SUSTAINABLE PLASTICS · Packaging Research and Development ... allow to use organic recycling...

This project is implemented through the CENTRAL EUROPE programme co-financed by the ERDF

www.plastice.org

SUSTAINABLE PLASTICS Training

for the National Information Points Greg Ganczewski, COBRO

Petra Horvat, NIC

Packaging Research and Development Department Packaging and Environment

Department Laboratory for Packaging Materials

and Consumer Packaging Testing Laboratory for Transport Packaging

Testing Certification Centre Information services Standardisation Department

COBRO is a state, self-supporting research institution subordinated to the Ministry of

Economy, founded in 1973

COBRO IS A MEMBER OF:

• World Packaging Organisation (WPO)

• International Association of Packaging Research Institutes (IAPRI)

• European Bioplastics

• Polish Chamber of Packaging (KIO)

This training workshop is divided into following parts :

PLASTiCE project – introduction

Guide for entrepreneurs – introduction

Plastics – basics

Plastics classification

Sustainability evaluation – three pillars of sustainability

Sustainable plastics – certification criteria

Contents

PLASTiCE project

Part I

Solution:

Use of plastics with higher level of sustainability –

biodegradable and biobased plastics

(bioplastics)

Challenge:

Intensive plastics use causes considerable and growing environmental burdens

• Use of limited resources (oil)

• Emissions released during production stage

• Waste management

PLASTiCE - Motivation

PLASTiCE Project focus

Identification and removal of barriers to the faster and more widespread use of

sustainable types of plastics,

particularly biodegradable plastics and plastics based on renewable resources, in

Central Europe.

How we intend to achieve this?

Joining strong centres of knowledge on biodegradable materials

Support and involvement of the complete value chain (production, processing, industrial use, consumer, waste management)

PLASTiCE - Objectives

Raising awareness among target groups regarding biodegradable plastics

Improving technology transfer and knowledge exchange mechanisms in biodegradable end-user industries

Improving access to scientific knowledge, use of already existing knowledge adapted to requirements of biodegradable polymer and plastic value chain

Intensifying application-oriented cooperation between research and industry.

PLASTiCE - Expected results

1. National information points

For providing unbiased and scientifically supported information about sustainable plastics to consumers and industrial users

2. Information Toolkit

3. Certification system for compostable plastics

Developed in Slovenia and Slovakia

4. Roadmap

For research and commercialization of new biodegradable polymers that meet overall market expectations

PLASTiCE PROJECT PARTNERS

13 partners from four countries (Slovenia, Slovakia, Poland, Italy)

Guide for Entrepreneurs

Part II

Today‘s training session:

1. National information points

For providing unbiased and scientifically supported information about sustainable plastics to consumers and industrial users

2. Information Toolkit

3. Certification system for compostable plastics

Developed in Slovenia and Slovakia

4. Roadmap

For research and commercialization of new biodegradable polymers that meet overall market expectations

Guide for Entreprenurs

Information Toolkit = Guide for entrepreneurs

A comprehensible guide about everything you need and want to know about bioplastics and sustainability

Revisions phase 5 – the final version of the guide is the core output of the project

Where do we start?

From what we know

We know that some materials can be harmful to the environment

We know that they may be harmful in their whole life cycle - especially when they turn into waste

We know that we need to share the planet with others and leave it for our children and grandchildren

What we can do?

How this translates into what we can do

We know that some materials can be harmful to the environment

Search for alternatives

We know that they may be harmful in their whole life cycle

Life cycle thinking

We know that we need to share the planet with others and leave it

for our children and grandchildren Sustainable development

What we can do?

How this translates into what we can do: Research new materials - especially

materials from renewable resources Use recycled materials in production Introduce life cycle thinking in

manufacturing practice – LCA and “carbon footprint” concepts

Use biodegradable materials which allow to use organic recycling method called composting

Part III

Bioplastics

Biobased and biodegradable plastics

BIOPLASTICS

FOSSIL

BIODEGRADABLE

NONBIODEGRADABLE

FOSSIL + RENEWABLE

BIODEGRADABLE

NONBIODEGRADABLE

RENEWABLE

BIODEGRADABLE

NONBIODEGRADABLE

SOURCES DEGRADABILITY

But they make up around 80 % of the current plastics production

With POLYMERS and PLASTICS!

3, 2, 1… START

Definitions - Polymer

BASIC TERM

A simplified analogy of a polymer is a pearl necklace composed of individual pearls (as monomers) arranged in a linear fashion.

Polymer - macromolecule composed of many repeating units.

Polymers (poly-mer from Greek: poly - many, meros - parts) can contain thousands of repeating units (monomers) arranged linear or branched.

Polymers are found in nature or are man-made (artificial, synthetic). Natural polymers (= biopolymers) are specific and crucial

constituents of living organisms. Man-made polymers are a large and diverse group of

compounds not known in nature. They are synthesized through chemical or biochemical methods. The global annual production of man-made polymers is estimated to be 230 million tons in 2009 (Plastics – The Facts 2010).

The main use of man-made polymers is in the production of plastics.

Definition - Plastics

Plastics – polymer-based material that is characterized

by its plasticity.

