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Content archived on 2024-06-18

Development of a flexible and energy-efficient pressurised microwave heating process to produce 3D-shaped renewable bio-polymer foams for a novel generation of transportation packaging

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Biodegradable and compostable foamed packaging from renewable resources

Packaging materials are a vital part of the supply chain, ensuring components and products are undamaged. Thanks to EU research, some of these protective materials are now fully biodegradable and compostable according to international standard (i.e.EN13432).

Given their ubiquitous nature, the typically synthetic origin of many packaging materials has raised important environmental concerns. The EU-funded project REBIOFOAM developed a sustainable process to make biodegradable packaging from renewable materials, (i.e.starch and water). Energy consumption is minimised by using efficient microwave heating to induce expansion and foaming of a starch-based biopolymer through vaporisation of the water content in the polymer itself. Expansion occurs within the microwave mould cavity such that the biopolymer achieves the desired 3D shape. REBIOFOAM, thanks to the involvement of the whole supply chain, produced two demonstrators, a port hole spacer for washing machines and a corner piece for packaging applications. Both achieved target densities and demonstrated good physical and mechanical properties when compared to reference expanded polystyrene (EPS). A fully automated semi-industrial pilot line has been developed, which is able to produce foamed samples with density 40-45 kg/m3. REBIOFOAM materials can be used as protective packaging materials and its adoption and commercialisation are expected to have major environmental and economical benefits related to decreased energy consumption and when the complete biodegradability and compostability, in combination with the specific mechanical properties of the materials, is an added value for the selected applications.

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