Bio-Packaging: what does 'bio' actually mean and how does ...d3hip0cp28w2tg.cloudfront.net/uploads/block_files/2014...Starch-based materials (TPS) Novamont Hazy appearance Low stiffness

Copyright © 2012 Innovia Films – All rights reserved

Bio-Packaging:

what does 'bio' actually mean

and how does it compare to

conventional plastic packaging ?

Andy Sweetman Marketing Manager – Innovia Films

Chairman – European Bioplastics 2009-2013

Copyright © 2012 Innovia Films – All rights reserved 2 Copyright © 2012 Innovia Films – All rights reserved

Innovia Films

Manufacturing both

‘conventional plastic’ and

‘bioplastic’ films provides us

with a uniquely balanced view

of Plastics and Bioplastics…

‐ Production facilities in Europe, US &

Asia Pacific regions

‐ Headquarters in Cumbria, UK.

‐ Strongly innovation and R&D led.

‐ €400 Million turnover.

‐ Circa 1500 employees.


Sustainably-sourced Bioplastics

Customers now have a choice…

Nirvana


Conventional plastics:

The upsides

Clearly the benchmark...

Superb functional performance: Barrier

‐ Optics

‐ Processing (printability etc)

‐ Sealability

‐ Range of product families

‐ Rigid and flexible formats

‐ Lightweight

Benefit from massive economies of scale and fully optimised processes, so cost base is now very low

Provide massive levels of convenience for today‘s busy consumer


Conventional plastics:

The downsides

Petroleum derived and therefore

fundamentally finite.

Extraction and processing is not always

benign:

‐ Deepwater horizon disaster spilt

4.9 million barrels of oil into Gulf

of Mexico...

Sustainability profile now optimised,

with little room for further

improvement

End of life options are limited:

‐ Especially so for flexible packaging

So we’re looking for alternatives…


What are Bioplastics?

“Bioplastics are

bio-based, biodegradable or both.”

European Bioplastics Association

Copyright © 2012 Innovia Films – All rights reserved 7

Polymer families

•Exceptional barrier performance

•Optics

•Lightweight

•e.g. PP, PE, PET, PVC…

Conventional

•Naturally derived feedstocks to produce conventional plastics

•Identical tech performance to above

•e.g. Bio-PE films, Bio-PET bottles

Biobased Conventional

•Naturally permeable to moisture – great for semi-permeable applications

•R&D progress over last 5 years now means conventional barrier performance is achievable

•e.g. Cellulose, PLA, TPS, CoPET, PBS, PHA

Compostable


Production capacities are

growing in each sector…


A fast developing field…

Selection of easy available Bioplastics – 2014

More are coming…


Poly Lactic Acid (PLA)

High Clarity

Very high Stiffness

(similar to Polystyrene)

Good deadfold

Semi-permeable to moisture

Resin can be blended to modify

properties

Renewable raw

materials (Corn)

Industrially compostable

Rigid and Flexible options

Images: Natureworks


Starch-based materials (TPS)

Novamont

Hazy appearance

Low stiffness

(more like PE than PET)

Highly permeable to moisture

Resins can be blended to modify

properties

Renewable raw materials

(Corn, potatoes…)

Industrially compostable

Home compostable variants also

available

Images: Novamont


Copolyesters

Hazy appearance

Low stiffness

(more like PE than PET)

Highly permeable to moisture

Oil-derived sources currently, but

still industrially compostable

Home compostable variants

Various European sources for film,

depending on application

Resins often blended to modify

properties

Images: BASF


Cellulosics

NatureFlex™ - Regenerated Cellulose

Good stiffness & clarity

Excellent Moisture and Gas Barrier

performance

Principally used in food packaging &

labelling

‐ (single web and laminate form)

Clarifoil® – Cellulose Acetate

High stiffness & clarity

Principally used in board

lamination and window

applications

Images: Clarifoil & Innovia Films


Likely Future

Compostable Materials

PHA

Poly Hydroxy Alkanoate

Derived from renewable raw

materials

Described as having PP, PET, PE

type properties - TBC

PBS Poly Butylene Succinate

Derived from oil and/or renewable resources

Permeable and low stiffness

Anticipate better optics than some other biomaterials

4 resin suppliers moving from pilot scale to commercial scale over next couple of years


Renewable Conventionals

Renewable PET

Identical properties to standard

PET but derived from Sugar cane

Fastest growing bioplastic sector,

but main uses are rigid bottles

currently

‐ Can share same recovery schemes as

PET bottles

Renewable PE

Properties akin to standard PE,

but derived from Sugar Cane

Limited range of variants

currently, but developing

Images: Braskem & Coca Cola


Where do Bioplastics make most sense

today ?

