Il polypla BIOFOAM® la nascita di una nuova filiera ... · •Orange 414F •High Temperature Foam...
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Transcript of Il polypla BIOFOAM® la nascita di una nuova filiera ... · •Orange 414F •High Temperature Foam...
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Il polypla BIOFOAM® la nascita di una nuova filiera industriale in Italia
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Developments Presentation contents
Synbra Group Company introduction; BioFoam® project overview; BioFoam® processing
BioFoam® properties: • Energy requirements and carbon footprint; • CO2 footprint, Energy Mechanical thermal Applications
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Introduction
SYNBRA is the leading producer and converter of Expanded Polystyrene
(‘EPS’):
with about 800 employees
• with a turnover of about € 240 million
• the majority of the shares are owned by Gilde, Management, NPM
• focus on Sustainable Insulation Systems (SIS) and
Industrial Products & Solutions (IPS)
• innovative and vertically integrated through Technology & Innovation (T&I)
• Integrated producer with own EPS production of 65,000 tons, PLA 5000 ton.
• Dutch holding co-ordinates 5 Clusters and has 13 production locations in 4
countries
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Markets End products
Technical parts, Electronics
Industrial/ Technical
Fish, Meat, Produce
Food
Horticulture
Cavity, exterior Wall insulation
Boards, systems Floor insulation
Road construction Civil engineering
Pitched, flat Roof insulation
Sustainable Insulation Systems (SIS)
Seed trays
Markets End products
Industrial Products & Solutions (IPS)
Water filtration Biobased
Biostyr® Various
Synbra’s Broad range of Foam applications
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Synbra’s European coverage - About 800 employees; - Turnover of about € 240 million - Producer of EPS polymer - Producer of PLA polymer ( only one in EU) - Focus on Foam
-Synbra Technology supplies businesses with EPS beads – Local BUs convert the beads into products • Local BUs invest in product and application innovations – Synbra Technology supports with material
innovation
13 production locations in 4 countries
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… Synbra ranks in the top in its key home markets
Source: Synbra
Industrial Products & Solutions (IPS)
No.1 No.2 No.3
Denmark Synbra DS Smith Sunde
Benelux Wolters Synbra Lemahieu
Portugal Synbra Tome e Vaz Siplacor
Market position 2013 (in tons)
Sustainable Insulation Systems (SIS)
No.1 No.2 No.3
Benelux Synbra Kingspan VBI
Germany BACHL Rigips Synbra
Denmark Sunde Synbra Jackon
Portugal Synbra Tecnovite Petibol
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Special Extruded and coated EPS
• PS strips
• Orange 414F
• High Temperature Foam
• HT 200F
• HT 400
• Microwave absorbers
BioFoam®: PLA particle foam
Jan Noordegraaf, Synbra Technology bv
BioFoam® Awards Winner of the Frost & Sullivan Technology Innovation Of The
Year Award 2008 PLA polymerisation process
Winner 2009 gold sustainability medal awarded by the Dutch Rubber and Plastics Federation
#1 of the 2010 MKB top 100 : Earmarked most innovative
company in the Netherlands
Third Price in Dutch 2010 packaging “De gouden Noot”
Winner ‘Nederlandse Bouwprijs 2011’ at construction exhibition
in Utrecht (NL).
Winner of the Frost & Sullivan Technology Innovation Of The Year Award 2011 for BioFoam
Plus X award building products Germany 2013
Winner chain efficiency 2014
BioFoam® project overview
History BioFoam® project
• Formal project started April 2006; • R&D with Wageningen University WUR; • Starting point: use own EPS pre-expansion &
moulding; • Use Polylactic acid (PLA); best results blowing
with CO2; • Shape moulding with biobased coating • Integrated raw material PLA supply since 2011
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Biodegradable versus Biobased
BioFoam® processing
Raw bead production
Prefoaming raw beads
Maturing of prefoamed
beads
Moulding of prefoamed
beads
Impregnation with CO2
Coating of prefoamed
beads
Impregnation of coated
beads
EPS foaming
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PLA foaming
PLA foaming
• Prefoaming is done on a commercial EPS prefoamer;
• Density 17 g/l in one prefoam step , 13 g/l in 2 steps
Compared to EPS:
• Lower temperatures;
• Shorter cycle times.
To deal with:
• CO2 evaporates easily;
• Heat stability of PLA.
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PLA molding
• A special coating is applied to the prefoamed BioBeads to improve adhesion during moulding;
• Patented technology: WO 2008130226.
Continuous fluid bed coating unit (Glatt fluid bed)
Batch fluid bed coating unit (Wurster coating)
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PLA molding
• Moulding is done on a commercial EPS moulder;
• Similar process as with common EPS grades.
