Development of flexible, starch-based foam film for sustainable packaging and construction applications
In the project “Development of a flexible, starch-based foam film for packaging and construction applications” started on 1 January 2023, the extrusion process technology group is working on the development of marketable solutions for starch-based foam sheet to be used in packaging and construction applications based on renewable raw materials.
The use of fossil-based materials for single-use applications is still very common. Especially in the packaging sector, valuable resources are thus used for applications with a very short use phase and subsequent thermal recycling. The growing awareness for the problems resulting from the use of exhaustible resources is also creating a demand for solutions based on renewable raw materials with regard to foamed plastics that are used in packaging and construction applications.
© IKVOne possibility is the use of starch-based foam sheets. Marketable solutions, however, are currently lacking. In the project “Development of a flexible, starch-based foam film for packaging and construction applications”, a holistic approach for a starch-based foam film with tailor-made properties for packaging and construction applications is being developed. The project focuses on material formulation, processability and processing as well as end-of-life recycling. Due to the complexity of material and processing technology, a consortium consisting of the companies Loick Biowertstoff GmbH, SHS plus GmbH and Gefinex GmbH as well as the research centres IKV and Fraunhofer UMSICHT is tackling this task. The project started on 1 January 2023 and is scheduled to run for two years. It is funded by the German Agency of Renewable Resources (Fachagentur Nachwachsende Rohstoffe e.V., FNR) and the German Federal Ministry of Food and Agriculture (Bundesministerium für Ernährung und Landwirtschaft, BMEL).
Theoretical work is accompanied by extensive experiment series and parameter studies, which should subsequently enable rapid transfer of the results to industrial scale. The tasks of the IKV are the development of a suitable plant technology and the characterisation of the foam films.
First, the plant technology has to be adapted to ensure gentle processing of the starch based compounds. One challenge is to ensure a good incorporation of the blowing agent. For this purpose, ideal process parameters are determined for different material formulations and the foamed film production is optimised in terms of process technology.
Furthermore, the IKV characterises the foam properties of the starch-based foam films produced. In addition, the foamed films are examined regarding their tendency to expand when reheated. From these findings, the influence of the selected foaming process parameters like blowing agent formulation, throughput as well as melt temperatures and pressures on foam properties and mechanical parameters will be determined.
Projektdaten und Förderung
Das Projekt ist am 1. Januar 2023 gestartet und ist auf eine Laufzeit von zwei Jahren angelegt. Es wird gefördert durch die Fachagentur Nachwachsende Rohstoffe e.V. (FNR) und das Bundesministerium für Ernährung und Landwirtschaft (BMEL). Wir danken dem BMEL und der FNR für die Förderung des Projekts (Förderkennzeichen 2220NR291C) und den Projektpartnern für die Zusammenarbeit.
Projektlaufzeit: 01.01.2023 – 31.12.2025