The main component of plastics (from Greek: plastikos - fit for moulding, plastos - moulded) is a polymer, which is “formulated” by the addition of additives and fillers to yield the technological material – plastics. Plastics are defined by their plasticity – a state of a viscous fluid at some point during processing.

Plastic – Polymer distinction

Polymer = pure compound „chemical“

Plastics = material Polymer + plasticizers fillers stabilizers additives antistatic agents coloring agents…

Polymer ≠ Plastics

Plastics = Polymer + Additives

Classification

We can classify polymers by:

– physicochemical properties

– origin

– origin of the raw material

– susceptibility to microorganism enzymes activity

– …

Physicochemical properties

Thermoplasts – they become soft when influenced by heat, become hard after a decrease of temperature.

E.g. acrylonitrile-butadiene-styrene – ABS, polycarbonate – PC, polyethylene – PE, polyethylene terephthalate – PET, polyvinyl chloride – PVC, poly(methyl methacrylate) – PMMA, polypropylene – PP, polystyrene – PS, extruded polystyrene foam – EPS.

Thermoset (duroplasts) – after formed they stay hard, they do not become soft when influenced by heat.

E.g. polyepoxide – EP, phenol formaldehyde resins – PF, polyurethane – PUR, polytetrafluoroethylene – PTFE.

Elastomers – materials, which we could stretch and squeeze, which follow deformations but they almost reshape back to the original shape afterwards.

Indian rubber/caoutchouc has been almost entirely replaced with elastomers. Also many new adaptions have been discovered.

Source of the schemes: http://www.chempage.de/theorie/kunststoffe.htm

Origin

Synthetic polymers – originate from chemical synthesis (polymerization , copolymerization , poly-condensation)

Natural polymers – produced by organisms

e.g. cellulose, protein, nucleic acids

Modified polymers – those are natural polymers, chemically changed to receive new functional properties

e.g. cellulose acetate, modified protein, thermoplastic starch

Origin of raw materials

Renewable resources

plant and animal

Non-renewable (fossil) resources

petroleum, coal

Susceptibility to microorganism enzymes activity

Biodegradable (polylactide – PLA, regenerated cellulose, starch)

Non-degradable (polyethylene – PE, polystyrene - PS)

Part IV

Plastics: conventional plastics

and bioplastics

Plastics - history

First plastics were produced in the 2nd half of 19th

and beginning of 20th century. Celluloid and cellophane were first ones and they were bio-based.

After 2nd World War plastics became very popular. From ’60 till ’90 they have mainly been produced from petrochemical resources.

In ’80 plastics production was bigger than steel production.

In ’90 environment protection policies became more important.

New technologies were put into practice e.g. producing polymer plastics based on renewable resources; production technologies of biodegradable materials.

Source: http://poupee-mecanique.com/blog/category/uncategorized

1902, invention of petroleum based plastics

1924, Ford goes BIO

1941, first bioplastic car - Ford

PLASTICS

• Universal, used in many different fields: – Packaging

– Constructions

– Transport

– Electric and electronic

– Agriculture

– Medicine

– Sport

– …

• Properties can be modified to virtually any requirement

• Lightweight products (due to small density).

• Excellent thermo insulating and electro insulating properties.

• Resistant to corrosion.

• Transparent and therefore used in optical devices.

Conventional - petrochemical plastics

Conventional plastics are produced from fossil resources and find use in many areas of

The “big five” that take the biggest part in market are:

• Polyethylene (PE)

• Polypropylene (PP)

• Polyvinyl chloride (PVC)

• Polystyrene (solid – PS and foamed – EPS)

• Polyethylene terephthalate (PET)

Big role in industry is also attributed to:

• Acrylonitrile butadiene styrene (ABS)

• Polycarbonate (PC)

• Polymethyl methacrylate (PMMA) Plexi glass

• Polytetrafluoroethylene (PTFE) Teflon

80 % of the plastics production

We live in the „Plastic Age“

• High resistant polymeric materials, also resistant to natural degradation => landfill crisis!

• Thermal conversion of plastics? Generation of toxins

• GHG?

• Growth of the price due to the growth of the petrol price

Classic petrochemical plastics

In 2011 global production of plastics reached:

270 million tons.

In 2011 plastics production in Europe reached:

57 million tons (21 % of global production).

The biggest worldwide plastic producer China reached:

23 % of global production.

Plastics consumption in Europe by branches in 2010 and 2011

Consumption has risen from 46,7 million tons in 2010 to 47 million tons in 2011. In 2010 the biggest branch was packaging with 39 %

of all consumption, followed by construction industry (20,6 %), automotive industry (7,5 %), electric and electronic application (5,6 %). Other smaller branches include: sport and recreation, agriculture and machine production.

In 2011 packaging was also the major contributor with a slight increase of its share to 39,4 %. Second biggest branch in 2011 was construction industry (20,5 %), automotive industry (8,3 %), followed by electric and electrical industry (5,4 %).

Plastics consumption by type and industry in 2011

Bioplastics

Bioplastics are bio-based and/or biodegradable plastics.

