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K2016: ecovio® EA: Certified Compostable Packaging

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BASF's newest innovation in sustainable pacakaging solutions, a highly biobased, certified compostable packagaing foam that extends the current portfolio of innovative foam solutions.

Presentation held at K2016 Preview on June 28th, 2016. Presented by Dr. Sven Wenigmann.

Visit BASF at the K Fair 2016 from October 19th to 26th, Hall 5, C21/D21 in Düsseldorf, Germany. More information at www.basf.com/k2016.

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K2016: ecovio® EA: Certified Compostable Packaging

  1. 1. ecovio® EA BASF’s new certified compostable packaging foam with high biobased content Dr. Sven Wenigmann Business Development Biopolymers Packaging
  2. 2. General Introduction 2 Target area for ecovio® EA Biobased/ biodegradable Productsensitivity No Yes Low Cardboard ecovio® EA EPP EPS High
  3. 3. Life cycle of ecovio® foam 3 Expandable bead Multi-shock resistance Heat resistance Chemical resistance Raw material ecovio® Part. biobased Biodegradable (DIN EN 13432)* Biobased & biodegradable expandable particle foam *certification in progress
  4. 4. Composting of ecovio® EA Compostable ecovio® EA foam Fast Disintegration of foam (DIN EN 13432) in 5 weeks Sample 1 Thickness 0.6 cm (cup) Sample 2 Thickness 5 cm (box) ecovio® EA foam (11.7 x 8.8 cm² pieces) ecovio® EA foam (5 x 5 x 5 cm³ pieces) at start after three weeks of composting at start after three weeks of composting 7
  5. 5. * preliminary data Performance ecovio® EA vs. EPS Density (g/L) Expandable bead density (g/L) Cushioning factor Compressive strength @ 10% (kPa) Flexural work to break (J) Flexural strength (kPa) Product quality EPS 25 ~ 600 2.5 175 2.5 420 ecovio® EA foam* 25 ~ 680 2.7 90 2.7 220 8
  6. 6. Applications 6
  7. 7. ecovio® EA expandable beads  Expandable beads (density: 700 g/l)  Blowing agent: Pentane  Adjustable bead size: 0.8 - 1.2 mm (1.05 mm*)  Adjustable color: White & Brown*  Transportation: Octabin (to be stored at RT)  Shelf life: > 6 months * Current status Production of ecovio® granules through extrusion process 4
  8. 8. Processing I – Foaming ecovio® expandable beads Production of ecovio® foam beads using steam  Foaming using existing EPS pre-foamer, Drop-in solution  Adjustable foam density: 22 - 50 g/l ; closed cell foam  Adjustable foam bead size  Very short foaming time (< 15 secs); low temp: 98°C  Low steam consumption  Intermediate storage time: 24 – 48 hours 5
  9. 9. Processing II – Shape moulding ecovio® expandable beads Shape molding of ecovio® foam beads using steam  Shape molding using existing EPS / EPP machine, Drop-in solution  Min. foam part density: 23 - 25 g/l  Molding cycle time like EPS  Conditioning of parts necessary (60°C; 4 hours)  Part shrinkage: ~1,5 – 1,7% Necessary to design new mold considering the shrinkage 6
  10. 10.  production line ready  K 2016  packaging grade commercially available  customer sampling starts after K show  End of 2016:  FC-grade  2017:  small beads Outlook 11

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