Compared to EPS:
• Lower temperatures;
• To deal with:
• CO2 evaporates easily;
• Heat stability of PLA.
• Crystallisation of PLA
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BioFoam® properties
Synbra LCA Tool v. 1.0 For Holistic Environmental Evaluation of
BioFoam and EPS Foam
Based on Life Cycle Assessment Compliant With ISO 14 040 + 14 044 Standards
Prepared by Tobias Borén
AkzoNobel Sustainable Development, Sweden Peer reviewed by Martin Patel, Utrecht University
October 8th 2010
Sustainability
Sources: Life Cycle Assessment Compliant With ISO 14 040 + 14 044 Standards by TobiasBorénAkzoNobel Sustainable Development, Sweden. Peer reviewed by Martin Patel, Utrecht University October 8th 2010
PLA feedstcok: NON optimised sugar mill, with optimised ugar mill values are much lower
Other polymers LCA source Plastics Europe www.lca.plasticseurope.org
• PLA most sustainable polymer
• Bio-PE much less efficient than PLA
C02 emission per ton processed polymer
0 1000 2000 3000 4000 5000 6000
Biaxial PP film
PET film
Thermoform HIPS
PUR rigid foam
EPS foam
PE film
BioFoam moulded
Crude oil eq. consumption for 13 kg/m3 bean bag filling
Carbon footprint for 1 m3 of beanbag filling
Conclusion: BioFoam 40% CO2 emission compared to EPS
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Validation and supporting information
• LCA verified by, AkzoNobel – Technology & Engineering Sust. Dev.Group; Sweden – Peer reviewed by Prof. Martin Patel-Utrecht Univ.
• Fire test Bean Bags Efectis – meets BS 5852 ( sigaret/match) crib 5 – Meets Euroclass E fire classification – No halogens present
• Droptesting at Clemson University (South-Carolina);
• Compostability certification EN13432 • Passed EN117/118 Termite/pest and fungus tests • C2C Silver certified by EPEA;
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PLA cell structure
Structure looks very similar to EPS
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Drop test results
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1st drop (height/thickness = 10)
0,000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
0,00 5,00 10,00 15,00 20,00 25,00 30,00Static stress (kPa)
G (-
)
EPS (20 g/l) PLA (60 g/l)) PLA (35 g/l)
Composting results
5 x 5 x 5 cm3 BioFoam® blocks (various densities) disintegrate industrially completely at 70oC within 4 weeks.
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No breakdown at ambient temperatures
BioFoam® applicatons
BIOFOAM
BioFoam® E-PLA loose beads
– Production running for cavity fill and – Several bean bag projects – Density 16 g/l green beads, Grey 18 g/l – Approval for ‘Grey’ BioFoam:
improved lambda for cavity fill
BioFoam Construction
•
• NL; termokomfort • D: Isofloc
BioFoam inside ( how green do you want it)
• In blockform/Automatenplatte • Up to 10% Mix no effect on • kPa/Lambda, meets Euroclass E
BioFoam® E-PLA
Industrially Moulded parts – Density 30 g/l – Low cycle times – Food approved – Alabastine trays / Zandonella Bio-Eis – Sulpol Ice box
BioFoam Moulded Packaging
Fish box Pallets LCD buffer Childs seat Kelvin box Ice box
Other applications
• Puncture detector • Surf boards • BioFoam HR ( grey)
Very low emission VDA 277 test
Comparison
Characteristics compared materials
for 6 cm cavity filledBio
Foam grey
EPS HR PUR MW
Biobased + - - -Euroclase E, fire retarded + + + +Cradle to Cradle certified + - - -Contains no halogens + - - +Contains no fibres + + + -Contains no isocyanides + + - +Contains no formaldehydes + + + -No negative HSE media attention in 2013 in NL + + -# -##
# Realisatie meldpunt PUR slachtoffers, nav diverse NOS journaal uitzendingen over allergie
## Brandbrief aan tweede kamer door 8 professoren en longartsen, en NCRV uitzending "Altijd wat"; mbt Longfibrose
End of Life options
Characteristics compared materials
End of Life Bio Foam
EPS PUR MW
Incineration as Green energy + - - -Mechanical recycling () + + -# -Incineration without energy recuperation + + + -Incineration with energy recuparation + + - -fermentation (UK) + - - -Industrally compostable + - - -Feedstock recycling to monomeer + + - -Landfill + + + +
() Biofoam mixes with EPS #crosslinked, mix as powder
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• C2C Silver Awarded since March 2011 BioFoam PLA • New scrutiny passed May 2014 • Lowest VOC emission in foams in automotive applications • BioFoam has a Werkstoff number 7W0175 • Certified non GMO • Certified compostable
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BACK UP SLIDES
Sustainability of biopolymers Sources: Life Cycle Assessment Compliant With ISO 14 040 + 14 044 Standards by TobiasBorénAkzoNobel Sustainable Development, Sweden. Peer reviewed by Martin Patel, Utrecht University October 8th 2010
PLA feedstcok: NON optimised sugar mill, with optimised ugar mill values are much lower
Other polymers LCA source Plastics Europe www.lca.plasticseurope.org
• PLA most sustainable polymer
• Bio-PE much less efficient than PLA
Landuse
• Feedstock required for bioplastics production accounts for only a minimal fraction of global agricultural area.
