Pilot lines

  • Application

  • Development

Increasing efficiency in processing of nano-enabled biobased materials by additive manufacturing technologies

A unique heading prototype will allow surface modification while printing in one step.

What we want to achieve: The main benefits from this pilot line for SMEs and companies will include competitive costs of dedicated processing equipment to produce complex3D printed parts and products at a very competitive cost, unlocking a change in their manufacturing processes and reducing manufacturing time by more than 50%. Download pilot line pdf

Processing for confining polymers. Production of nano-layered films with high barrier properties

Production of recyclable and/or biodegradable bio-based nanolayered films /sheets providing high barrier and optical properties.

What we want to achieve:
  • A single film with thousands of layers with nano-range thicknesses are obtained through a series of Layer-Multiplying Elements (LME): 1000-5000 layers with 25-100 um thickness.
  • High gas barrier properties thanks to multinanolayering of films and biaxial stretching
  • Extrusion of films of 25-250 um and up to 600 mm in width. This extrusion flat die is also equipped with a deckling system to have more flexibility in film width.
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Process and data optimisation in the surface treatment concept

SuTCo (Surface Treatment Concept) is a versatile pilot-scale coating and film preparation line with several coating units (e.g. rod, cast, slot and spray). Various bio-based dispersions and polymers have been applied with a rod coating applicator on fiber-based substrates.

What we want to achieve:
  • Upgraded surface treatment pilot line enables fast development of end-products for SMEs, while ensuring a high flexibility to adapt to their needs.
  • SMEs can enter the market 25% faster with optimized products.
  • The industrial productivity will be improved by 20% with thin coating layers and lower environmental impact due to recyclable and reusable materials.
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Large smart surface for industrial scale-up

Development of smart surfaces with embedding electronic functionalities, such as printed/stretchable/flexible antennas/filters, sensors, actuators, organic FT-circuits (e.g., gate drivers), piezoelectric energy harvesters as well as SMD (surface mount devices),bare die and LEDs.

What we want to achieve:
  • The possibility to realize prototypes and studies using a large set of printing and characterization equipment prior to an industrial scale-up.
  • Other benefits: Industrial transfer of printed electronic functions and related technologies, Research and Development services in the field of printed electronics and Training of future pilot line operators.
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Production of electrodes for the optimisation of the production of bio-based materials

The manufacturing of roll-to-roll electrodes of at least 60m length that will be tested in industrial sized ultracapacitor cells. This electrodes will be produced using novel cellulose in water-based slurries.

What we want to achieve:
  • The pilot line will allow companies developing new materials and electrodes, based on water processing and bio-based slurries, to manufacture electrodes in order to evaluate their performance, production methods and cost.
  • The pilot line services will allow SMEs and companies to optimize and test new products or manufacturing processes.
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Establishing of a development environment for bio-based particle foams

The Fraunhofer ICT particle foaming pilot line will enable a fully controlled development/ production environment for particle foams tailored to the needs of the respective customers with nano-scaled additives incorporation to (bio)polymers to increase functionality.

What we want to achieve:
  • Product ideas that exist in companies can be turned into products much faster with the help of the new and improved pilot line, which increases the innovation rate of companies in the bio sector.
  • Shorter development cycles and integrated real-time characterisation methods enable a better understanding of the material-property relationship for a new material.
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Quality improvement of biobased coatings and nanoparticle synthesis

Improving the production quality and - quantity of bio-based lacquers and machinability of bio-based materials in Roll2Roll processes for more efficient industrial use.

What we want to achieve:
  • The advantage for customers is the flexibility in synthesis. We can produce, process or modify almost all materials (bio-based or fossil-based). In addition to the technical equipment, the safety technology is also available.
  • Through our experience, we can also scale up laboratory synthesis, so that we can also increase the TRL that have run through third parties.
  • The coating facility is also very flexible and can even process rigid substrates.
  • The equipment (upgrade of the pilot facility) with the SiOX system is unique in the world and offers barrier coatings without the use of vacuum for polymer and fibre based substrates.
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Compounding and processing of nano-enabled bio-materials

The Extensional Flow Mixer METEOR (patented by IPC) is used to develop new formulations with an efficient dispersion of additives while reducing the overheating, and so the thermal degradation of sensitive material, like PLA.