The term was coined by European Bioplastics

What differentiates bioplastics from conventional plastics?

Source: http://en.european-bioplastics.org/bioplastics/

The term bioplastics encompasses a whole family of materials which are biobased, biodegradable, or both.

Biobased means that the material or product is (partly) derived from biomass (plants). Biomass used for bioplastics stems from e.g. corn, sugarcane, or cellulose.

What differentiates bioplastics from conventional plastics?

Source: http://en.european-bioplastics.org/bioplastics/

The term biodegradable depicts a chemical process during which micro-organisms that are available in the environment convert materials into natural substances such as water, carbon dioxide and compost (artificial additives are not needed). The process of biodegradation depends on the surrounding environmental conditions (e.g. location or temperature), on the material and on the application.

Of course, materials and products can feature both properties. They then offer all the benefits and additional options outlined.

Research of new materials and their production technologies is closely linked to: Knowledge development in environmental sciences,

which show negative influence of plastics in its whole life cycle

Improving evaluation methods of plastics influence on environment, especially through LCA

Using sustainable development policies, which in manufacturing and trading practice means ecological aspects equal to social and economic aspects

From 2007 to 2008 global biodegradable plastics production was about 500 thousand tons. In 2011 it was forecasted for about 700K tons, realization was 675K tons, total production of bioplastics was 1161 tons. (no data for 2012 yet)

Biodegradable plastics

Plastics susceptible to biodegradation

BASIC TERM

Microorganisms recognize biodegradable plastics as food and consume and digest it.

Different types of biodegradability

• Compostable in industrial composting facilities

• Home compostable

• Soil degradable

• Water degradable

• Anaerobic degradable

• Oxo degradable???

What is biodegradation?

Different parallel or subsequent abiotic and biotic steps, it must include the step of biological mineralization.

Takes place if the organic material of a plastic is used as a source of nutrients by the biological system (organism).

Biodegradation is NOT necessary connected with renewable origin of the feedstock

• Biodegradation • Photodegradation • Oxidation • Thermal degradation • Stress induced degradation

Degradation vs. BIOdegradation

Fragmentation: first step in the biodegradation, material is broken down into microscopic fragments

Biodegradability: Complete microbial assimilation of the fragmented material as a food source by the microorganisms

Compostability: Complete assimilation within 180 days in a composting environment

Fragmentation Biodegradation

Methane is then converted to energy, methane is more harmful for GHG

Determination of the rate of biodegradation

Respirometry

Surface/volume ratio!!!

Composting

Composting (organic recycling)

oxygen processing capability of bio-waste

strict controlled conditions by microorganisms, which turn carbon in to carbon dioxide (mineralization).

Product of this process is organic matter

called compost.

Composting

Composting is a manner of controlled organic waste treatment carried out under aerobic conditions (presence of oxygen) where the organic material is converted by naturally occurring microorganisms. During industrial composting the temperature in the composting heap can reach temperatures up to 70 °C. Composting is done in moist conditions. One composting cycle lasts up to 6 months.

Compostable plastics

Is plastics that biodegrades under the conditions and in the timeframe of the composting cycle

Biodegradable ≠ Compostable

Compostable = Biodegradable

Directive 2008/98/EC of the European Parliament and of the Council of 19 November on waste, article 4: Waste hierarchy: (a) Prevention (b) Preparing for re-use (c) Recycling (d) Other recovery, e.g. energy recovery (e) Disposal

European Parliament and Council Directive 94/62/EC of 20 December 1994 on packaging and packaging waste, article 3.9 says: Organic recycling shall mean the aerobic and anaerobic treatment under controlled conditions and using microorganisms, of the biodegradable parts of packaging waste, which produces stabilized organic residues or methane. Landfill shall not be considered a form of organic recycling.

Article 6: By 31 December 2008 the following minimum recycling targets for materials contained in

packaging waste will be attained: (iv) 22,5 % by weight for plastics, counting exclusively material that is recycled back into plastics.

And composting is obviously not "back to plastics". That means, that composting of packaging is defined as recycling, but this recycling does not count to the fulfillment of the plastics packaging recycling quota.

REGULATIONS

Compostable plastics are defined by a series of national and international standards e.g. EN 13432, ASTM D-6400 and other.

More about this topic will be said at the end of todays training

Biodegradable plastics can be divided into 2 groups:

Biodegradable plastics from renewable resources

Biodegradable plastics from fossil resources

Biodegradable plastics from renewable resources

• Thermoplastic starch (TPS)

• Polyhydroxyalkanoates; PHAs (made by microorganisms) PHBV, P3HB, P4HB, PHV

• Polylactide (polylactic acid, PLA)

• Cellulose based plastics

Often those polymers appear in mixtures

Thermoplastic starch - TPS

Starch = Amylose + Amylopectin

Amylopectin prevents starch to become plastic-like => AcOH

Glycerol

Mater-Bi

Starch based material MaterBi is a trade name for the group of materials, produced by the Italian company Novamont, also partner in the PLASTiCE project, used for production of: • thermoformed flexible and durable films,

• trays,

• containers,

• foamed fillers (foamed peanuts),

• injection molded durable packaging and

• paper and cardboard coating.

