Characterization of short fiber-reinforced polylactic acid ...
World’s most versatile bioplastic -...
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World’s most versatile bioplastic
www.floreon.com
Floreon NEW A4 Brochure v10.indd 2 14/04/2015 11:03
Floreon was created from a desire for a greener, safer form of plastic water bottles for office water coolers.
Unhappy with the options available we decided to develop our own...
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Floreon was created from a desire for a greener, safer form of plastic water bottle for office water coolers
Unhappy with the options available, we decided to develop our own...
Floreon NEW A4 Brochure v10.indd 3 14/04/2015 11:03
The possibilities for Floreon are endless. We’ve gone far beyond the original remit of replacing the traditional water bottle, or even replacing PET plastic and other plastic derivatives. I believe it has the potential to transform both packaging and the way we think about plastic.”
Shaun Chatterton Founder
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Shaun started his own business
(CPD plc) in 1988 and it soon
became one of the UK’s largest
independent distributors of
cleaning and hygiene products.
He is the founder and Chief
Executive of Floreon.
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A Knowledge Transfer Partnership with the University of Sheffield was formed to develop a high performance bioplastic using polylactic acid (PLA) blends.
However, standard PLA does not have the toughness needed for many applications and Floreon was born.
This is how it all started
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Floreon was born out of a passion to innovate
Floreon was awarded the highest grade of “Outstanding” by the KTP Grading Panel and Innovate UK Best Research Partnership
Floreon is a range of specially formulated PLA based compounds
Our goal was to transform the way we think about plastic and the impact we have on the environment. Our approach is simple. Make it fast and make it right. We took an existing bio-based polymer (PLA) with beautiful material properties and added our own technology to make it work better than all the alternatives.”
Alma HodzicProf. of Advanced Materials Technologies at The University of Sheffield
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Alma was one of the original
inventors of Floreon. After
completing her PhD in Science
of Engineering Materials she was
a research fellow in Department
of Applied Chemistry at RMIT
University and lectured at both
The University of Sheffield and
James Cook University.
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Made from sustainable feedstocks, Floreon is the best choice for companies looking for high performance, versatile and green packaging solutions
• Lower carbon footprint – derived from non-mineral oil feedstock
• Easy to compost – certified to EN 13432 for industrial composting
• Recyclable – multiple end of life solutions available
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Made from plants not oiland derived from abundant100% annually renewable plant resources
Polys
tyre
ne
Polye
ster
LD Po
lyeth
ylene
Polyp
ropy
lene
(PLA
) Inge
o 2005
(PLA
) Inge
o 2009 C
IT*
3.4 3.22.7
2.1 1.9 2.01.3
4
3
2
1
0
GPPS PET PVC LDPE PP Ingeo Ingeo
From cradle to factory gate(kg CO2 eq. / kg polymer)
Reduced carbon footprint with PLA bioplastics
Polyv
inyl C
hlorid
e
7Source: NatureWorks LLC 2009 *CIT stands for “currently implemented technology”
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Capacity in 1,000 metric tonnes
5,000
4,000
3,000
2,000
1,000
0
776
5003
486
675
342
226674
23
5,779
1,1611,016
249Biodegradable
Biobased/non-biodegradable
Total Capacity
Source: European Bioplastics | Institute for Bioplastics and Biocomposites (December 2013)
2009 2010 2011 2016
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Readily available with a steady increase in capacity
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*In relation to global agricultural area
Land used for bioplastics (2011)
Global Agricultural Area
5 billion ha
37%
Bioplastics are not even close to being in competition with food and feed.
Food & Feed1.29 billion ha / 27%
Pasture3.5 billion ha / 70% Material Use
100 million ha / 2%
Biofuels 55 million ha / 1%
Bioplastics*
2011 300.000 ha0.006%
2016 1.1 million ha0.022%
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Floreon performance v PLA
• Vastly increases the number of applications for PLA• Excellent form, stiffness and rigidity • Excellent gloss and printability• Easy to blend, mold, shape, emboss and process
on existing equipment• UV stable• Non-allergenic components• Food packaging compliant (EU 1935/2004)
Floreon has developed a range of specially formulated compounds based on PLA - so special that they are four times tougher.
PLA already has excellent stiffness and transparency, our technology allows us to enhance its performance in other areas such as toughness and durability, without compromising the compostability and high bio content.”
Dr. Andrew GillTechnical Director
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Andrew helped develop Floreon through a Technology Strategy
Board sponsored Knowledge Transfer Partnership between CPD
and the University of Sheffield. He is Technical Director of Floreon.
