Periodic Reporting for period 2 - BARBARA (Biopolymers with advanced functionalities for building and automotive parts processed through additive manufacturing)
Berichtszeitraum: 2018-11-01 bis 2020-10-31
BARBARA project aims at the valorisation of side-stream fractions and residues from agro-food production into novel polysaccharides and functional additives. These raw materials were selected based on the advanced functionalities that they could provide to the polymer matrices. The extracted polysaccharides have been compatibilized with polyesters and polyamides and reinforced with extracted, modified, and functionalized additives to obtain engineering bioplastic formulations adapted to current Fused Filament Fabrication (FFF) processes. The target of BARBARA project is the development of novel bio-based engineering bioplastic materials to be validated in functional prototypes with advanced properties for building and automotive sectors.
BARBARA has directly contributed to KPI 5 of the SIRA document (4 new advanced biobased materials) and KPI 6 (3 validated consumer products through 2 novel value chains for FFF). The BARBARA consortium involved 10 partners (5 RTD, 3 SME and 2 Large Companies) accounting to 2 BIC full members and 3 associated members.
BARBARA project has achieved the creation of 8 new materials from agro residues and by products meeting industrial needs. With these new materials, by means of 3D technology, three prototypes were printed: door trim and dashboard fascia for cars (with the participation of the Centro Ricerche FIAT) and moulds for truss joints for buildings (developed for ACCIONA Infraestructuras).
This project has also contributed with a direct impact on four essential facilitating technologies: biotechnology, nanotechnology, advanced materials and advanced manufacturing technologies,
which are the foundations of a wide range of industries.
BARBARA has directly contributed to KPI 5 of the SIRA document (4 new advanced biobased materials) and KPI 6 (3 validated consumer products through 2 novel value chains for FFF). The BARBARA consortium involved 10 partners (5 RTD, 3 SME and 2 Large Companies) accounting to 2 BIC full members and 3 associated members.
BARBARA project has achieved the creation of 8 new materials from agro residues and by products meeting industrial needs. With these new materials, by means of 3D technology, three prototypes were printed: door trim and dashboard fascia for cars (with the participation of the Centro Ricerche FIAT) and moulds for truss joints for buildings (developed for ACCIONA Infraestructuras).
This project has also contributed with a direct impact on four essential facilitating technologies: biotechnology, nanotechnology, advanced materials and advanced manufacturing technologies,
which are the foundations of a wide range of industries.
The BARBARA partners extracted and characterized functional additives from lemon and pomegranate agrowastes, from the residue of discarded fruits by Spanish farmers and supplied by FECOAM. The UA team was in charge of developing and optimizing microwave assisted extraction (MAE) protocols at the laboratory scale for lemon and pomegranate agroresidues by using multivariate experimental designs. These protocols allowed the extraction of essential oil from lemon, pigments (lemon and pomegranate), and biomordants from pomegranate (tannins and other polyphenols) as well as its functionalisation and design to be used as additives for polymers. CELABOR was responsible for the purification of the active additives and their upscaling. The optimization of chlorophylls extraction from broccoli at lab scale by MAE was also performed by UA (supported by UNIPG). Seven additives with colouring, fragrance, antimicrobial or biomordant functionalities were obtained from the studied agrowaste residues in the work carried out by the partners UA and CELABOR: lemon essential oil; yellow pigment from lemon; pomegranate pigments and antibacterial biomordant from pomegranate; green pigment from broccoli; and antimicrobial extract and reinforcing additive from almonds.
Regarding the development of engineering bioplastic blends combining polysaccharide fractions isoltaed from corn by-products (starch from broken corn and arabinoxylan from corn fiber) and engineered polymer resins (polyamides and polyesters) provided by NUREL, KTH optimized and implemented the chemical modification procedures. In total, 16 new formulations using BARBARA polysaccharide substrates were produced and characterized. The upscaling production of the target final matrix based on starch and PA for the construction mould was carried out by AITIIP. To this end, a grafting approach was selected, developed, upscaled and implemented.
TECNOPACKAGING successfully upscaled the selected formulations from lab level (work carried out by UNIPG) as best candidates for the final 3D printing prototypes. 8 materials (33 spools) were produced.
AITIIP developed a new heading for the 3D printer particularly designed to overcome Fused Filament Fabrication weaknesses: layer thickness quality and anisotropy. Modifications were required in the printer and the heading device in order to optimise the printing process and properties of the samples. Mechanical characterization of injected and 3D printed samples was also conducted, with the main aim of verifying the role of the processing conditions of the overall performance of produced formulation in the frame of the project. Disintegrability, recyclability, fragrance release and antimicrobial activity was also tested.
Three industrial prototypes were manufactured through FFF processing using BARBARA materials: fascia and interior door trim for the automotive sector and a mould for the construction sector. All the prototypes were successfully validated by CRF and ACCIONA.
