DIBBIOPACK PROJECT FINAL CONFERENCE

Zaragoza, 23 to 24 February, 2016

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INTRODUCTION

DIBBIOPACK is a European Research & Development Project funded by the

European Commission within the Seventh Framework Programme for research,

technological development and demonstration (under grant agreement No 280676),

with 19 partners from 10 different countries. Its final budget is 7,745,570 euros, - with

5,702,632 coming from the European Commission. The project will have lasted 4

years, from March 1, 2012 to February 29, 2016.

The project full title is “DEVELOPMENT OF INJECTION AND

BLOW EXTRUSION MOLDED BIODEGRADABLE AND

MULTIFUNCTIONAL PACKAGES BY NANOTECHNOLOGY:

IMPROVEMENT OF STRUCTURAL AND BARRIER

PROPERTIES, SMART FEATURES AND SUSTAINABILITY”.

Dibbiopack´s main objective is the development of smart and multifunctional

packaging from bioplastics (bio-based, compostable and biodegradable) for the

three most relevant packaging sectors: food, cosmetics and pharmaceutical.

Dibbiopack Project Partners

The Project partners fall under the following categories:

Research Centres:

AITIIP Centro Tecnológico (coordinator). Spain, Zaragoza.

INSTM (Consorzio Interuniversitario Nazionale per la Scienza e Tecnologia dei

Materiali). Italy.

CNR (Consiglio Nazionale delle Ricerche). Italy.

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VITO. Belgium.

Fraunhofer ISC. Germany.

TECOS. Slovenia.

University of GALWAY (Ireland)

Small, Medium and Big Companies with high Research & Development capacity:

AVANZARE. Spain, Logroño.

CONDENSIA. Spain, Barcelona.

ARCHA. Italy.

TEHNOS. Slovenia.

PLASMA. Macedonia.

INNOVIA Films. United Kingdom.

GORENJE. Slovenia.

End-Users:

NUTRECO. Spain, Toledo.

HELP Pharmaceuticals. Greece

COSMETIC. Greece.

Other types of entities:

ALMA. France.

SOGAMA. Spain, A Coruña.

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RATIONALE FOR DIBBIOPACK PROJECT

The Dibbiopack Project attempts to respond to the industrial and technological

challenge of developing new smart and more sustainable packaging. It is labelled

“smart” as bioplastic materials present new characteristics that turn them into real

actors for product preservation, increasing product durability, keeping its quality, while

reporting to the consumer on content preservation conditions.

Developing packaging by means of bioplastics provides this project with high relevance

alongside a social responsibility component in our modern society. It is becoming

increasingly indispensable to move towards a new waste management and disposal

policy to meet the global challenge of replacing old types of plastic packaging with

recyclable and biodegradable materials. It should not be ignored that plastic packaging

(whether rigid or flexible) makes up 40% of all packaging used worldwide. That is why

it is essential to develop it from sustainable resources that assure a similar

performance to that found in traditional petroleum-based plastics. To obtain materials

with these characteristics and a high level of insulation, preservation and asepsis it has

been essential in this project to resort to nanotechnology in order to improve the

behaviour of biomaterials.

Thus, Dibbiopack, by resorting extensively to applied research and establishing tight

collaboration ties among entities and industries all over Europe, truly provides an

answer for three overarching problems regarding bioplastics: those related to

legislation, market and a respect for the environment.

At the regulatory level, it is true that local and national legislations are increasingly

imposing restrictions or even completely banning the use of petroleum-based plastic

packaging. Thus, there are great opportunities for alternative products from bioplastics.

In 2015, the City of New York banned the use of expanded polystyrene and San

Francisco did the same with plastic water bottles. Much earlier, in 2007, it had imposed

a ban on the use of plastic carrier

bags. Closer to us, in France,

there will be a ban on non-

compostable carrier bags from

2016. This is no trivial matter,

bearing in mind that 17 billion

plastic carrier bags are used per

year, half of which alongside lots

of other packaging, end up being

dumped, taking hundreds of

years to degrade, as well as

being ingested by birds and sea-

creatures. It is a proven and

widely-known fact that experts Problema de las bolsas no biodegradables en el mar

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have detected huge amounts of packaging flotsam in all oceans, which end up in the

seabed and back into the food chain.

Other countries are moving in

the same direction regarding

one-use-only plastic packaging

items. Even the European

Parliament has taken steps in

this respect. In 2014, it

requested that by 2019 the EU

countries bring down the use

of this type of bags by at least

an 80% as to the 2010 figures,

a year in which a European citizen made an average use of 200 plastic bags.

Countries will have to limit the number of packaging items per person and the fact that

these are handed over, free of charge, at selling outlets.