BSc, Chemistry, MSc, Chemistry with Biochemistry, Doctor of
Philosophy (PhD), Tissue Engineering.
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PLA
In house testing on sheet specimens to *ISO 6603-1/A and **ISO 527-3 on extruded sheet, thickness 750 micron
4
4
4
180-220
490
12
4
4
4
160-220
1950
70
11
Recyclable
Biodegradable
Biobased
Process T (OC)
Impact Resistance* (mJ)
Elongation at Break**
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Floreon performance v oil based plastics
Floreon also offers significant benefits over oil based plastics.
Environmental• More stable feedstock
price compared to volatility of world oil price
• Less energy needed to produce
• Not from fossil fuel• Composts more readily
than most oil based plastics
Performance• Higher strength than
PS and even PET • Modulus (stiffness) higher
than polystyrene, great for rigid sheet applications
• Excellent impact resistance for performance
Our vision with Floreon was to create a range of PLA based compounds with performance equal to if not better than the oil based plastics they replace.”
Bill StringerCommercial Director
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3.1
63
3.7
170-180
1.4
32
10
220-310
0.2
10
106
220-260
2.4
55
2
250-280
1.5
33
7
210-290
3.0
34
2
200-250
Rigidity/Modulus (GPa)
Tensile Strength (MPa)
Impact Resistance* (kJ/m2)
Process T (OC)
HDPE
LDPE
PET
PP PS
Based on independent testing and comparison with Floreon 100
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This is how FloreonworksFloreon is biodegradable and fully recyclable. It can be converted back into feedstock in an energy efficient manner and re-polymerised back into virgin PLA.
Pure polymers are often restricted in their applications and properties and require careful formulating to achieve the best results. This is obviously a normal approach in the conventional plastics industry but one which is only recently being pursued in the bioplastics sector.
Floreon is an excellent example of producing a range of plastics based on PLA, which maximises and enhances the properties of PLA and produces bioplastic products with a wide range of applications and functional benefits, in combination with positive environmental credentials.”
Dr. John Williams Non-Executive Director
John is a globally experienced
technology manager and advisor in
the field of renewable materials and
sustainable technology. John is a Non-
Executive Director at Floreon. BSc,
Chemistry, PhD, Polymer Chemistry.
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SciencePlants’ sugars are transformed into biopolymers which become Floreon after a special additive has been added.
BiomassPLA is taken from 100%
annually renewable resources.
End of lifeFloreon has a
range of options.
CompostFloreon, unlike PET,
can also be composted.
ApplicationFloreon is used to make
plastic items such as packaging.
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Energy from waste
Energy Recovery maintaining a short
carbon cycle.
RecycleFloreon can be
recycled.
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Floreon 100 is a versatile blend containing 90% polylactic acid combined with the optimal amount of two other biodegradable polyesters, which enhance both the processability and impact resistance of the base polymer.
• Enhanced processability • Increased impact resistance
Floreon 200 is an opaque white pigmented grade of Floreon specifically intended for sheet extrusion. The Floreon additive levels have been adjusted to enhance durability and processability, while also being cost competitive.
• Enhanced durability• Cuts easily• Good printability
Floreon 300 is optimised for extrusion blow moulding (EBM). Floreon was designed for injection moulded applications requiring a high melt flow index. However by optimising the additives used the toughness of the base material can still be boosted while lowering the melt flow index and maximising melt strength.
• Low melt flow index• Improved toughness
Floreon 400 is a grade of Floreon optimised for film production.The material has been optimised for melt strength and low temperature processing.The material is slightly softer than unmodified PLA.
• Enhanced melt strength • Lower processing temperature
Floreon Grades
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Floreon
300
EXTRUSION BLOW MOULDING
Floreon
40
0
FILM
Floreon
200
SHEET EXTRUSION/ PRINTING
Floreon
100
GENERAL PURPOSE / INJECTION MOULDING
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Floreon 500 is intended for injection stretch blow moulding, for the production of bottles. The blend contains at least 90% Ingeo PLA, combined with the selected Floreon additives to enhance the toughness of the finished items while also making them easier to process.
• Enhanced toughness• Improved processability
Floreon 600 is a versatile blend of polylactic acid combined with the optimal amount of two other biodegradable polyesters, which enhance both the processability and impact resistance of the base polymer. The material is tougher than PLA across the temperature range.
