New developments on Ingeo-based
compostable packaging with ecovio®
BASF SE
Dr. Martin Bussmann
G-PM/PB – Team Leader Compostable Packaging
150 Jahre
Outline
Compostable bio-polymers? What are we talking about?
ecovio® grades for packaging applications
Coffee packaging solutions based on ecovio®
Summary and outlook
150 Jahre
Bio-polymer – What does it means?
Bio-PE, Bio-PA, BioPUR, PEF, …
Ingeo, PHA,
PHB, …
PE, PP, PVC, PA,
PBT, POM, …
In general:*
PBAT, PBS, …
+ PLA =
* ecovio gen. 1
➨
Fossil-based and biobased polymers can both be 100% biodegradable.
3
ecovio® applications & solutions
Organic Waste Bags
Thermoforming
Compostable
Can Liners
Injection molding
T-Shirt Bags
Mulch Films
Paper Coating
Particle Foam
Food containers with lids
Injection molded food containers:
•
Can be processed on conventional injection
molding machines
•
Can be colored in different certified master
batch colors of BASF color solutions
Development partner:
5
IML decorated packaging
ecovio® for decorated thin wall packaging
offers:
•
the production of thin walled packaging
parts
•
in fast cycle times
•
with modern surface decoration
6
Coffee capsules
ecovio® for hot beverage single serve packaging:
•
excellence resist to hot water and pressure applied
during the brewing process
•
thin wall capsules can be molded with and without
O2 barrier properties
•
processable on high cavity molds in fast cycle times
•
offers an good barrier property against mineral oils,
fats and aroma
Compostable solutions for coffee capsules
based on ecovio® - End of life
High variety of hot drinks easily
preparable via capsules
Compostable
5 Mio t/a coffee grounds
world wide
Missing
property
Used coffee
capsule contains
70 wt-% of water
Plastic waste
To use coffee grounds as composting material, degradable capsules are required
8
Coffee capsules details
Transport packaging:
- Strapping band
- Shrink film
Secondary packaging:
- Pouch
- Multi or mono-layer
- with or w/o barrier
- Card board
- with migration barrier
Lidding film:
- Single layer film or (filter) paper
- Multi-layer film with or w/o barrier
Capsule:
- Injection molded
- with or w/o co-injected barrier
- Thermoformed
- with or w/o co-ex barrier
-
Inner filter:
Compostable filter paper
Injection molded filter inlay(s)
9
Compostable solutions for coffee capsules
based on ecovio®
Compostable
Transport packaging:
- ecovio®-based strapping band
- ecovio® F- based shrink film
Compostable
Secondary packaging:
- ecovio® Pouch films
- Multi or mono-layer
- with or w/o barrier
- Card board coated w. ecovio®
- with migration barrier
Compostable capsule:
- Self produced or purchased?
- ecovio® IA or TA with or w/o
G-Polymer®*
-
Compostable inner filter:
Some supplyers available
Compostable lidding film:
- ecovio®-based solutions available
* G-Polymer is a brand of a third party
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Application Development with ecovio®
for single serve packaging
Door
opener for
market
beanarella
ecovio IS1335
High wall
thicknesses
2013
Thin walled,
brewable and
compostable
capsule for
tea without
barrier
2014
Thin walled,
brewable and
compostable
capsule for
coffee with
secondary
packaging
2015
Thin walled,
brewable
and
compostable
capsule for
coffee with
barrier
2016
Complexity of capsule system
Ease of implementation in market
11
03
Packaging solution based on
ecovio®
12
Thermoformed K-cup at PackExpo 2014
made of ecovio® TA1241
2014
13
Compostable IMLs by Verstraete
…based on compostable BO-PLA film supplied by Taghleef
14
First impressions of the prototypes
compostable IML K-cup with barrier
(by 2-K injection molding)
Project leader:
Tool made by
Barrier polymer:
IML made by
Producer of compostable films:
15
04
Summary/Discussion
16
Summary
YOU can do a lot with
ecovio® in packaging
Coffee packaging seams
an interesting field of
application
Have a good cup of coffee
and think about it!
17
Compostable coffee solutions
Isn’t it more than just capsules ?
18
ecovio® for packaging
where also ‘end of life’ matters
Disclaimer
10.09.2013
20
Behind the scene:
2-K compostable barrier by IM
wall thickness: 0.4 mm
- Both components filled the cavity
up to its top
- The IML is 100% „welded“ to the
surface of the cup
Gating/
injection point
- Capsule are ejected
AMODO MIO* compostable
details of the first run with ecovio®
§
Initial flat sheet thickness
down-sized to 500µm
(from 650µm)
§
Thermoforming with the
same speed like PP-film
§
Sealable with a lot of
compostable lidding films
§
Colorable with Sicoveral
Master Batches
* Lavazza and Amodo Mio is a brand of a
third party – no relation to BASF and ecovio®