Injection mouldable biomaterials for recyclable furniture BIOMATERIALS – Towards Industrial Applications 22.5.2013 Startup Sauna, Otaniemi Heidi Peltola VTT Technical Research Centre of Finland

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Contents  Drivers for biopolymers and fibre composites  Definitions  Biocomposite research at VTT  Biopolymer research  Cellulosic fibre research  Processing and process development  Commercial biocomposite compounds for injection moulding  Case Ekokeittiö – Puustelli Miinus

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Drivers for biopolymers and fibre composites      

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Alternative for non-renewable based polymers and composites Closed CO2-cycle New environmental laws and regulations, European strategic research programs Price increase in petrochemical based polymers (-> need for cheap fillers and renewable or bio-based polymers) Increasing demand and customer interest of bio-based materials → increasing production -> decreasing price Research activity of WPC and bio-based composites is increasing → property development towards engineering materials, new grades of materials Image, ‘natural’ look and feeling Biodegradable and non-biodegradable Increasing help and interest in industry by creating new recycling possibilities for bio-based materials helps to adapt these materials in use Packaging industry is moving from cost cutting towards renewable materials Safer and lower weight materials (smaller fuel consumption) for transportation About 20% yearly increase in market (NFC&WPC)

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Green Composites

Injection mouldable…

Bio-based composites

NRPC Naturally Reinforced Plastic Composites Biocomposites NFC Natural Fibre Composites Natural Composites WPC Wood Plastic Composites

= Natural/renewable fibre + N o n b i o d e g r a d a b l e

Renewable polymers Renewable PE Renewable PET Renewable PA Renewable PU…

PLA, PHA (PHB) Lignin Starch, cellulose and protein derivatives

Petrochemical based polymers PE, PP PS, PVC PET, PA, PC…

PCL PVA PBS…

B i o d e g r a d a b l e

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Biocomposite research at VTT

Development of Polymers

Natural fibres Different fibre types and shapes: wood, flax, hemp, cotton etc.  Industrial minor flows  Nanofibres  Fibre treatments

business operations

Processing & Process Development

Additives  Commercial additives  Nanoparticles  Additives developed by research centers and companies

 Commercial polymers: PE, PP, PLA, PCL, PHB etc. Biopolymer blends Biopolymers developed by research centers and companies

and value chains

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Biopolymer research at VTT

Polymers from biomass

Synthesized from biobased monomers

Tall / Vegetable oil based PGA Polymers from C2-C6 PLA applications New co-polymers

Chemically synthesized bio/degradable polymers Cellulose derivatives Starch derivatives Lignin derivatives Hemicellulose derivatives Protein derivatives

Polyesters (succinates, lactones..)

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Cellulosic fibre research for biocomposites

Pelletising

Physical treatments

Chemical treatments

Plasticising Enzymatic treatments

Fibre fractionation

Chemoenzymatic treatments

Additives

Cellulosic fibres as reinforcement

Better fibre/matrix adhesion

Improved compatibility Optimised fibre aspect ratio

Better fibre dispersion

Better processability

Improved material properties for composites

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Processing and process development Fibre dimensions, dispersion and distribution: Determined by process parameters, methods, melt viscosity and pre-processing Parameter combination >15  Screw geometry  Processing steps and methods  Viscosity & shear  Orientation

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Correlation between composite strength, fibre content, and plastisizer content

Nättinen et al. Mech. of Time-Depend Mat, 16, 2012, 47-70. Peltola et al. Plastics, Rubber and Composites: Macromol, 40 (2011) 86-92 Peltola et al. Journal of Materials Science and Engineering. Vol. 1 (2011) No: 2 , 190-198 Nättinen et al. Journal of Composite Materials Vol. 45 (2011) No: 20, 2119-2131

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Commercial biocomposite compounds for injection moulding  UPM ForMi – cellulose fibre reinforced plastic composite with high (up to 50%) renewable material content, specially designed for injection moulding applications  Kareline® - natural fibre reinforced composite granulates available based on PP, ABS, PS, POM and PLA matrix, excellent for injection moulding and extrusion  Tecnaro Arboform® - made from 100% renewable materials (lignin, natural fibres and additives) and is mainly used for injection moulded wood applications  Beologic – Recyclable, ready-to-use compounds filled with 25 up to 85% of wood fibres in PVC, PP, HDPE or PLA matrix  Among others!

ISKU Prima chair, seat made from WPC http://www.iskuinterior.fi

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Case Ekokeittiö – Puustelli Miinus New biocomposite based materials and solution for kitchen furnitures launched in 2013 by Puustelli Company Impact:  Reduction of waste material using injection moulding instead of carpenter work  New production method and material allows totally new frame structures and lower weight furnitures, lower weight components  30-45% Reduction to carbon footprint compared to current materials (MDF or fibre boards)  Reduced VOC emissions in new materials  Possibility to use domestic industry in component manufacturing  Biocomposites allows new joining techniques  Developed by Puustelli Group Oy and Desigence Oy, with industrial designer, Professor Juhani Salovaara as the lead designer. UPM, VTT and the Wood Chemistry Laboratory of Aalto University, as well as a number of top specialist companies in the field, also made a large contribution to the technological design process.

Additional information: Lisa Wikström or Kirsi Immonen

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VTT creates business from technology

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