• Higher crack resistance in roll stage• Increased impact resistance• Improved processability
Floreon 700 is a Floreon formulation designed to give stable extrusion (for uniform filament diameter) over a wider range of temperatures. The finished product is tougher than PLA allowing the creation of more resilient structures. The printability and finish is excellent making this a good choice for 3D printing applications. Colours and pigments can be added as required.
• Good processing stability • Stable (or uniform) filament diameter • Improved mechanical performance• Good printability • Higher flexibility
Floreon 800 is a compound containing polylactic acid developed for injection moulding. This formulation has a high melt flow index allowing new applications for PLA with smaller feature sizes. The mechanical properties of the resulting products are also substantially enhanced.
• Higher elongation at break• Higher impact resistance • Higher melt flow index• Easier moulding with lower inject pressures
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Floreon
600
THERMOFORMING
Floreon
500
STRETCH BLOWMOULDING
Floreon
700
3D
Floreon
800
ENHANCED INJECTION MOULDING
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Patent Filings UK Granted Patent GB 2488811
EU Pending Pat App EP 12710776.1
US Pending Pat App US 14/003557
Canada Pending Pat App CA 2828190
Australia Granted Patent AU 2012226557
New Zealand Granted Patent NZ 614394
China Pending Patent App 201280012321.2
Japan Pending Patent App JP 2013-557174
Standards All components of Floreon satisfy the standard EN13432
(ASTM D6400 equivalent).
Floreon NEW A4 Brochure v10.indd 19 14/04/2015 11:03
• Cast sheet/ film
• Injection moulded items
• Injection stretch blow
moulded items,
• Thermoformed items
SuggestedApplications:
Floreon 100 is a versatile blend containing 90%
polylactic acid combined with the optimal amount of
two other biodegradable polyesters which enhance
both the processability and impact resistance of the
base polymer. Specific benefits over PLA alone include:
• Higher impact resistance
• Higher melt flow index
This can be readily demonstrated using cast sheet as an example:
Floreon 100 cast sheet specimens (60 mm x 60 mm, thickness 750 micron)
were found to have impact resistance four times higher than unmodified
pla. (e50 = 1950 mJ versus 490 mJ, Iso falling dart impact test).
samples were produced on a Betol BK38 single screw extruder. The Ingeo
material required a metering and die temperature of 210 °C, and a screw
drive motor current of 20 amps with significant fluctuation. The Floreon
material extruded easily with a drive current of <10 amps (steady current)
and a metering and die temperature of 190 °C.
In injection moulded applications the higher melt flow index of Floreon (10
g/ 10 minutes (Floreon) and 4.2 g/ 10 minutes (Ingeo), 2.16 kg @ 190 °C)
allows lower pressures and temperatures to be used relative to unmodified
pla. standard 24g bottle preforms for IsBM were produced on a Husky
HypeT injection moulding machine at 210 °C with a mould temperature of
20 °C. Floreon required 20% lower injection pressure than Ingeo with a
commensurate cycle time (trials conducted in collaboration with Constar
International (leeds, uK). preforms as large as 300 g were produced in
collaboration with peT engineering solutions (Bergamo, Italy).
Technical Data sheet
Floreon meets the requirements of eu food contact materials legislation (regulation no.1935/2004) and the specific controls on plastics in contact with food
(regulation no.10/2011) and associated directives. This encompasses the constituent monomers, overall and specific migration limits. 500 ml prototype IsBM
bottles passed the standard migration tests required by eu regulations, for all standard food simulants, when examined by a certified test house (smithers rapra,
shrewsbury, uK). Information updated 15/12/2013. Final performance and processing parameters will vary depending on your equipment. Figures may be revised
without notice. Detailed technical datasheet available upon request.
Floreon
100
generalpurpose
Floreon
200
sHeeT exTrusIon
/ prInTIng
• Cast sheet
SuggestedApplications:
Floreon 200 is an opaque white pigmented grade of
Floreon specifically intended for sheet extrusion.
Addition of pigment achieves opacity at a thickness of
450 microns, and the melt flow index of the material
has been further increased to compensate for the
thickening effect of the pigment. The Floreon additive
levels have been adjusted to enhance durability and
processability, whilst also keeping the cost low. The use
of recycled PLA in the blend makes the material
unsuitable for food contact applications, but enhances
the environmental credentials of the blend even further
without compromising quality. The specific benefits of
this grade of Floreon are:
• Improved impact toughness (as with Floreon 100)
• Improved processability (as with Floreon 100)
• enhanced stability upon regrind
• excellent glossy finish
• Improved environmental credentials
• Competitive price
Floreon 200 has been optimised through trials with leading sheet extrusion
companies and is designed to achieve a suitable balance between melt
viscosity (preventing excess loads being placed on the extruder) and melt
strength (minimising die sag). The results achieved will depend on the
settings used and optimal processing is typically achieved with barrel/ die
temperatures between 180-210 °C, and rollers heated to around 40 °C to
prevent freezing the material into a glassy state. exceeding these
temperatures can have an adverse effect on the material.