Dissemination of key results were disseminated through diverse tools and channels; such as webpage, social networks, 7 scientific publications, 3 brochures, 9 videos, 15 radio/TV interviews and 7 newsletters (sent to stakeholders with targeted sectors and audiences).
A specific business plan has been developed for the key exploitable results (the ones which represent a potential business) to drive the generation of value of BARBARA project for the different partners and stakeholders in the value-chain. The activities associated to the Business Plan are strictly related to the technological activities within the BARBARA project, and are directly fed by dissemination and exploitation strategies, providing the guidelines to be followed and the key aspects of marketing that are crucial to ensure positive follow-up. .
Regarding the development of engineering bioplastic blends combining polysaccharide fractions isoltaed from corn by-products (starch from broken corn and arabinoxylan from corn fiber) and engineered polymer resins (polyamides and polyesters) provided by NUREL, KTH optimized and implemented the chemical modification procedures. In total, 16 new formulations using BARBARA polysaccharide substrates were produced and characterized. The upscaling production of the target final matrix based on starch and PA for the construction mould was carried out by AITIIP. To this end, a grafting approach was selected, developed, upscaled and implemented.
TECNOPACKAGING successfully upscaled the selected formulations from lab level (work carried out by UNIPG) as best candidates for the final 3D printing prototypes. 8 materials (33 spools) were produced.
AITIIP developed a new heading for the 3D printer particularly designed to overcome Fused Filament Fabrication weaknesses: layer thickness quality and anisotropy. Modifications were required in the printer and the heading device in order to optimise the printing process and properties of the samples. Mechanical characterization of injected and 3D printed samples was also conducted, with the main aim of verifying the role of the processing conditions of the overall performance of produced formulation in the frame of the project. Disintegrability, recyclability, fragrance release and antimicrobial activity was also tested.
Three industrial prototypes were manufactured through FFF processing using BARBARA materials: fascia and interior door trim for the automotive sector and a mould for the construction sector. All the prototypes were successfully validated by CRF and ACCIONA.
Dissemination of key results were disseminated through diverse tools and channels; such as webpage, social networks, 7 scientific publications, 3 brochures, 9 videos, 15 radio/TV interviews and 7 newsletters (sent to stakeholders with targeted sectors and audiences).
A specific business plan has been developed for the key exploitable results (the ones which represent a potential business) to drive the generation of value of BARBARA project for the different partners and stakeholders in the value-chain. The activities associated to the Business Plan are strictly related to the technological activities within the BARBARA project, and are directly fed by dissemination and exploitation strategies, providing the guidelines to be followed and the key aspects of marketing that are crucial to ensure positive follow-up. .
A number of key results have been achieved:
(1) Subcritical water extraction (SWE) of arabinoxylan from corn fibre,
(2) Functionalized nano-pigments (clays plus dyes), antimicrobials and essential oils,
(3) Functionalised bio based filament for FFF process,
(4) Heading device,
(5) automotive part,
(6) construction parts (moulds for RTM).
The BARBARA project has contributed to create two new value chains, as well as to the development of an innovative and forward-looking modern industry with the potential to revolutionise the production of new materials. An industry more in tune with the environment and where new and more environmentally friendly extractive processes are implemented.
Other impacts of the Project:
- MAE and SWE show strong advantages in terms of environmental performance in comparison to traditional extraction processes.
- The comparative LCA study performed in all formulation show that those based on INZEA matrix have lower overall impact and in particular, the minimum weight on climate changes
- Developing new additive manufacturing technologies involves the reduction of energy consumption, and material consumption. This can be done by utilizing AM abilities to create complex structures and reducing the amount of waste in the process
- Replicability with other agrowastes will help European policies of reducing waste-to-landfill requirement
(1) Subcritical water extraction (SWE) of arabinoxylan from corn fibre,
(2) Functionalized nano-pigments (clays plus dyes), antimicrobials and essential oils,
(3) Functionalised bio based filament for FFF process,
(4) Heading device,
(5) automotive part,
(6) construction parts (moulds for RTM).
The BARBARA project has contributed to create two new value chains, as well as to the development of an innovative and forward-looking modern industry with the potential to revolutionise the production of new materials. An industry more in tune with the environment and where new and more environmentally friendly extractive processes are implemented.
Other impacts of the Project:
- MAE and SWE show strong advantages in terms of environmental performance in comparison to traditional extraction processes.
- The comparative LCA study performed in all formulation show that those based on INZEA matrix have lower overall impact and in particular, the minimum weight on climate changes
- Developing new additive manufacturing technologies involves the reduction of energy consumption, and material consumption. This can be done by utilizing AM abilities to create complex structures and reducing the amount of waste in the process
- Replicability with other agrowastes will help European policies of reducing waste-to-landfill requirement