Up-Scaling of Biobased Boxes

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The use of so-called foam boxes is huge. They keep food warm, protect medicines and organs. The problem is that the foam material currently consists of fossil materials that are not biodegradable or recyclable. INN-PRESSME partner FRAUNHOFER ICT, together with its partners VTT, WSVK, POLYMARIS, CEA, IWN and AITIIP, wants to change this. The aim is to produce boxes in industrial quantities from a mixture of different biomaterials, by processing the raw material in such a way that the shape and flexibility meet the current standard and the requirements of the industry.

One of the biggest challenge for achieving industrial quantities is the combination of different biological raw materials such as flax, hemp, cellulose nano fibres and biocompatible synthetic polymers. The use of various production processes, such as 3D printing or moulding, demonstrates the wide range of possible applications. 

Facts & Figures

  • Incorporation of fibres into EPLA is not beneficial for improvement of foam properties
  • Successful optimization of material via recipe and process modification for implementing of bio-materials in demanding products
  • Improved material properties without increase in material costs are shown
  • Incorporation of 3D-printed elements in foam moulding process
  • Demonstrator designed and produced

Related pilot lines

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

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.
Download pilot line pdf

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.
Download pilot line pdf

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.
Download pilot line pdf

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.
Download pilot line pdf