Floreon sheet has demonstrated to have up to four times higher impact
resistance than unmodified Ingeo material resulting in more durable sheet
which is less prone to brittle fracture whilst maintaining the excellent
stiffness of pla.
Technical Data sheet
Floreon meets the requirements of eu food contact materials legislation (regulation no.1935/2004) and the specific controls on plastics in contact with food
(regulation no.10/2011) and associated directives. This encompasses the constituent monomers, overall and specific migration limits. 500 ml prototype IsBM
bottles passed the standard migration tests required by eu regulations, for all standard food simulants, when examined by a certified test house (smithers rapra,
shrewsbury, uK). Information updated 15/12/2013. Final performance and processing parameters will vary depending on your equipment. Figures may be revised
without notice. Detailed technical datasheet available upon request.
Floreon
300
exTrusIon Blow MoulDIng
• extrusion blow
moulded items
SuggestedApplications:
Floreon 300 is a grade of Floreon optimised for
extrusion blow moulding (EBM). Floreon was designed
for injection moulded applications requiring a high melt
flow index, however by optimising the additives used,
the toughness of the base material can still be boosted
whilst lowering the melt flow index and maximising
melt strength. Benefits of Floreon 300 include:
• Tougher blow moulded items such as
‘wet wipe tubs’
• low melt flow index tailored to eBM
• Higher melt strength
• low processing temperatures
Bioplastics such as pla are not generally recommended for extrusion blow
moulding due to their inherent low melt strength. Through working with
processors operating standard eBM equipment, a specialised Floreon eBM
grade was developed suitable for the production of various items including
standard ‘wet wipe’ tubs and other pots and containers. a noticeable
difference in parison stability and strength was achieved by altering the
characteristics in the Floreon blend.
a melt temperature of around 160 °C and a gently tapering die is
recommended to achieve best results. Floreon 300 was trialled on a
standard HDpe extrusion line and produced mouldings of a suitable quality
compared to the HDpe equivalent. a machine equipped with a hot knife is
recommended as pneumatic cutters struggle to separate the moulding from
the parison.
Technical Data sheet
Floreon meets the requirements of eu food contact materials legislation (regulation no.1935/2004) and the specific controls on plastics in contact with food
(regulation no.10/2011) and associated directives. This encompasses the constituent monomers, overall and specific migration limits. 500 ml prototype IsBM
bottles passed the standard migration tests required by eu regulations, for all standard food simulants, when examined by a certified test house (smithers rapra,
shrewsbury, uK). Information updated 15/12/2013. Final performance and processing parameters will vary depending on your equipment. Figures may be revised
without notice. Detailed technical datasheet available upon request.
Floreon
40
0
FIlM
• Cast film
• Blown film
SuggestedApplications:
Floreon 400 is a grade of Floreon optimised for film
production. The material has been optimised for melt
strength, clarity and low temperature processing. The
material is slightly softer than unmodified PLA. The
specific benefits of Floreon 400 include:
• Clarity and transparency
• easier processing via blown film extrusion
• softer feel compared to unmodified pla
• low temperature processing and heat sealing
a common complaint with early pla films was the noise generated when
the material is ‘crinkled’. The softer feel of Floreon 400 and the unique phase
structure of the polymer blend leads to effective dampening of the noise
generated by crinkling the film.
The material maintains the high biobased content (over 90% pla) and does
not compromise the biodegradability of the base pla material. Despite
being significantly softer, the tensile strength of the film is not lowered
significantly making this a strong and durable film.
Film samples have been produced using both blown film extrusion and cast
film extrusion lines.
Technical Data sheet
Floreon meets the requirements of eu food contact materials legislation (regulation no.1935/2004) and the specific controls on plastics in contact with food
(regulation no.10/2011) and associated directives. This encompasses the constituent monomers, overall and specific migration limits. 500 ml prototype IsBM
bottles passed the standard migration tests required by eu regulations, for all standard food simulants, when examined by a certified test house (smithers rapra,
shrewsbury, uK). Information updated 15/12/2013. Final performance and processing parameters will vary depending on your equipment. Figures may be revised
without notice. Detailed technical datasheet available upon request.