What we want to achieve:
  • A quality control will be integrated thanks to an inline capillary rheometer to be able to optimize compounding parameters. Control compounding parameters for zero material degradation and optimize distribution of the micro and nano-fillers.
  • Inline integration of 3D printing filament at 2 diameters 1.75 and 2.85 mm. Additionally, a flexible cooling system will be implemented with water or air for water-sensitive materials.
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Increasing the production of bio-based nano composites

Melt blending processes as the key to efficient production of bio-based compounds of nano composites.

What we want to achieve:
  • We will be able to support SMEs and companies interested in the development of nanocomposites with no experience in nanomaterials handling at the industrial scale, from the materials fine-tuning (few kg) up to pilot scale (50 kg) for materials qualification, without any preliminary nanosafety investment in their plants.
  • Also, industrials interested in printed electronics from nano-enabled materials, will find a unique environment which will allow them to deal with the nano-safety issue during the development of new materials, up to development of 2D substrates for preliminary printing test, in coordination with the CEA-PICTIC pilot line.
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Data mining as the basis for efficient production of PLAX copolymers

Optimised data acquisition and evaluation should enable faster production of PLAX copolymers with desired structure, architecture and molecular weight.

What we want to achieve:
  • Pilot facilities are flexible to produce different formulations for dispersion coatings. Existing facilities and highly skilled personnel enable faster application development.
  • Companies can have access to develop novel barrier dispersion coatings based on PLAX materials for fibre-based packages, which can be recycled and reused in fibre-based packaging value chain.
  • Facility enables material production in variable scale, also larger amounts of material for testing purposes is possible.
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Scaling of graphene and carbon-based bio-nanomaterials

A novel technology for the generation of a new family of nanomaterials based on graphene and other forms of carbon from different biosources, combined with metal oxide nanoparticles shall be produced on an industrial level.

What we want to achieve:
  • A proper channel to bring nanocomposites based on carbon materials from bio-resources and metal oxide nanoparticles to industry.
  • Companies will have access to hundreds of grams-kilograms productions instead of milligrams, besides the offering of ad-hoc design of new products formulations with improved features and at competitive manufacturing costs.
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Production of novel cellulose-based bio-inks and slurries

Further development of the production of bio-based printable inks from laboratory status to industrial use.

What we want to achieve:
  • The pilot line will allow companies to develop and test bio-based printable/coatable formulations and assess the possibilities and benefits that these eco-friendlier solutions can bring them.
  • The pilot line services will allow SMEs and companies to develop and test such new products or manufacturing processes at affordable cost.
  • It will also allow them to be well positioned in the field of bio-based materials and support decision-making for further and larger investments for production scale implementation.
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Processing & modification of micro natural fibres

Optimisation natural microfibers flax or hemps as an important component of biocomposites.

What we want to achieve:
  • The fibers can show high adhesion to any polymer matrices and can be functionalised by different method to meet final requirements.
  • There is lack of such raw materials on the markets. Small fiber dimension allows to produce precise composite elements.
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Production of biopolyester from marine bacteria

Polymaris wants to industrialise the production of Polyhydroxyalkanoates (PHA), so-called for example biopolyesters, from marine bacteria.

What we want to achieve:
  • The pilot line will deliver amounts of Pol PHA large enough for process and product development.
  • The pilot line will be available to produce molecules by fermentation.
  • The pilot line will offer natural microfibers flax or hemp as component of any bio composites.
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Increasing the available amount of cellulose nano crystals

RISE wants to optimise and increase the production of Nano Cellulose Crystals (CNC) to reach an output of 10Kg/day.

What we want to achieve:
  • Deliver amounts of CNC large enough for process and product development.
  • the pilot line aims to have a scalable process with a commercially relevant product to support decision making for production scale implementation.
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Efficient industrial use of Cellulose NanoFibril

Improving and optimising the production of nano cellulose as a sustainable biomaterial to reduce the use of fossil plastic.

What we want to achieve:
  • The pilot line will deliver amounts of CNF large enough for process and product development
  • Furthermore, the pilot line aims to have a scalable process with a commercially relevant product (with qualities similar to what a commercial supplier would produce) to support decision making for production scale implementation.
  • State of the art pilot facilities can be used to produce nano cellulose tailored based on the end-product requirements.
  • Scientific competence, characterisation methods and quality control tools will support the tailoring and optimization work.
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