Polyhydroxyalkanoates

Polyesters, produced by different

microorganisms from renewable

resources

The only family of bioplastics, entirely produced and degraded by living cells. PHAs are energy and carbon reserves for the microorganisms.

BIOCOMPATIBLE

Author: Dr. Martin Koller, TU Graz

Source: www.rsc.org

Use of PHAs

In agriculture: carriers for controlled release of nutrients, mulch films

Medical and therapeutic: Controlled release of drugs, implants, surgical pins

Packaging

Energy: biodiesel, obtained by transestrification of PHAs with longer side chains (mcl PHA)

Source: http://www.fastcodesign.com/1669598/philippe-starck-s-miss-sissi-lamp-now-made-from-sugar-waste

Source: Metabolix

Polylactide - PLA

Aliphatic polyester, produced by poly-condensation of lactic acid (LA is produced by fermentation of glucose)

PLA is NOT degradable in soil and also NOT suitable for home composting, is recyclable

Normal PLA (PLLA): Heat resistant up to ~50 °C

High heat resistant PLA (PDLA and PLLA stereocomplex): up to ~110 °C

BIOCOMPATIBILE

Natureworks, Purac, Kingfa

Use of PLA

Disposable food packaging (cup, bowls, containers, water bottles)

0 3 17 19 21 24 26 28 33 38 47 Day

Source: EARTHFIRST®PLA

PLA cup composting process

Industrial composting!!! In home composting environment PLA is NOT! compostable

Cellulose plastics

• Dissolved wood pulp from hard wood species eucalyptus

• Production process is based on cellophane films production

• Properties:

transparent, colorized or metabolized

High gas, odor and oil and grease barrier

Printable

Thermal stabile

Suitable for lamination to other biopolymers

Biodegradable plastics from fossil resources

Polyesters made of fossil resources including:

• Synthetic aliphatic polyesters – polycaprolactone (PCL);

• Synthetic and half-synthetic aliphatic copolymers (AC) and polyesters (AP);

• Synthetic aliphatic-aromatic copolymers (ACC);

• Polymers soluble in water – poly(vinyl alcohol) (PVOH)

Polycaprolactone

Often added as an additive for resins to improve their processing characteristics

compatible with a range of other materials, can be mixed with other materials to lower the costs and improve biodegradability

BIOCOMPATIBLE (drug delivery, in dental medicine – root canal filling(TM Resilon)

3D printing material

Other biodegradable polymers

Polyesters (hydrolysis of the estric bond)

Aliphatic polyesters (no aromatic groups) – PBS polybutylene succinate

– PBSA polybutylene succinate adipate

Aliphatic aromatic polyesters – PBAT polybutylene adipate

terephthalate

– PBMAT (Ecoflex BASF)

Water-soluble polymers – PVOH polyvinyl alcohol

– EVOH ethylenevinyl alcohol

Biodegradable plastics are not designed to be disposed in the nature!!!

Biodegradability is not function of origin of the raw material but is only related to structure!

Oxo-degradable plastics

Aggressively promoted materials, available on the market

Principle:

• Catalyst catalyzing oxidation is added to nondegradable plastics

• Thermal and/or photo activated catalysation

Fragmentation is inconclusive

Biodegradation e.g. mineralization is not proved.

NOT biodegradable, NOT compostable, available on the market – misleading marked

ASTM D6954 = standard test method STM You can not meet the requirements of a STM

Bio-based plastics

Biobased – derived from biomass, made from renewable resources

• Plastics can be fully or partially based on biomass (= renewable resources). The use of renewable resources should lead to a higher sustainability of the plastics because of the lower carbon footprint.

• Although fossil resources are natural they are not renewable and are not considered a basis for biobased plastics.

Source: R. Narayan

Carbon cycle

Green PE

Plastics, made from ethanol which is produced from sugarcane.

Equivalent to traditional PE

-CH2-CH2-CH2-

100 % biobased (ASTM 6866)

NONbiodegradable

Braskem 2009, 200.000 t/a, Dow 2011, 350,000 t/a

Efficiency of the fermentation???

Sugarcane ↓ fermentation, distillation Ethanol ↓ dehydration Ethylene ↓polymerization PE

Green PET

Second very often used plastics being replaced with renewable feedstock is PET for production of PET bottles (PlantBottle).

This method saves global fossil resources and also reduces CO2 by 25 %.

Green PET is easily recycled and can be collected with conventional PET items.

Green PET

Coca-Cola has applied this technology in their production. PlantBottle is made of PET, produced from terephtalic acid (70%) and monoethylene glycol (30%). Terephtalic acid comes from oil processing, glycol is produced from ethanol (produced in polysaccharide fermentation). Pepsi is planning to produce 100 % PET bottle, where TA is produced from plant-based p-xylene

Source: Coca Cola

Bioplastics available on the market Some examples of bioplastics available on the market are:

Bioplastics Production In 2011 global bio plastics producing ability reached 1,161 million tonnes.

This is much less than global classical plastics production figure of 265 million tonnes, but forecast for 2015 shows that bio plastics production will reach almost 6 million tonnes.