Floreon
500
sTreTCH Blow
MoulDIng
• Injection stretch blow
moulded items
SuggestedApplications:
Floreon 500 is intended for injection stretch blow
moulding, for the production of bottles. The blend
contains at least 90% Ingeo PLA, combined with the
selected Floreon additives to enhance the toughness of
the finished items whilst also making them easier to
process. Colour additives are also available to make the
bottles transparent green, blue and potentially other
colours. The blend has a high melt flow index to
facilitate rapid, low temperature and pressure
fabrication of bottle preforms achieving lower injection
pressure than unmodified PLA. The finished bottles are
tougher than virgin PLA bottles. Independent testing of
injection moulded specimens of Floreon by Smithers
Rapra has shown that Floreon is around twice as tough
as PET, a common material for ISBM bottles.
Advantages of Floreon 500 include:
• High pla content
• Compostability of pla not compromised
• superior durability compared to pla and peT
• lower inject pressure and equal cycle times for
injection moulding
• lower preform reheat temperatures for blow
moulding
The additives in Floreon 500 affect the thermal behaviour of pla, making
the material crystallise faster than unmodified pla. This may be exploited in
the future to produce heat resistant grades of the material, however this
does impose stricter processing parameters on pla preforms. If excessive
heat is applied, Floreon preforms may crystallise and fail to blow. Testing has
shown that a maximum wall thickness of 5 mm can be allowed for Floreon
bottle preforms. For larger bottles, this necessitates a longer preform to
achieve sufficient bottle material.
Technical Data sheet
Floreon meets the requirements of eu food contact materials legislation (regulation no.1935/2004) and the specific controls on plastics in contact with food
(regulation no.10/2011) and associated directives. This encompasses the constituent monomers, overall and specific migration limits. 500 ml prototype IsBM
bottles passed the standard migration tests required by eu regulations, for all standard food simulants, when examined by a certified test house (smithers rapra,
shrewsbury, uK). Information updated 15/12/2013. Final performance and processing parameters will vary depending on your equipment. Figures may be revised
without notice. Detailed technical datasheet available upon request.
Floreon
600
THerMoForMIng
• Thermoformed items
SuggestedApplications:
Floreon 600 is a versatile blend containing 90%
polylactic acid combined with the optimal amount of
two other biodegradable polyesters which enhance
both the processability and impact resistance of the
base polymer. The material is tougher than PLA across
the temperature range allowing items such as food
trays to be kept in a refrigerator. Further innovations
such as antimicrobial activity are possible, preventing
food spoilage.
• stability across temperature range
• low energy thermoforming
• Tougher than peT and pla
• antimicrobial activity an option
Thermoformed trays were produced from sections of Floreon cast sheet.
process temperatures commensurate with standard Ingeo 7000D were
achieved.
Technical Data sheet
Floreon meets the requirements of eu food contact materials legislation (regulation no.1935/2004) and the specific controls on plastics in contact with food
(regulation no.10/2011) and associated directives. This encompasses the constituent monomers, overall and specific migration limits. 500 ml prototype IsBM
bottles passed the standard migration tests required by eu regulations, for all standard food simulants, when examined by a certified test house (smithers rapra,
shrewsbury, uK). Information updated 15/12/2013. Final performance and processing parameters will vary depending on your equipment. Figures may be revised
without notice. Detailed technical datasheet available upon request.
Full technical data sheets available on request
For more information on Floreon and how it could be a great solution for you please get in touch by phone: +44 (0) 1482 625 669 or email: [email protected]
Floreon NEW A4 Brochure v10.indd 20 14/04/2015 11:03
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www.floreon.com
General Enquiries [email protected]
Floreon-Transforming Packaging LimitedUnit F5, The Bloc, 38 Springfield Way Anlaby, East Yorkshire, HU10 6RJUnited KingdomTel +44 (0) 1482 625 669
Floreon
300
EXTRUSION BLOW MOULDING
Floreon
40
0FILM
Floreon
700
3D
Floreon
600
THERMOFORMING
Floreon
500
STRETCH BLOWMOULDING
Floreon
200
SHEET EXTRUSION/ PRINTING
Floreon
800
ENHANCED INJECTION MOULDING
Floreon
100
GENERAL PURPOSE / INJECTION MOULDING
Floreon NEW A4 Brochure v10.indd 1 14/04/2015 11:03