The bioplastics market is in its infancy, both at a global and European level. Thus, in

Europe, Dibbiopack has meant a huge step forward regarding the injection of these

materials, a step not exempt from highly technical complexities. Bioplastics is a sector

undergoing a clear development and paradoxically, Europe, despite being at the

cutting-edge of research in this field, could lag behind other regions such as Asia or the

USA as for its production capacities. Those regions have invested more heavily in

measures towards the rapid introduction of these materials into their markets, which

show a more rapid growth as a result. Most projects are being introduced in countries

such as Thailand, India and China and it is estimated that, by the year 2019, about

80% of bioplastics in the world will be produced in Asia. This is also an opportunity for

Europe, where bioplastics production is forecast to grow by 300% by 2018. The

European Commission reinforced this growth by designating bioplastics as one of the

emerging and innovation sectors to get legislative support (lead market).

The Dibbiopack Project has a direct impact on a third field of great importance: the

preservation and respect of the environment. Among other reasons, bioplastics help

us reduce our dependence on limited fossil resources, foreseeably to become more

expensive in the years to come, by replacing them with other renewables such as

annual maize or sugar beet crops, or perennial crops such as manioc or sugar cane.

The use of this biomass to create products based on bioplastics cuts down greenhouse

effect gases and can be turned into renewable energy by resorting to recycling at the

end of the product´s useful-life cycle. As a result, it can be asserted that one of the

main benefits from bioplastics is that they allow us to put an end to the cycle and

increase resource efficiency.

The raw materials (corn-starch, sugar cane…) to make this material, feed on biomass.

This material (polylactic acid) is transformed into a useful product, from which, at the

end of its useful lifespan and during its disposal phase and organic recycling, energy is

Parlamento Europeo

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recovered and new biomass is obtained. This organic recycling (composting) also

enables us to obtain valuable biomass and humus for plant growth and closes the

cycle once more. Thus, the use of bioplastics can notably increase waste

management efficiency all over Europe.

BIOPLASTICS, A GREAT OPPORTUNITY

The majority of plastic bags and packaging used Europe are imported, reaching 90% in

most cases for fruits and vegetables. From that perspective, the transition towards the

production of bioplastics in Europe means a great opportunity for Research &

Development and job creation, which the Dibbiopack project keeps in mind. Likewise,

there are a number of competitive advantages that act as driving forces in this sector.

With 20 % annual growth, it is interesting for the industry as, among other reasons, it

offers advantages such as advanced technical properties that increase product

attractiveness, potential cost-reduction through economies of scale and development

of new waste disposal options. We should not forget the high level of acceptance of

these products among consumers, the imminent danger from climate change, the

growing proportion of fossil resources used and our overdependence on them.

The bioplastics family offers good perspectives both for society and industry. In

Western Europe nearly 50 million tonnes of polymers are consumed per year.

According to the University of Utrecht, bioplastics could substitute about 42 million

tonnes. This replacement of 85 % of polymers, which is possible in theory, is not so in

the short and mid-term, as our present day production capacity does not allow it, even

if it were possible to increase it fourfold in the next 5 years. The rising volume of

bioplastics, non-biodegradable plastics and new polymers that can be replaced

represents a huge opportunity for transforming industry, trademark owners, vendors

and consumers.

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DIBBIOPACK PROJECT STRUCTURE

The Dibbiopack Project has been structured into four different work packages, ranging

from eco-design; through areas of material, technologies, smart applications,

integration, and end-users; to their dissemination and exploitation.

There habe been three fundamental development axes:

Environment: renewable material sources, sustainability, power consumption,

reduction in the use of materials and eco-design.

Performance: barrier properties, thermal resistance and processability.

Functionalities: Safety, oxygen sensing, intelligent antimicrobial devices and

traceability.

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Dibbiopack provides solutions to three fields:

Top quality materials, fully compostable and biodegradable, and from renewable

sources.

New manufacturing processes for bioplastics by resorting to nanotechnology.

New compostable and multifunctional packaging.

This project has allowed us to make remarkable progress in vital working areas for

bioplastics development such as:

- Development of new materials.

- Plastic transformation processes.

- Barrier technologies.

- Added Value Packaging.

- Small nanotechnology-activated devices.

- Technology integration.

MAIN PREMISES FOR THE DIBBIOPACK PROJECT

Dibbiopack aims at developing multifunctional and environmentally-friendly bioplastic

packaging by using materials from renewable sources, thinking of their sustainability

and a circular economy, while reducing power consumption and raw materials by

means of more efficient manufacturing processes that without losing sight of eco-

design.

In order to get packaging items that fulfil the requirements previously mentioned, and

for them to have a valid industrial use, additives have been incorporated in order to

increase packaging processing possibilities and performance. It was necessary to

do so, as bioplastics present a higher difficulty in their processing than other ordinary

compounds, with improvable thermal and mechanical properties. For example, they are

somewhat rigid and brittle and begin to soften when they reach over 65-70ºC.

As for the films developed within the Project, in order to use them in food packaging,

their barrier properties to gases by means of surface coating treatment have been

increased.

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Finally, a twofold attempt has been made to increase and enhance food safety in

packaging. On the one hand, in order to avoid all content contact with additives, an IML

tag has been designed (in-mould labelling). This label

physically keeps packaging and food apart and is

biodegradable. At the same time it contains an

antimicrobial agent released in the event of humidity in

order to prolong the freshness of the packed product. On

the other hand, it provides both the consumer and

manufacturer with information related to packed product

quality by means of an RFID tag that acts as an oxygen

sensor warning about oxygen presence in modified

atmospheres.

