Injection mouldable biomaterials for

recyclable furniture

BIOMATERIALS – Towards Industrial Applications

22.5.2013 Startup Sauna, Otaniemi

Heidi Peltola

VTT Technical Research Centre of Finland

223/05/2013

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

323/05/2013

Drivers for biopolymers and fibre composites

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)

423/05/2013

B

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Renewable polymers

Petrochemical based polymers

Injection mouldable…

Biocomposites

WPC Wood Plastic Composites

Green Composites Bio-based composites

Natural CompositesNFC Natural Fibre Composites

NRPC Naturally Reinforced Plastic Composites

Renewable PE

Renewable PET

Renewable PA

Renewable PU…

PLA, PHA (PHB)

Lignin

Starch, cellulose and

protein derivatives

PCL

PVA

PBS…

PE, PP

PS, PVC

PET, PA, PC…

= Natural/renewable fibre +

523/05/2013

Biocomposite research at VTT

Polymers Commercial polymers:

PE, PP, PLA, PCL, PHB etc.

Biopolymer blends

Biopolymers developed by

research centers and companies

Natural fibresDifferent fibre types and shapes:

wood, flax, hemp, cotton etc.

Industrial minor flows

Nanofibres

Fibre treatments

Additives Commercial additives

Nanoparticles

Additives developed

by research centers

and companies

Processing

& Process

Development

Development of

business operations and value chains

623/05/2013

Biopolymer research at VTT

Polymers from biomass

Cellulose derivatives

Starch derivatives

Lignin derivatives

Hemicellulose derivatives

Protein derivatives

Chemically synthesized

bio/degradable polymers

Polyesters

(succinates, lactones..)

Synthesized from

biobased

monomers

Tall / Vegetable oil based

PGA

Polymers from C2-C6

PLA applications

New co-polymers

723/05/2013

Cellulosic fibre research for biocomposites

Additives

Fibre

fractionation

Pelletising

Physical

treatments

Chemical

treatments Plasticising

Enzymatic

treatments

Chemo-

enzymatic

treatmentsCellulosic fibres

as reinforcement

Better

fibre/matrix

adhesion Better fibre

dispersion

Better

processability

Improved

compatibility

Optimised

fibre aspect

ratio

I m p r o v e d m a t e r i a l p r o p e r t i e s f o r c o m p o s i t e s

823/05/2013

Fibre dimensions, dispersion and distribution:

Determined by process parameters, methods, melt viscosity and pre-processing

Parameter combination >15

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

Screw geometry

Processing steps

and methods

Viscosity & shear

Orientation

Processing and process development

0

2

4

6

8

10

0.100.20

0.300.40

0.50

05

10

15

20

25

30

35

Young's

modulu

s (

GP

a)

Fiber weight fraction

Pla

stic

izer co

nte

nt (%

)

Correlation between

composite strength,

fibre content, and

plastisizer content

923/05/2013

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

1023/05/2013

Case Ekokeittiö – Puustelli Miinus

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

New biocomposite based materials and solution for kitchen

furnitures launched in 2013 by Puustelli Company

1123/05/2013

VTT creates business from technology