Bioplastics Production

Partly-biodegradable packaging material, PE-LD films with 5% addition of modified starch (little interest of this product)

Trays made of modified starch –laboratory scale only (Starch and Potato Products Research Laboratory, Poznań)

Bioplastics in Poland

Biotrem technology – wheat bran-based trays and containers wheat bran - waste from the milling industry

Additives

Pre-treatment Milling Bran

Compression moulding

Coating

Food companies

Retail Consumers Waste

collection

Composting

Compost

Landfill Incineration

PLA Packaging

BioErg from Dąbrowa Górnicza

First Compostable certificate on the Polish Market

T-shirt bags

Market bags

Bags for kitchen, biodegradable waste

Little bags for groceries

BIOZON Sp. z o.o. PLA bottle for mineral

water BIAŁOWIEŻA

PLA Bottle Pre-forms

Next generation of cellophane - NatureFlex™

First compostable carrier bags in Poland, introduced by Carrefour hypermarkets stores.

Pakmar PLA products EARTHFIRST PLA Sidaplax film

BAHPOL company conducts testing on compostable laminates and printing on biodegradable films.

Sustainable Development

Part V

Sustainable Development To use the traditional definition, sustainable development is: "development that meets the needs of the present without compromising the ability of future generations to meet their own needs", in other words ensuring that today's growth does not jeopardize the growth possibilities of future generations. Sustainable development thus comprises three elements - economic, social and environmental - which have to be considered in equal measure at the political level. The strategy for sustainable development, adopted in 2001 and amended in 2005, is complemented inter alia by the principle of integrating environmental concerns with European policies which impact on the environment.

- source: http://europa.eu

Sustainable development concept for business, consists of taking into consideration widely understood economic, environmental and social issues in the daily and long term operations of a company.

Sustainable Developement Sustainable development concept for business consists of taking into consideration widely understood economic, environmental and social issues in the daily and long term operations of a company. In plastic industrial practice that means being responsible for the introduction of new products on a plastics market from the perspective of those three issues. This means that new products should be evaluated with regards to environmental, social and economic impacts they generate. This evaluation, which gives equal rank to all three elements, should be performed in whole product life cycle stages (designing, manufacturing, using, recycling).

This fulfilment has to be present in all product life cycle stages, starting from: production processes, delivery chain, processing methods, packaging, distribution, usage and waste management including transport.

At the same time sustainable products should match up or exceed conventional products by functional and quality properties, fulfil todays environmental protection standards, and also contribute to waste management system.

Sustainable Developement Due to the fact that polymers are used in many industry branches it is hard to set an equal standards and specify define sustainable development policy for all of them. That is why basic standards should be set for all polymer products and for specific sustainability standards should be set for different groups of uses.

LCA method can be used to rate and compare a product with another products with similar functionality.

LCA method consists of different criteria of evaluation in all life cycle stages of a selected product.

Potential environmental influence of every life cycle process of a chosen product is quantitatively recorded in different impact categories

Sustainability - Environment

What is LCA ??

LCA = Life Cycle Assessment

Probably the most popular sustainability and environmental assessment methods

Can be used to assess products, value chains, processes, whole companies, economy and even socio-cultural implications

Its main goal is to assess the aspects of environmental impacts in whole life cycle of selected subject matter.

Packaging LCA is used to assess the environmental impact of packaging and includes such factors as infrastructure (transport), multi-usability of packaging and how the packaging is/can be disposed.

LCA is best used as a comparative assessment tool – i.e. in terms of packaging it is best to compare different packaging types for the same group of products.

Packaging LCA

What is LCA ??

Life: Detailed Biography and Family Tree of our product

Input: What we have taken from the environment

Output: What we are leaving behind - emissions

LCA as a description of reality

LCA is used to model complex reality

+ Each model simplifies the reality

= Contradiction – simplification distorts the

reality

Main goal of LCA – minimise this distortion

How to use LCA

Internal LCA – used by enterprises

‘knowing your product’, identification of ‘hot spots’, strategic management goals

Marketing / Benchmarking

Preparation for legislation changes, arguments for lobbying

External LCA – full public reports

Published by public institutes/research institutes

Need to be peer reviewed

Not often used by enterprises due to bad experiences in the ‘90 (benchmarking backfire)

LCA Standards

2 main standards:

EN ISO 14040 – main concept

EN ISO 14044 – details

Other relevant standards:

EN ISO 14020 series – Environmental labels and declarations 14021 – Type II

14024 – Type I

14025 – Type III

14064 – GHG emissions – due soon

14067 – Carbon Footprint calculation – due soon

LCA CEN Reports

2 CEN Reports for packaging: CR 12340:1996 – Recommendations for LCI of

packaging systems

CR 13910:2009 – Criteria and methods for packaging LCA

LCA in 4 steps

Goal and scope definition

Inventory(LCI)

Impact assessment

Interpretation

Direct uses: Development and

improvement of products Strategic planning Shaping of public policy Marketing Other

Step 1 – Goal and Scope

Product

Life Cycle

Scope Goal

How does it look like ??

