New developments on Ingeo-based compostable packaging with ecovio. BASF SE Dr. Martin Bussmann G-PM/PB Team Leader Compostable Packaging

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Oliver McDaniel
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1 New developments on Ingeo-based compostable packaging with ecovio BASF SE Dr. Martin Bussmann G-PM/PB Team Leader Compostable Packaging

2 Outline 150 Jahre Compostable bio-polymers? What are we talking about? ecovio grades for packaging applications Coffee packaging solutions based on ecovio Summary and outlook

3 Bio-polymer What does it means? 150 Jahre Bio-PE, Bio-PA, Bio- PUR, PEF, Ingeo, PHA, PHB, PE, PP, PVC, PA, PBT, POM, PBAT, PBS, In general: * + PLA = * ecovio gen. 1 Fossil-based and biobased polymers can both be 100% biodegradable. 3

4 ecovio applications & solutions Organic Waste Bags Compostable Can Liners T-Shirt Bags Mulch Films Thermoforming Injection molding Paper Coating Particle Foam

molding machines Can be colored in different certified

5 Food containers with lids Injection molded food containers: Can be processed on conventional injection molding machines Can be colored in different certified master batch colors of BASF color solutions Development partner: 5

6 IML decorated packaging ecovio for decorated thin wall packaging offers: the production of thin walled packaging parts in fast cycle times with modern surface decoration 6

to hot water and pressure applied during

can be molded with and without O2 barrier

molds in fast cycle times offers an good

7 Coffee capsules ecovio for hot beverage single serve packaging: excellence resist to hot water and pressure applied during the brewing process thin wall capsules can be molded with and without O2 barrier properties processable on high cavity molds in fast cycle times offers an good barrier property against mineral oils, fats and aroma

8 Compostable solutions for coffee capsules based on ecovio - End of life High variety of hot drinks easily preparablevia capsules Compostable 5 Mio t/a coffee grounds world wide Missing property Used coffee capsule contains 70 wt-% of water Plastic waste To use coffee grounds as composting material, degradable capsules are required 8

9 Coffee capsules details Transport packaging: - Strapping band - Shrink film Capsule: - Injection molded - with or w/o co-injected barrier - Thermoformed - with or w/o co-ex barrier Secondary packaging: - Pouch - Multi or mono-layer - with or w/o barrier - Card board - with migration barrier Lidding film: - Single layer film or (filter) paper - Multi-layer film with or w/o barrier Inner filter: - Compostable filter paper - Injection molded filter inlay(s) 9

10 Compostable solutions for coffee capsules based on ecovio Compostable Transport packaging: - ecovio -based strapping band - ecovio F- based shrink film Compostable capsule: - Self produced or purchased? - ecovio IA or TA with or w/o G-Polymer * Compostable Secondary packaging: - ecovio Pouch films - Multi or mono-layer - with or w/o barrier - Card board coated w. ecovio - with migration barrier Compostable inner filter: - Some supplyers available Compostable lidding film: - ecovio -based solutions available * G-Polymer is a brand of a third party 10

Application Development with ecovio for single serve packaging Door

Thin walled, brewable and compostable capsule for tea without barrier

secondary packaging 2015 Thin walled, brewable and compostable capsule

11 Application Development with ecovio for single serve packaging Door opener for market beanarella ecovio IS1335 High wall thicknesses 2013 Thin walled, brewable and compostable capsule for tea without barrier 2014 Thin walled, brewable and compostable capsule for coffee with secondary packaging 2015 Thin walled, brewable and compostable capsule for coffee with barrier 2016 Complexity of capsule system Ease of implementation in market 11

12 03 Packaging solution based on ecovio 12

13 Thermoformed K-cup at PackExpo 2014 made of ecovio TA

14 Compostable IMLs by Verstraete based on compostable BO-PLA film supplied by Taghleef 14

15 First impressions of the prototypes compostable IML K-cup with barrier (by 2-K injection molding) Project leader: Tool made by Barrier polymer: IML made by Producer of compostable films: 15

16 04 Summary/Discussion 16

17 Summary YOU can do a lot with ecovio in packaging Coffee packaging seams an interesting field of application Have a good cup of coffee and think about it! 17

18 Compostable coffee solutions Isn t it more than just capsules? 18

19 ecovio for packaging where also end of life matters

20 Disclaimer

21 Behind the scene: 2-K compostable barrier by IM wall thickness: 0.4 mm - Both components filled the cavity up to its top - The IML is 100% welded to the surface of the cup Gating/ injection point - Capsule are ejected

PP-film Sealable with a lot of compostable lidding films Colorable with Sicoveral

22 AMODO MIO* compostable details of the first run with ecovio Initial flat sheet thickness down-sized to 500µm (from 650µm) Thermoforming with the same speed like PP-film Sealable with a lot of compostable lidding films Colorable with Sicoveral Master Batches * Lavazza and Amodo Mio is a brand of a third party no relation to BASF and ecovio

ecovio -based compostable packaging solutions Tabea Manne BASF South Africa

ecovio -based compostable packaging solutions Tabea Manne BASF South Africa Strong Commitment to Biodegradable Polymers We believe in this market and invest long term! 1993: kickoff R&D 1998: market introduction