In. Crops Enterprise Hub Renewable Materials in Consumer Products and Packaging Dr Liliya Serazetdinova Business Innovation Manager Crops Enterprise Hub
Innovation in Crops • Technology transfer project stimulating innovation in alternative and non food crops • Working with businesses to stimulate the development uptake and introduction of green products and processes
Support from EEDA and ERDF • Total project value £ 3, 800, 00 million • East of England Developmental Agency (EEDA) funding is worth £ 1, 050, 000 • European Regional Development Fund (ERDF) £ 1, 153, 500 • Matching contribution from In. Crops Partners
Target Outputs by 2013 • • 250 regional businesses assisted 70 jobs created 30 new business start-ups € 3 m funding leveraged into region
In. Crops Team Beatrix Schlarb Ridley University of Cambridge and UEA Crops for biorefinering, plant oil applications, algal innovation and bioenergy, nanotechnology applications Mark Coleman IFR and UEA Norwich Natural fibres, composites, functional extracts and ingredients, phytochemicals and nutraceuticals Penny Wright Project Administrator In. Crops Office, UEA Norwich Liliya Serazetdinova Julia O’Rourke JIC and UEA Norwich • Events co-ordinator Plant based biopolymers, plastic • In. Crops Office, UEA Norwich packaging, textiles for furnishings, fashion and design, natural pigments and eco-paints
In. Crops Team Bianca Forte Rothamsted Research, Harpenden, Eco-innovation centre, Peterborough , and UEA Sustainable biofuels and bioenergy, second and third generation, plants for cosmaceuticals Benedict Binns BRE Watford and UEA Natural products and construction, Bio based building materials and low carbon supply chains Carlos Gonzalez-Esquivel Easton College, Easton and UEA, Agri-business supply chains, innovation in crop development and use, new crops and demonstration trials
International knowledge and business competitiveness • • Bioscience for Business KTN Nova Institut European Industrial Hemp Association Lisavenko Research Institute in Russia Fraunhofer Institute in Germany National Non Food Crops Centre Kew Gardens Collaborations in India, China and Brazil
Partnership at the core
In. Crops for business • Specialist business support for businesses and entrepreneurs wishing to set up businesses • Support is targeted at areas of green innovation and its stimulation within the East of England economy Bamboo • Contact with multinationals and corporates involved in our steering group Sea Buckthorn
Sector specialisation • Automotive • Built Environment • Bioenergy / Biorefining • Plastic packaging / biopolymers • Personal care products • Functional foods / nutraceuticals / biopharmaca • Oleochemicals substitutes • New green consumer markets
Sustainability and your business • Confidential discussion of initial ideas • Access to scientific, knowledge transfer • Access to product development support • and partnership facilitation • Access to finance or investment • Up to 14 h of FREE consultancy
What can we do for your business: · Market research · Advice on renewable materials, their carbon footprint and costs · Patent or branding technical advice · Linking-up with supply chain, sourcing samples · Links with testing and certification organisations · Assisting in Life Cycle Analysis · Leveraging funding · Facilitating interaction between businesses and knowledge base · Holding Workshops to transfer knowledge or build up supply chain
Why renewable materials? Drivers: oil price increase and volatility kiweb 2008, CRB 2008, nova-Institut 2008
Why renewable materials? Drivers: environmental advantages nova-Institut 2007
Bio-renewables • Natural materials • Sustainable supply • Existing and new crop material supply chains • Co-products or multiple products from feedstock • And, utilising waste resources Hemp filed Pressed hemp for fuel
Renewable materials in packaging • Biopolymers • Natural fibres, pulp • Wood fibres • Waste products
Compostable materials - definition • biodegrade using naturally occurring microorganisms • can be safely composted together with organic solid waste (e. g. garden waste) • all truly compostable materials conform to EN 13432 • product can be labelled ‘home compostable’ (at present no specific EN standards)
Most significant biopolymer types • Starch –polysaccharides from corn, potato, wheat • Cellulose - polysaccharides, regenerated cellulose from wood pulp • PLA – polyester, derived from polysaccrides by fermentation and polymersiation, from corn, wheat • PHA - polyester, microbial fermentation of polysaccharides • PE – Polyolefin derived from ethanol from fermentation of sugar • PA – Polyamide, from castor oil
Biopolymers from food co-products Cereals Non -Cereals Bran Wheat Pulp 15 -20% Sugar beet Spent grain Barley 4 -5% Meal 15 -20% Rapeseed 60% Gluten meal Peel 8% Maize Bran Potato 15 -20% Dominique M R Georget, UEA 2%