- Functional Unit - System Boundaries

What/Why/For Whom We need LCA

Step 1 – Goal and Scope

Natural resources

Packaging resources

production

Packaging materials

production

Landfiling Energy

recovery

Recycling

Preperations for re-use

Other uses of

resources

Other products

Goods production

Good usage phase

Packaging production

Filling/Packing

Distribution and sales

Emptying

Boandary includes packaging production loses

Step 1 – Goal and Scope – Functional Unit

Unit of reference

Quantitative system effect – unit has to measure same effect when comparing 2 or more products

All data should be referenced to the functional unit

Step 1 – Goal and Scope – Functional Unit

Functional Unit examples:

Paint: 20 m2 area coverage for 20 years

Ice-cream: kcal / mass / leisure time

Beverage packaging: volume of beverage

Public transport: person-kilometer

Packaging waste: kg

Shopping bags: 5 kg of shopping carried for 500 meters

Hand towels: 10 000 washed hands

Step 2 - LCI

Data collection – depends on the goals and scope of our research.

What shall be taken into account:

System boundaries

Geography

Time of data collection

Functional Unit

Allocation methods

But most importantly: Time and Money!!

Step 2 - LCI

Step 2 effect – Process Tree

Process Tree includes all LCI results in the form of inputs and outputs emissions from and to soil, atmosphere, water etc.

Examples of quantitative results of LCI: CO2, CFC, P, SO2, NOx, DDT used/emitted during different stages of life cycle.

Step 2 – Process Tree PET bottle – recycling 30%

Fossil Fuels

PET Granulate

PET Bottle

Injection Moulding

Injection Blowing

30% PET recycling 70% PET Landfill

Energy + Transport

Step 2 – Process Tree PET bottle – 30% recycled

Step 3 – Impact Assessment

LCI results while interesting do not give us any specific information about the environmental impact of a particular product

LCI results should be interpreted and characterised into impact categories

There are many characterisation methods available, many of them with normalisation and weighting options

Step 3 – Method example

Step 3 –Midpoint and Endpoint in a method

LCI results: CO2 VOS P

SO2 Nox CFC Cd PAH DDT etc

Impact categories: Examples

Global warming Acidification Cariogenics Radiation Resource utilisation

Fossil fuels etc

Damage categories: According to eco-indicator 99

Human Health Ecosystem quality

Resources

Low uncertainity

High uncertainity

Difficult to interpret

Relatively easy to interpret

Step 3 –Midpoint & Endpoint Method Details

Step 3 – Impact Assessment 3 PET bottles – No recyling / recycling 30% &

recycling 50% Method: Eco-indicator 99

Step 4 - Interpretation

ISO 14044 standard recommends that before drawing conclusions and preparing a report from 3 previous steps, following elements should be checked:

Check consistency of results with goal and scope definitions

Check processes with highest environmental impact

Check for anomalies (use best judgment)

Check whether the method is consistent with assessed product

Some methods omit substances present in the LCI – check whether the number of omitted substances influence the result by choosing a different method

LCA is not objective, therefore it is helpful to check how the LCA results are dependent on our choices throughout the process.

Perform uncertainty and sensitivity analysis where logical and possible. Prepare few scenarios.

Summary

Resources

Natural resources utilisation

Environmental damage

Energy utilisation

Gas emissions Liquid waste

Solid waste

Damage impact assessment

Production of materials

Packaging production

Packaging

Product Distribution

Recovery Landfilling

LCA Summary

LCA importance: selected beverage packaging in Germany is

excused from obligatory deposit fees introduced from 1st of

January 2003 based on LCA results

Beverage packaging included in deposit fees legislation: single

use packaging for beer, mineral water and carbonated drinks,

i.e. glass bottles, PET bottles and aluminium cans

Packaging excused from deposit fees include: boxes from

laminates and film bags for fruit juices, milk and non

carbonated beverages. Life Cycle Assessment of those

materials proven to be similar to multi-use bottles, hence the

provision.

Sustainability - Environment Responsible resources usage in manufacturing Current extensive exploitation of non-renewable resources (hard coal, brown coal, oil, petroleum gas) will one day result in their final depletion. This in turn could have a catastrophic effect for future generations. That is why, according to the sustainable development policy it is recommended to try to utilise less materials in product applications and use renewable resources whenever possible.

Sustainability - Environment Responsible resources usage in manufacturing With regards to the responsible usage of resources another important issue is the greenhouse effect and greenhouse gases emission from production. An indicator called “Carbon Footprint” shows total greenhouse gases emission produced directly and indirectly in all life cycle stages of a given product. Usually the indicator is given in tons or kilograms of carbon dioxide equivalent gases.

Sustainability - Environment CO2

„New” carbon Biomass, agriculture

Fossil resources oil, gas etc.

„Old” carbon

polymers, chemical substances and fuels

1 year

> 106 years

chemical industry

1 – 10 years

Sustainability - Environment

Meeting of higher requirements than set by current law, including non-obligatory environmental protection certification

There are many non-obligatory environmental certifications systems in existence in EU. For example:

compostable products certification

products with renewable source certification

greenhouse gases emission reduction confirmation

Sustainability – Sociology

Fulfilling customers’ expectations

According to current marketing trends products should offer attractive look, high usage comfort, ergonomic shape, durability, etc.

