Wood replaces plastic

New business from Finnish forest 10.5.2014Prof. Ali Harlin, Esa Torniainen, Jouni LattuVTT Technical Research Centre of Finland

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Bioeconomy – extended value

Modified from the source: Metsäteollisuus ry

2

Harvesting and logistics

Bioenergia- lämpö ja sähköteollisuudelle ja kotitalouksille

Biopolttoaineet liikenteeseen

Biokemikaalit

Biomateriaalit

Lääkkeet jakosmetiikka

Value

Volyme

Sellu, paperi ja kartonki viestintään, pakkaamiseen japehmopapereihin sekä puutuotteet mm. rakentamiseen

Coatingsladhesives…

CompetitiveExistingproducts

Uuden osaamisenkerryttäminen

Investoinnit uuteenteknologiaan jaliiketoimintoihin

Globaali verkostoituminenT&K ja innovaatiot

Bioenergy, Heat andElectricity

Biofuels

Biochemicals

Biomaterials

MedicalCosmetics

Wood products, cellulose,paper and board

,Pelletsgasification…

Biopolymers, composites…New materials,products andservice

BioenergyBio fuels

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Eco-efficient materials

DriversGoals

Reduce

Renew

Recycle

Light

Hi-performance

Replace oil

Low resouces

Raw-material efficiency

Click to edit Master title style

Click to edit Master text stylesSecond level

Third levelFourth level

Fifth level

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Basic research

Applied research

Development

UNIVERSITIES

INDUSTRY

VTT

VTT’s status as performer of R&D work

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Global packaging industry

Global packaging industry turnover 2013 nearly 600 Mrd EUR,mainly in converted materials.

Primary packaging market is fragmented according tomaterials, converting and packaging technologies.

Transport packaging dominated by corrugated board.

Industrial packaging is mainly corrugated, plastic films anddifferent containers.

Corrugated board 105 milj. tons, Plastics 80 milj. tons,Cardboard 46 milj. tons, Bioplastics 1 milj. tons.

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100% bio-based packages

Recycled pulp and biopolymersCompatibility in value chainEffective production methods in packaging applications.Flexible processing with conventional methods

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Typical Environmental Statements

Biodegradability

Compostability

Degradation in ocean

Biobased

Low carbon foot print

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Sustainable development is coming

Braskem sugar based polyethylene since 2009.Johnson&Johnson, Danone, Tetrapak.

Coca-Cola launched 2009PlantBottle with 30% bio- targeting 100 % for PET .

Natureworks PLA has beenon markets for years, newapplication coming (Danone).

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Hybrid cardboards – improved strength

From MD/CD to multiaxial strength

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New fibre materials

Changed view-point:

Transparency

Moldabilty

Printability

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Example: Fibre based blister

Concept:

Designed blisters

Simplified production

Apply moldable web

Apply bio barrier tech

Replace plastic and aluminum

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Moldable web

NewFibre basedSustainableEasy waste mgtCommunication

Material and design by VTT

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Moldable web examples

Tray packaging demo, Drupa 20124 inventions:

Foam formingDispersionsThermoformingTranslucency

Next onWood based deep drawn packages

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Modified hemicellulose (side stream)

Products out of modified hemicelluloseOxygen and grease barrierFlexible and transparent filmMoldable filmHydrogels (hygienic)Active films

Hemicellulose hydrogel(Aca/VTT)

Heat-activated cellulose film(FC/VTT)

Flexible hemicellulose film(FC/VTT)

Hemicellulose barrierdispersion (KCL/VTT)

Mouldable hemicellulose film(VTT)

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What is nanocellulose?

Microscope Macro

Totally NewProperties

Esau, Anatomy of seed plants,1977, Wiley, NY

Pääkkö et al,Biomacromolecules,8(2007)1934 1,7% solids

Young´s modulus 140 GPa(T. Nishino et al. J.Polym.Sci.,Part B,1995)Tensile strength 3 GPa(D.Page, F. El-Hosseiny, J.Pulp Paper Sci. 1983)Coefficient of thermal expansion 0,1 ppm/ºK(H.Yano, Seminar lecture, Otaniemi 2009)

Aalto: SeppäläVTT

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Use of nanocellulose based on patents

Applications (NFC)Composites (38%)Disposables (18%)Paper and board (16%)Food products (13%)Paper converting ( 8%)Cosmetics (3%)Filters (4%)

13 %

3%

18 %

4 %16 %

8 %

38 %

NFC applications

Data collected by Dr. Juha Merta, Aalto University School of Science and Technology.

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SEM x50 SE images from uncalenderedpaper surfaces.

Peruspaperi

NFC-pinnoitettu paperi

Nanocellulose as paper coating

Thin filmApplied as foamSurface can be modified efficientlyReduce air permeabilityNo bindersTowards monomaterials

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Nanocellulose films

PropertiesWood basedBiodegradableLike HDPE filmNot dischargingPrintableSustainable intelligent applications

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Rigid foams made of bio-materialsReplacing oilLight weightInsulation, both thermal and mechanical

Applications from packaging to buildingconstruction Nanofibrillated cellulose

Pääkkö et al,Biomacromolecules, 8(2007)1934

Nanocellulose foam

Light materials – Cellulose foam

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VTT FiCus Concept – Simple, Flexible, Cost Competitive

Mixingpulp,

surfactantand air

Molding,water

removal,layering

Drying

Technology readiness level:Demonstrators ready

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Bio-barriers in food packages

Dry foodReplacing fluorochemicals in fast-foodpackages.Grease barrier for cookies and pizzaOxygen barrier in frozen goodsHigh barrier solutions

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Bioplastic synergy• Plastic performance

• Production and logistics known• Performing products

• Waste management: recycle or energy

Benefit• Sustainable products for brands and retailers• Added value for chemical and material industry

Our vision

Fibre materials are renewable• Easy to recycle• Low environment burden• Synergy with (bio)plastics

TECHNOLOGY FOR BUSINESS