MATERIALS AND PROCESSES USED

The base polymer used is polylactic acid (PLA), a polymer from starch with additives

such as a plasticizer to make it more easily processable, or a nanometre-size

reinforcing agent that improves mechanic and barrier properties, both inert or

biodegradable so as not to have a negative impact on the composting and

biodegrading process of the final packaging.

Nanomaterials have been present throughout the project with an

aim to improve the mechanical properties of bioplastics, to provide

them with, at least, similar characteristics to those found in

conventional plastics. Nanofibers from Avanzare, Spanish partner

in Dibbiopack, have been used, and their validity as reinforcing

agents has been proven throughout the project.

In order not to have any contact between a cosmetic product (cream) or food product

(chicken burger) with this nanoadditive in particular, biodegradable labels that

physically keep packaging and content apart have been used. Migration essays

conducted during the project by ARCHA Laboratories have proven that under standard

trial test conditions no transfer of any nanoparticles takes place.

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The manufacturing processes used were Blow Extrusion moulding for the

manufacturing of bottles for pharmaceutical use and Injection moulding for the

production of cosmetic jars and food trays.

In both processes in-mould labelling was used to shorten the process, and micro-

foaming in order to reduce the final weight, amount of material and power required. As

for the manufacturing of films, Biaxial blowing was used and a further plasma

treatment, plus organic coating (bioORMOCER®) developed by Fraunhofer ISC with a

surface barrier to gases treatment (when used in tray films) or antimicrobial treatment

(when used for IML film labels).

The solution incorporated to DIBBIOPACK films is based on a three-layered

configuration as shown in the image below, with a planarization base of bioORmocer, a

second coating of inorganic material through plasma so as to boost the barrier effect,

and finally another bioOrmocer layer.

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Main findings and results of the Dibbiopack project

Amongst the main results obtained we should mention:

Formulations of biodegradable and compostable materials with enhanced

properties adapted to an industrial use.

Bio-based and biodegradable films with enhanced barrier or antimicrobial

properties.

Bottles for Pharmaceutical use from biodegradable and compostable materials with

IML biodegradable labels on the outside (for decorative or informative purposes)

and oxygen absorbing, with a sealing effect on the cap, with a very light weight.

Jars for cosmetic use with biodegradable IML labels both in the inside (for an

antimicrobial effect) and the outside (for decorative or informative purposes).

Food trays for food prepared in an internal oxygen-free atmosphere. Made from

compostable and biodegradable materials, with IML antimicrobial labels in the

interior. The film used for closing is bio-based and biodegradable, with enhanced

barrier and antimicrobial properties. They fall under the category “smart” packaging

as they have an oxygen sensing device that provides the user with thorough

information on content condition. The sensor changes its colour depending on the

oxygen concentration found inside the packaging.

Thus, any valuable information on content condition is readily available with no

actual content contact thanks to a RFID antenna integrated in a mobile phone or

Tablet with Android Operating System, leading to higher convenience for

traceability, access to online information records, allowing a follow-up by means of

an App.

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Output and results of Dibbiopack Project

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FINAL CONFERENCE DIBBIOPACK PROJECT. ZARAGOZA, 24

FEBRUARY 2016

The Final conference of the Dibbiopack Project will be held in Zaragoza, Spain, in

February 2016. Based in Zaragoza, Aitiip Technological Centre has coordinated this

initiative for the last 4 years. Among its main lines of research we find bioplastics and

their transformation processes.

During this conference, in different plenary and working sessions, partners in the

Project will revise all technical details linked to planning, implementation and results.

They will also visit the pilot lines where two out of the three demonstrators were built.

On February 24, the results of the Project will be released in an open social event. If

you wish to attend, you may sign in here:

http://www.aitiip.com/dibbiopack/dibbio_en.html

The final conference, to be held in the Caixaforum Congress Centre, will see an

institutional presence at the European, national and regional levels and will include

open sessions for stakeholder sectors. Therefore an invitation has been issued to a

wide range of stakeholders in agreement with one of Dibbiopack priorities: Awareness-

raising and the dissemination of knowledge on bioplastics and their application in

Europe.

CaixaForum Zaragoza, venue for the presentation of Project results and findings to society

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For further information, please addres your queries to:

http://www.aitiip.com/dibbiopack/dibbio_en.html

PROJECT COORDINATOR: Berta Gonzalvo ( berta.gonzalvo@aitiip.com )

TECHNICAL COORDINATOR: Víctor Peinado ( victor.peinado@aitiip.com )

ENQUIRIES ABOUT THE FINAL EVENT: José Andrés López ( jal@aitiip.com )

FOR INTERVIEWS AND ADDITIONAL MATERIAL, PLEASE ADDRESS YOUR

REQUESTS TO: prensa@izecomunicacionindustrial.es (Santiago Izuel, +0034 616-

418-026)