In other words the race for sustainability should not reduce aspects that are appealing from the point of view of end consumers.

Sustainability – Sociology Waste collection system existence and recycling availability Introduction of new products on a

market should consider waste collection systems and recycling methods availability in the region. A product can be sustainable from the point of view of environment, but when it turns into waste it can become a problem if end-of-life treatment is not supported in the region. For example compostable plastic waste which is not collected with organic waste, but is being deposited on a landfill will have a negative social environmental impact.

COLLECTION network INFRASTRUCTURE

recycling value chain

KNOWLEDGE education & information

INSTRUMENTS legislative & economic

IDENTIFICATION certification & labels

ORGANOSPHERE

TECHNOSPHERE

END-OF-LIFE recycling technologies

Sustainability – Sociology Recycling System

Collection of organic waste (biowaste).

Packaging fulfilling PN-EN 13432:2002 requirements

ANAEROBIC DIGESTION INSTALATION

COMPOSTING PLANT

Sustainability – Sociology Customers knowledge and education level

New technical and technological solutions approvals by market and society requires high level of customers awareness which depends on capital and education expenditure.

This factor depends on knowledge level and awareness of society and can be influenced by marketing/PR actions and educational schemes on different levels

Legal and normative regulation for defined actions for certain products, including environmental protections requirements

Example: Directive 94/62/EC

External effects evaluation – hidden costs of end-of-life

Decisions made in microeconomic scale by producers and customers may cause an occurrence called “the external effect”. Depending if an action causes an advantage or a disadvantage we identify:

– positive external effect (external advantages)

– negative external effect (external costs)

Kt – production costs

Ko/u – external costs connected with recycling or wastes disposal

Sustainability – Economy Demand of polymer materials Launching a new product on

a market, and determining its price should be of course based on the total costs of manufacturing, including polymer material costs.

This however should be based on the market analysis of a potential consumers on specific output market.

Questionnaire responses for packaging producers / users

Polish Market Research

Questionnaire responses for end consumers

Question I - I rank my environmental awareness as high Question II - I rank my awareness of new technologies as high Question III - Packaging is important for my purchase decision Question IV - I gladly choose innovative looking packaging when buying goods Question V - I gladly choose packaging advertised as environmental friendly when buying goods Question VI - I gladly choose environmental friendly looking packaging when buying goods Question VII - I take notice of the symbols and special markings on the packaging Question VIII - I will pay more for product in innovative packaging Question IX - I will pay more for product in environmental friendly packaging Question X - When buying a product I think what I will do with used packaging

Slovenian Market Research

Sustainability – Economy

Life cycle costs evaluation (LCC). Processes costs in all life cycle

Processes costs evaluation in all life cycle stages could be analysed by LCA method taking into consideration costs of processes. With this approach to LCA separate processes contribution could be analysed and managerial decisions can be fashioned on this basis.

Economically supported polymer choice

Polymer sources should be chosen by:

– market analysis

– risk analysis (feasibility study)

– producers and suppliers portfolio analysis (competition analysis)

Important!

plastics according to sustainable development policy are already fulfilling ecological, economic and social criteria with higher standard than analogous conventional products.

Glass Environmental:

(+) – when reused

Social:

(+) – reuse and acceptance

Economic:

(-) – Expensive for fillers

Sustainability examples

Oxo-degradable Bags Environmental:

(-) – Barrier in recycling

Social:

(-) – grey PR practices

Economic:

(+) – Cheaper than sustainable alternatives

Packaging plastics Environmental:

(?) – greatly depends

Social:

(+) – acceptance, end-of-life options

Economic:

(+) – Cheap

Bioplastics Environmental:

(+) –whole life cycle

Social:

(+) – education, end-of-life – this is what PLASTiCE is all about!!

Economic:

(+) – Getting cheaper and cheaper and desirable

Evaluation systems for

selected criteria

Part VI

Plastics evaluation system for selected criteria

• Compostable plastics certification

• Plastics including renewable resources certification

• Confirmation of greenhouse gases emission reduction

Standard = Certificate Standard

• Set of requirements that a product/service shall conform to

• Two types: – Specification (e.g. EN

13432)

– Test method (e.g. ISO 14855)

• Basis for certification systems

Certificate

• Independent confirmation that material/product conforms to specific requirements

• Product/material verifications are based on standard test methods

Standardization of bioplastics

• Very difficult to distinguish bioplastics from “conventional” plastics

• Overcome difference in opinion

• To prevent false advertising

• Basis for

– a guarantee for consumers

– a tool for producers

• Developed and published by standardization organizations (ISO, CEN, ASTM, JIS, … SIST…)

• Each standardization organization has own standards

• CEN obligatory for EU member states

• Common to harmonize with ISO

• Standards

- Specification (criterion: pass/fail)

- Test method, Practice, Determination, Evaluation

Standardization of bioplastics

Compostable

• First standard for compostable products was DIN V54900 (1997), but in 2000 the standard was withdrawn because EN 13432 was published. (standard harmonized with Directive 34/62/EC concerning packaging)

• Now the field of standards for compostable plastics is very broad

– Specifications: 12

– Test methods: ~ 20

Specifications for composting

Standardization for biobased

• Use of renewable resources

• Basis: radiocarbon (14C) analysis

Standards

• ASTM D6866

• CEN/TS 16295:2012

• ISO/CD 16620

• Result related only to carbon!

