer) /sample 1-3 weeks Characterization of biodegradable copolyesters (PHA) using sequencing and tandem mass spectrometer ESI-MS n (Electrospray Soft Ionisation with Multi-step Mass Spectrometry) /sample 1-3 weeks Product the client receives Report on polymer molecular structure and characterization of additives included in the plastic.

19 Main research activities Area of research service Modification of polymer properties by chemical routes, including: Modification (polymer modifiers) Estimated price range Estimated service delivery time Functional polymers Synthesis of chemical modifiers Contract research, conditions negotiable 1 months 2 years Determination of physical properties of polymeric materials According to price list, typically between EUR per test 3 days up to 2 weeks Description of the research activity Modification of polymers to achieve special properties: cross linking of polymers for better solvent resistance Contract research, conditions negotiable 1 months 2 years Modification of polymers to achieve special properties: increasing polymer surface polarity for better printability or increased adhesion, increased thermal and oxidation stability Contract research, conditions negotiable 1 months 2 years Product the client receives Standard commercial polymers possessing certain special properties

20 Main research activities Area of research service Modification of polymer properties by physical routes including: Modification by additives Polymer blends Estimated price range Estimated service delivery time Polymer composites including nanocomposites Modification of properties of particular polymer by addition of low molecular additives, e.g. plasticizers, chain-extenders, stabilizers or blending with small quantities of another polymer to achieve desired properties Contract research, conditions negotiable 1 month 2 years (or more) Description of the research activity Blending two polymers in full concentration range, desired properties are achieved by modification of the interface and compatibilization of the components. Contract research, conditions negotiable 1 month 2 years (or more) Preparation of composites based on polymeric matrix with tailored properties via modification of interface. Contract research, conditions negotiable 1 month 2 years (or more) Product the client receives Report on alternatives for compatibilization of blends of various BDPs.

21 Main research activities Area of research service Processing, including: Rheology, processing parameters Homogenization (by internal mixers, single screw, twin screw extruders) Estimated price range Estimated service delivery time Description of the research activity Selection of most prospective blends of BDPs for application purposes, proposal for areas of application Determination of processing parameters of the materials Consultancy, conditions negotiable /sample per parameter 1 day 3 months 1 4 weeks Product the client receives Report on processing parameters of selected BDPs, recommended general ways of processing including processing equipment and typical processing parameters

22 Main research activities Area of research service Industrial production (research on industrial processing properties), including: Production of films Production of rigid packing Production of flexible packaging Estimated price range Estimated service delivery time Production of mulch films Production of foamed materials Production of coated materials Descriptio n of the research activity Product the client receives Laboratory scale production of films (PP12): research on processing and blending, production of master-batches (Mini twin-screw extruder (MINI LAB II) combined with the injection molding machine (MINI JET II) HAAKE, using the force feeder, continuous extrusion with very small volumes, mini-injection molding machine allows to create specimens for material testing, simultaneously the rheological properties can be recorded) /hr 1-2 weeks Laboratory scale production of flexible packaging (PP12) /hr 1-2 weeks Support of pilot production on the site (PP5) Controlling of the mechanical properties of the product in the production process: mechanical properties measurements, Instron Model 4204 tensile tester (PP12) Controlling of the molecular properties of the product in the production process (PP12) Report on the polymer stability with respect to the content of the packaging 500 / day plus expenses /sample /sample 1 day 6 weeks 1-2 weeks 1-3 weeks

23 Main research activities Area of research service Description of the research activity Product the client receives Testing of application properties of polymer products (packaging materials and packaging), including: aging properties of polymer materials barrier properties of polymer materials (gas permeation properties) thermo-mechanical properties of polymer materials durability properties testing packaging for food contact (Food contact according to the European Directive EX 2002/72) Estimated price range Estimated service delivery time Xenotest method used for determination of material behaviour in the natural conditions Months* Determination of total organic carbon and the biobased content in polymer materials Month* Testing permeability of water vapor, oxygen and carbon dioxide Weeks* Determination of tensile properties (stress at break, elongation at break, modulus of elasticity etc.) ~ 175 per test 2 Weeks* Determination of tear resistance Weeks* Determination of impact resistance by free-falling dart method Weeks* Sealing properties (max. load at break, sealing resistance etc.) Weeks* Hot-tack sealing testing Weeks* DSC (scanning calorimetry) and FTIRS (infrared spectroscopy) Week* Sensory analysis Month* Overall and specific migration testing of low molecular substances from foodstuffs Months* Testing of the contents of monomers in plastics materials and emission of volatile substances Month* Investigation of bioplastics (biodegradable/biobased) materials aiming at determination of their properties. Report and analyses on the properties polymer materials useful for packaging applications.

24 Main research activities Area of research activities Description of the research activity Product the client receives Biodegradation and compostability testing (according to EN, ASTM and ISO) including: Under laboratory conditions and at municipal and industrial aerobic composting facilities Degradation and compostability testing under laboratory conditions: preliminary tests of biodegradation on the basis of packaging materials under simulated composting conditions in a laboratory scale test according to EN 14806: 2010 (PP13) Degradation and compostability testing under laboratory conditions: hydrolytic degradation test in water or buffer solutions (Degradation tests of biodegradable polymers in simple aging media to predict the behavior of such polymers) (PP12) Degradation and compostability testing under laboratory conditions: laboratory degradation in compost with respirometry test (Respirometer Micro-Oxymax S/N COLUMBUS INSTRUMENTS for measurement of CO 2 in laboratory conditions according to PN-EN ISO : Determination of the ultimate aerobic biodegradability of plastic materials under controlled composting conditions - Method by analysis of evolved carbon dioxide - Part 2: Gravimetric measurement of carbon dioxide evolved in a laboratory-scale test) (PP12) (Bio)degradation and compostability testing at composting facilities (tests of biodegradable material in industrial composting pile or KNEER container composting system) (PP12) Certification of compostable goods associated with possibility of marking packaging with "compostable" (in cooperation with DIN CERTCO, Germany) (PP13) Report on behavior of the new polymeric materials in (bio)degradation tests. Certificate Estimated price range Months /sample /sample /sample Estimated service delivery time From few weeks to 6 months depending on the type of materials, according to standard From few weeks to 6 months depending on the type of materials, according to standard From few weeks to 6 months depending on the type of materials, according to standard Months

25 R&D scheme final acceptance and translation : Final acceptance of the document, proposals are gathered by WP3 leader at latest until : WP3 Partners receive the R&D scheme for translation : R&D scheme translated into 5 language versions : R&D scheme on institutes websites and on NIP websites : 30 companies informed on R&D scheme and possible cooperation opportunities detected : assessment report on information process (feedback will be used in the roadmap)

26 WP3 action 3: Roadmap development based on the Joint R&D Scheme Preparation of the roadmap by WP Final acceptation of the roadmap by WP3 partners 06/ Roadmap in 5 versions (electronic, printed?) WP3 third workshop in Vienna to discuss the roadmap methodology and content

27 Roadmap Goal To promote the R&D consortium and its potential among companies in CEE To convince companies to enter into a change process for developing and commercializing new products Structure Information on environmental biodegradable plastics (state of the art) Main challenges for industry to overcome R&D scheme with elements of case studies integrated Who is who: contacts and links

28 Thank you for your attention! Luk Palmen Marcin Baron