FUNBIOMAT

The aim of the CORNET project is the development of innovative functionalization methods to achieve an optimal distribution of bio-based additives from cellulose nanofibers (CNF) in biopolyesters. The methods shall create a significant improvement of the materials’ thermomechanical properties, barrier function against gases, and biodegradability. The motivation: Global warming, resources deficiencies, plastic wastes and microplastic pollutions are all key factors which highlight the need to find bio-based, recyclable and biodegradable alternatives to conventional petro-sourced plastics. The main economically viable biobased polyesters such as PLA, PBS, PBAT and PHB are strong candidates to fulfil this need, but they have poor thermal, mechanical and barrier properties, which limits their use in highly demanding applications like packaging, consumer goods, automotive or construction. Additives are generally used to improve these properties, but they are neither bio-based nor appropriately dispersed in the polyester matrices, preventing any substantial improvement. Over the last decade, the use of biobased fillers from cellulose or lignin in their nanometric form has raised high hopes to produce high-performance biobased materials. Cellulose nanofibers (CNF) have been long regarded as a key additive to improve the properties of polyesters but, up to now, not all efforts have achieved the expectation because of a non-industrially transferable process or an inefficient nanoparticles dispersion state.

The solution: One of the main objectives of the FUNBIOMAT project will be to develop advanced functionalization methods for bio-based additives to ensure an optimal distribution within the biopolyester materials. Through this approach, a significant improvement of the key material properties is expected, opening the door to their valorization into new specific applications. More precisely, the project aims to develop an innovative aqueous process for producing highly filled and easily dispersible masterbatches containing CNF and biopolyesters. These masterbatches will be used for producing highly homogeneous cellulose-biopolyester nanocomposites. By means of extrusion, the nanocomposites will be incorporated into biopolyesters to improve their mechanical properties. Alternatively, they will be applied as a coating on the surface of a biopolyester film, enhancing its barrier properties. The developed materials will be tested via the production of pouches for cheese or dry food products, thermoformed trays for cheese, meat or fish packaging and injection molded coffee capsules. The recyclability and biodegradability of the different systems will also be evaluated.

The project partners: The project will be performed by two Belgian (CELABOR, MATERIA NOVA) and two German RTOs (Fraunhofer IVV, Fraunhofer UMSICHT) which will use their complementary expertise on bio-based filler production and modification, compounding, polymer processing and biodegradability, life cycle and cost assessment. The outlook: The development of the masterbatch technology will increase the market potential of biobased products, which will be beneficial for biopolyester manufacturing industries and plastics processing companies. Packaging companies can increase their potential market share, especially for food packaging, by proposing new sustainable bioplastics solutions (100% bio-based, recyclable and biodegradable). These advances enable food companies to stand out from their competitors with more sustainable packaging and to attract environmentally conscious customers. Furthermore, improving the barrier and mechanical properties of biopolyesters may create new applications in other sectors, like automotive or agriculture.