Sustainable Product Design Considerations Source Fossil Renewable Sustainable Carbon footprint Functionality Collation Presentation Physical Protection Security Shelf Life Extension Convenience Cost impact Food contact… Slide from Peter Etterige, Amcor Flexibles Disposal Recycling Composting Landfill Incineration Anaerobic digestion
Carbon Footprint for Converted Packaging Substrate Production Ink & Coating Packaging Transport Site energy 73. 6% 5. 9% 16. 0% 0. 3% 1. 5% 2. 8% Data based on in-house Carbon Footprint Tool, Amcor Flexibles
Innovative bio-based food packaging Nature. Flex™ for confectionary
Market demand –current & future trends • Increase of anaerobic digesters opens up new opportunities for compostable food packaging • Consumer-led and retail-led requirements for sustainable packaging
Biopolymers for packaging farm produce
Agricultural and horticulture Biodegradable plant pots and plant trays Farm/ Garden sacks Mulch film Flagging tape Garden anchoring stakes
Costs for bio-based packaging Price range compound for food packaging: PLA or PLA based blends Cellulose based films € 4. 1 -4. 75/kg € 5. 5 -8. 0/kg Typical finished goods prices for bioplastics: PLA sheet / bottles PLA / Starch based films Starch based compost bags Sourced from. Solutions 4 Plastic £ 2200 -£ 3500 / tonne £ 4000 – 5000 / tonne £ 5000 -6000/ tonne
Biopolymers for advanced manufacturing • Multitude of options - compostable and durable, bio- and fuel-derived • Fillers, binders, and adhesives for the construction sector, marine sector, GRP and FRP applications, insulation, furniture • Plastic electronics, consumer goods e. g. kitchen appliances • Composite materials for automotive, construction sectors, sports
Thermoset resins from vegetable oils Applications • Timberboards, laminates, mouldings • Mineral wool insulation • Foundry sands and casting materials • GRP and FRP • Mineral and structural composites • Non-wovens • Furniture Picture from Cambridge Biopolymers
Natural fibre composites Fibre - only Properties Glass Flax Hemp Jute Sisal Density g/cm 3 2. 55 1. 48 1. 46 1. 33 Tensile strength 10 E 6 N/m 2 2400 1000 1400 550 900 400 800 600 700 E-modulus (GPa) 73 60 - 80 70 10 - 30 38 Elongation at failure (%) 3 1. 2 - 1. 6 1. 8 2 -3 Resins. Synthetic (e. g. PP, PET, epoxy). Biopolymer (e. g. PLA, furan-based)
Natural fibre composites in automotive Potential market (EU, 2010): 105 -120 kt (7 -8 kg per vehicle) Potential market (EU, 2010): 180 -200 kt (12 -13 kg per vehicle) Potential market (EU, 2010): 375 -450 kt (25 -30 kg per vehicle) Potential for >30 kg per vehicle with new technology A-Class, 26 units, 24 kg Collison, 2009 nova-Institute, 2008 E-Class, 50 units, 32 kg Bleached flax/PP door inserts, Eco. Technilin
Natural fibre composites Curran® , Cellu. Comp Ltd, nanocellulose fibres from carrot waste Hemp fibre lug on the bamboo bike, image from RAW Bamboo Bike
Sustainable construction • • Local sourcing Numerous technologies Biocomposites SIPS Flying factories Natural paints Carbon sequestration Retrofit BRE
Renewable materials in construction Insulation materials: • Breathe –hemp and flax • Eden. Block 35 – recycled wool and biopolymer • Isonat+ - hemp and wood fibres • Isovlas – flax • Pavatex Pavatherm – wood fibre and paraffin • Steico Canafle – hemp, ammonium phosphate Hemp insulation
Renewable materials in construction
Low impact Low Carbon Supply Chains Forest Products in the East of England • • • Life cycle analysis Cradle to cradle The Green Guide Welsh Assembly building Image from Forestry Commission Image from www. worldculturepictorial. com
Wood Plastic Composites Press-wood and board pallets Wood Plastic Composite Decking FKu. R, Fibrolon ®
Consumer Products Linseed oil-based paints – long lasting, cost effective solvent free Images from http: //www. holkham. co. uk
Natural Pigments Woad-inc™ Natural indigo pigment extracted from woad plant. High quality range of textiles dyed with natural indigo - wool, silks, cotton, linen, alpaca and bamboo Bamboo/cotton towels and bamboo/wool throws and cushions. Woad pigment Different fibres absorb the dye at varying rates, creating a wide range of shades
Business Directory for Innovative Renewable Materials and Biobased Products
Forthcoming events: • Biolubricants, 16 th November, Essex • Green Hospitality – end 2010
Promoting innovation in alternative and non-food crops – a new science and knowledge transfer initiative based in the East of England University of East Anglia T: +44 (0) 1603 591765 Norwich NR 4 7 TJ F: +44 (0) 1603 597186 E: john. french@uea. ac. uk www. incropsproject. co. uk
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