3 illustrations…


1. “Drop in” Products

Renewable resources

Reduced carbon footprint

Operate in existing recycling infrastructure


2. The ‘What do we do with…’

products…

Capsules and outer packaging

Manufactured from compostable

and largely renewable resources

Includes:

Innovia NatureFlex™ barrier films

Sappi Algro Nature® paper

BASF Ecovio® polymers

BASF Epotal® adhesives

The same rationale applies to sectors

such as foodservice...


ADVANTAGES…

Outstanding pack performance with

minimal use of raw materials:

‐ Lightweight

‐ Marry the performance benefits of

different individual materials

‐ Excellent barrier to moisture, gases,

aromas and light

‐ Optical properties and exceptional on-

pack graphics.

DISADVANTAGES…

Use of mixed materials also brings

some critical issues:

‐ Recycling effectively impossible

(Residuals Contamination,

incompatible materials, inks &

adhesives)

‐ Overall Life-cycle impacts may be

higher than anticipated

‐ Majority of raw materials are

fundamentally finite


Triplex Laminate Components

The ABC of lamination

Drives functional performance

• Appearance, Print, Strength, Heat-resistance A – Outer layer

• Barrier, Protection, Shelf-life B – Core Layer

• Containment, Sealant, Protection C – Inner layer


A conventional multilayer structure

Transparent PET:

Stiffness,

Heat-resistance,

Printability

Alu-foil or Met.PET

Moisture barrier

Light barrier,

gas & aroma barrier

Polyethylene:

Tenacity,

seal-strength,

seal-integrity


The same, but ‘Bio’ …

Biopolymer film:

Tenacity,

seal-strength,

seal-integrity

Metallised NatureFlex:

Moisture barrier

Light barrier,

gas & aroma barrier

Transparent NatureFlex:

Stiffness,

Heat-resistance,

Printability

Image: Parkside flexibles


So is the world now a beautiful

place again..?

& Will you just

take my word for it ?


Substantiating Sustainable Performance

4 key elements to quantify the demands of the 4 key stakeholder groups


High levels of readily renewable raw materials.

Biobased carbon content can be measured according to ASTM D6866. Total biomass can also be calculated separately.

Managed Forestry sources . E.g. Innovia Films UK FSC & PEFC Chain of Custody certified January 2014

Independent Sustainability protocols (e.g. ISCC+) emerging for other biomaterials

Growing emphasis to ensure claims are validated


Process Management


“InnPrint” Flexible Packaging Carbon Footprinter

Based on GaBi software and database

Ensuring a fair material comparison


Effective product protection is a fundamental

sustainability indicator as the resources

required to produce food are extremely high

Therefore shelf life optimisation

to reduce food waste is paramount

Bioplastics typically have good to

excellent gas barrier properties

NatureFlex™ also provides the highest

H2O barrier of any bioplastic film

Good barrier to mineral oils

Laminate complementary biofilms

to enhance barrier, strength and seals

and you can increasingly match

conventional pack performance


End of life is where bioplastics

can really score

Recycle bioplastics where it

makes sense ‐ E.g. ‘drop-ins’, bioplastic bottles etc…

Use bioplastics to aid organic

recovery where typical

recycling is impractical

‐ This is the ultimate point of

differentiation for compostable

bioplastics versus all other

plastics

The EU generates 50 million

tpa* of municipal organic

waste…

* Source Eurostat 2007


Anaerobic Digestion Unit

Vitorio, Spain

Organic Waste Is Actually

Organic Opportunity

Anaerobic Digestion Triple the

Value:

If 50 million tonnes of organic

waste were recovered, this could

deliver:

• A saving of 75 million tonnes of

fugitive CO2 landfill emissions

• 5 Billion litres of biofuel

• 42.5 million tonnes of

fertilizing digestate,

• reducing the need for

synthetic fertilizer


Filmic barrier pouch

0% RRM

Fossil Derived

0.5kgCO2

eq/m2

MVTR <1

OTR <1

Incinerate

or

Landfill

Conventional Pack: 12mPET//8mALU//60mPE

“Bio” Pack: 20mNK//20mNKME//50mbiofilm

55% RRM

Managed Forestry

0.41kg

CO2eq/m2

MVTR ~2

OTR <1

Organic recycling

or Incinerate


Andy Sweetman

Marketing Manager – Packaging & Sustainability

• DDI +44 (0)16973 41549

• Mobile +44 (0)7767 447067

• Email [email protected]

• www.innoviafilms.com

http://www.innoviafilms.com/

Bio-Packaging: what does 'bio' actually mean and how does ...d3hip0cp28w2tg.cloudfront.net/uploads/block_files/2014...Starch-based materials (TPS) Novamont Hazy appearance Low stiffness

Documents