Demonstrating a new innovative production process of a unique and green substitute for plastic materials

PROJECT DESCRIPTION

BACKGROUND

In Europe there are roughly 60 million tonnes of plastics consumed today. Global plastic production increased from 1.5 million tonnes per year from 1950 to 245 million tonnes in 2008, of which 60 million tonnes were produced in the EU. An estimated 66.5 million tonnes of plastic will be placed on the EU market in 2020 (if no action is taken) and the global plastic production is estimated to triple by 2050.

The global packaging market is estimated to be worth €450 billion with plastic accounting for nearly 40% of the market share, followed by paper and board with 30%. With a growth rate of about 6%, the European market for food trays is expected to amount to 10-12 billion trays in a few years, the equivalent of around 2 million tonnes of plastic. In many cases, the packaging gives the product a significantly longer life span, which means that food wastage is reduced. This suggests that there will always be a need for food packaging.

The demand, however, for replacing plastic with fibre-based packaging is growing steadily. If production of a fibre-based packaging that creates an oxygen-free atmosphere can be achieved, then there is the potential to break into the market for packaging of fresh food. However, existing paper converting processes struggle to compete with cheap plastic converting processes. The need for developing new converting techniques for fibres that are competitive is clear.

OBJECTIVES

The main objective of DURAPULP for LIFE was to successfully demonstrate the production of 3D formed fibre-composite products, through the use of Airlaid conversion technology.

Specifically the project aimed to:

• A  verified  process  technology  (from  raw  material  to  end-product)  for  production  of  3D formed fiberbased products using Airlaid thermoforming technology.
• Validate the market potential using commercial reference products with chosen potential customers and actors in the value chain (Initial results show a potential for commercialisation of DuraPulp within two years of the completion of the LIFE project); and
• Further knowledge of Airlaid technology and establish a platform  for Airlaid thermoforming of high-performance 3D products.

 

RESULTS

In the DURAPULP for LIFE project the production of 3D formed cellulose based products has been demonstrated, using a dry technology – meaning that the production is done without water,  with a potential to replace plastic packaging materials. The project encountered a number of problems and delays, but succeeded in launching prototypes and an operational demonstration plant at the beginning of 2019.

 

The project team demonstrated the use of Airlaid conversion technology to produce 3D formed fibre-composite products. There has been active support for further commercialisation of this biodegradable material through the C2M initiative.

 

One demonstration plant was developed during the project and to demonstrate the possibilities with the technology three different products were produced during the project, using different pulps and/or additives. In total the following prototypes were produced and evaluated: (i) 14 prototype plates, including different films; (ii) 20 prototype drug test kits (of which 6 were considered very successful); and (iii) 5 prototype meat trays.

 

The project team also proved near industrial scale by producing 5 000 tableware units. Food and industrial packaging were produced only as prototypes during the project. A big challenge related to food packaging is to ensure products are hydrophobic, and this challenge is still to be fully overcome.

 

A market analysis and a Life Cycle Assessment (LCA) (including cost analysis) were completed for the products. The LCA for the meat tray showed a potential CO₂ reduction of 80-85%.

The target energy savings of up to 80% compared to traditional techniques was reached. According to the estimates of the coordinating beneficiary, the forest industry group Södra, the dry-forming process developed and demonstrated by the project gives an energy reduction in the range of 55 to 85% compared to currently-used wet moulding technology.

Further information on the project can be found in the project's layman report and After-LIFE Communication Plan (see "Read more" section).