• The surface required to grow sufficient feedstock for today’s bioplastic production is less than 0.006 percent of the global agricultural area of 5 billion hectares. This is the key finding published in May 2013 by European Bioplastics, based on figures from the Food and Agriculture Organization of the United Nations (FAO) and calculations of the Institute for Bioplastics and Biocomposites (IfBB, University Hannover, Germany).
• In a world of fast growing population with an increasing demand for food and feed, the use of feedstock for non-food purposes is often debated controversially. The new brochure “ Bioplastics – facts and figures” published today by European Bioplastics, moves the discussion on to a factual level.
• Of the 13.4 billion hectares of global land surface, around 37 percent (5 billion hectares) are currently used for agriculture. This includes pastures (70 percent, approximately 3.5 billion hectares) and arable land (30 percent, approximately 1.4 billion hectare).
• These 30 percent of arable land are further divided into areas predominantly used to grow crops for food and feed (27 percent, approximately 1.29 billion hectares), as well as crops for materials (2 percent, approximately 100 million hectares, including the share used for Bioplastics), and crops for biofuels (1 percent, approximately 55 million hectares).
• Source :http://en.european-bioplastics.org/download/labelling/EuBP_Land_use_2013.jpg • Minimal fraction of land used for Bioplastics • European Bioplastics market data depicts production capacities of around 1.2 million tonnes in 2011.
This translates to approximately 300,000 hectares of land-use to grow feedstock for bioplastics. In relation to the global agricultural area of 5 billion hectares, bioplastics make use of only 0.006 percent.
Landuse
No competition with food and feed A glance at the global agricultural area and the way it is used makes it abundantly clear: 0.006 percent used to grow feedstock for bioplastics are nowhere near of being in competition with
the 98 percent used for pastures and to grow food and feed. According to European Bioplastics, increasing the efficiency of feedstock and agricultural technology will be key to assuring the balance between land-use for innovative bioplastics
and land for food and feed. The emergence of reliable and independent sustainability assessment schemes will also contribute to this goal.Source;
http://en.european-bioplastics.org/blog/2013/04/05/pr-20130408/ More information: European Bioplastics’ brochure „facts & figures“:
http://en.european-bioplastics.org/wp-content/uploads/2013/publications/EuBP_FactsFigures_bioplastics_2013.pdf
Synbra’s supply position • Synbra polymerises PLA and is the only EU producer of PLA. Synbra’s raw material supplier of lactide
monomer is Purac Biochem. Named Corbion per 18/6/2013. Purac produces lactic acid by fermentation of biomass crops; sugarbeet and starch. This lactic acid is used to make lactide feedstock. Purac Biochem is investing heavily in technology to be able to move away from what can even be perceived as food crops and will use 2nd and 3rd generation non-sugar non-food crops plant waste to produce lactic acid by fermentation.
• Even waste paper is being researched and considered feasible as feedstock for fermentation into lactic acid and facilities to produce this are already being built to operate on pilot scale.
• source: http://www.purac.com/EN/About_us/News/Press-release-Purac-joins-waste-paper-consortium.aspx
• To be more specific, feedstock for making Synbra’s PLA is either sugerbeet from the EU, grown in
Spain and the Netherlands, and/or sugarcane/cassava starch grown in Thailand, where Purac’s larger lactide factory is based. Purac also makes lactic acid in Brazil, but that is not used to make lactide nor PLA. Thailand is a net exporter of locally abundant biomass and is striving to become the bioplastics centre in Asia. There is no negative implication of using food to make bioplastics and thereby causing hunger.
Note from Akzo Nobel on LCA use
Disclaimer This tool has been developed in cooperation between Synbra and AkzoNobel Sustainable Development (furthermore: SD), a part of AkzoNobel and legally residing within AkzoNobel Surface Chemistry AB, Sweden. The tool and the underlying data have been developed with best knowledge and conscience. Information contained herein have been checked and verified by SD, constructed according to SD best practice and/or have been compiled or derived from sources believed to be reliable. The accuracy and usability of the individual results from the tool is heavily dependent on the user inputs. SD is unable to take over liability for possible damages, loss in profit or economic downturn as a result of using the tool and the information provided. SD will only support claims regarding the results under the presumption that SD reviews the claims and the information forming the basis of the results.
