REBIOFOAM

Development of a flexible and energy-efficient pressurised microwave heating process to produce 3D-shaped renewable bio-polymer foams for a novel generation of transportation packaging

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 Obiettivo del progetto (Objective)

'Expanded Polystyrene (EPS), Polyurethane (EPU), Polyethylene (EPE) and Polypropylene (EPP) represent the most popular moulded cushion packaging materials applied for transport packaging applications. However, despite of their functionality, the widespread use of these polymer foams of synthetic origin implies considerable environmental concerns. The depletion of non-renewable fossil raw material resources associated with emissions of greenhouse gases, such as C5H12 and CO2 applied as blowing agents during processing, are the most direct impacts on the environment. Moreover, their non-biodegradable / non-compostable nature associated with the short life of cushion packaging products rises up fundamental concerns regarding waste disposal. Recycling, which is the solely applicable solution for preventing those synthetic foams entering the waste stream, appears in fact to be rarely applied due to cost-ineffectiveness and lack of effective recycling system. With this in mind, bio-based plastics represent an emerging highly promising solution for protective transport packaging provided that they can be processed in foamed products resulting in adequate functional requirements. Within this framework, the project idea is to develop a flexible, energy-efficient and environmentally-sustainable manufacturing process enabling the production of biodegradable foamed 3D-shaped packaging originating from renewable raw materials (i.e. starch and water). Within the proposed process, expansion and foaming of the bio-polymer will be driven by pressurized microwave technology, exploiting the inner water content of the material itself to generate vapour. The proposal is fully compliant with the targeted topic “NMP-2007-2.4-1 Flexible efficient processing for polymers”, as the proposed process offers a valid alternative to petroleum-based polymer processing, involving the use of renewable feedstocks, and involving microwaves as energy-efficient processing solution.'

Introduzione (Teaser)

Packaging materials are a vital part of the supply chain, ensuring components and products are undamaged. Thanks to EU research, some of these protective materials are now fully biodegradable and compostable according to international standard (i.e.EN13432).

Descrizione progetto (Article)

Given their ubiquitous nature, the typically synthetic origin of many packaging materials has raised important environmental concerns. The EU-funded project http://rebiofoam.eu (REBIOFOAM) developed a sustainable process to make biodegradable packaging from renewable materials, (i.e.starch and water).

Energy consumption is minimised by using efficient microwave heating to induce expansion and foaming of a starch-based biopolymer through vaporisation of the water content in the polymer itself. Expansion occurs within the microwave mould cavity such that the biopolymer achieves the desired 3D shape.

REBIOFOAM, thanks to the involvement of the whole supply chain, produced two demonstrators, a port hole spacer for washing machines and a corner piece for packaging applications. Both achieved target densities and demonstrated good physical and mechanical properties when compared to reference expanded polystyrene (EPS). A fully automated semi-industrial pilot line has been developed, which is able to produce foamed samples with density 40-45 kg/m3.

REBIOFOAM materials can be used as protective packaging materials and its adoption and commercialisation are expected to have major environmental and economical benefits related to decreased energy consumption and when the complete biodegradability and compostability, in combination with the specific mechanical properties of the materials, is an added value for the selected applications.