Standardization for biobased plastics

Requirements

– min. 50 % of organic compounds

– min. 20 % of carbon from renewable resources

– non-toxic

• Medical products are excluded

Result

• % of renewable carbon

• No pass/fail

• Range 0 – 100 % - how much is enough?

Certification

CLEAR, TRUSTED, BACKED BY SCIENCE

• proof issued by an independent authority

• based on a certification process, which often follows standard specification/test method

• voluntary, commercial

• a document and a logo, on-line record -> public recognition

• For bioplastics: DIN CERTCO, Vinçotte, BPI

Certification process

Valid certificate contains a name of the certification organization and the certification number Other claims, although also called certificates, are not valid.

Certification of bioplastics

Certification of compostability

• First certification scheme Vinçotte, 1995

• Products certification

• Intermediates/additives registration

• Chemically unmodified materials and components of natural origin

• Organic components > 50 % (volatile solids)

• Printing dyes - compostable

• Blends and laminates – all compostable, ½ thickness

• Certification of products made of registered materials (IR, thickness)

Compostable plastics certification

1. Chemical Composition No substance that are harmful to the environment. Level of heavy metal contents and other hazardous elements within standardized limits.

2. Biodegradability More than 90 % conversion of organic carbon into CO2, in maximum of 180 days.

3. Disintegration during composting Quick disintegration of the material (12 weeks, sieve fraction)

4. Eco toxicity Positive results from testing of the compost quality (germination rate, biomass mass)

5. Labeling Labeling according to certification scheme, allows the inhabitants to identify and collect the waste in organic waste bins

Specifications for composting

Biobased plastics

“Carbon age” signifies a time needed to get carbon for manufacturing a product. Classical plastics are manufactured from fossil resources containing fossil – old carbon.

On the other hand, plastics manufactured from renewable crops (corn, sugarcane, potatoes also farm and food production waste) contain carbon which circulates in nature for maximum a few years. For wooden products “carbon age” is about several dozen years.

Biobased plastics certification

CO2 „New” carbon

Biomass, agriculture

Fossil resources oil, gas etc.

„Old” carbon

polymers, chemical substances and fuels

1 year

> 106 years

chemical industry

1 – 10 years

This system could be used for many products completely or partly manufactured from natural origin materials/polymers/resources (except solid, liquid and gaseous fuel).

Analysis is based on the ASTM D6866 standard, method B or C.

When a product contain more than one component then the company applying for the certificate needs to certify each component separately.

On the other hand it is possible to certify a group of products, provided they are made from the same material, have similar shape and size is the only differentiating factor.

Europe certification logo map

CONCLUSION Stand&Cert

• Standardization and certification of bioplastics complex

• Rapidly changing

• Solid basis of test methods and specifications

• Certification has a marketable value

• Need to inform industry and users

Confirmation of greenhouse gases emission reduction

Legislative restrictions on emissions of greenhouse gases influenced many evaluation methods of those emissions, including methods that can be applied to products including packaging. Most popular method is called the “carbon footprint” or “carbon profile”. For a polymer product a “carbon footprint” amounts to overall directly and indirectly emitted CO2 (and other greenhouse gases) throughout its whole life cycle. In Europe most popular “carbon footprint”

calculation is currently based on PAS 2050:2008

In 2007 Carbon Trust (organization financed by British government) introduced a new mark called “carbon reduction label”. “Carbon reduction label” shows overall CO2 and other greenhouse gases emission calculated as CO2 equivalent in all life cycle stages (production, transport, distribution, removal and recycling). Basis for evaluation is PAS 2050:2008. “Carbon reduction label” informs consumers about greenhouse gases emission level and helps them to make deliberated decisions that are beneficial for the environment.

Producers cooperating with Carbon Trust analyse process maps related to life cycle of their specific products. With understanding of the greenhouse gas emissions of their processes companies are able to change technical and logistic solutions which can then reduce emissions.

Coca-Cola is another notable example of cooperation with Carbon Trust.

Carbon Trust evaluated the “carbon footprint” of Coca-Cola’s packaging for several of their products.

For a glass bottle “carbon footprint” attributed to the packaging amounts to 68,5% of total CO2 emissions. For a 0,33l metal can this value is 56,4%, a PET bottle (0,5 l) has a share of 43,2% and for a large PET bottle (2 l) amounts to 32,9% of total carbon.

Summary

Today we discussed the following:

PLASTiCE project – introduction

Guide for entrepreneurs – introduction

Plastics – basics

Plastics classification

Sustainability evaluation – three pillars of sustainability

Sustainable plastics – certification criteria

THANK YOU!! www.plastice.org

SUSTAINABLE PLASTICS · Packaging Research and Development ... allow to use organic recycling...

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