Novel bioplastics applications: design breakthroughs and recycling pathways

Novel Bioplastics Applications: Design Breakthroughs & Recycling Pathways 3 Today 1. Project Pitches: Innovations in Bioplastics 2. Speed Networking: Connecting Research and Industry Innovative Products &End-User Applications •BioSupPack demonstrators Víctor Sevilla (AIMPLAS) and Lorena Rodríguez (GPI) •REPurpose prototypes Hanaa Dahy (Aalborg University) •TERRIFIC prototypes Alberto Castellanza (NOVAMONT) Innovative Recycling Technologies •ReBioCycle Kevin O’Connor (BiOrbic,University College Dublin) and Jan Pels (TORWASH) •MoeBIOS Miriam Lorenzo (ITENE) •PROSPER Wouter Post (Wageningen University &Research) Plastic Packaging Recovery •Francesco Baldi and Eleonora Castellani (ALIA) 4 About European Bioplastics 5 12 Members Foundation of IBAW Biodegradable polymers Germany 50 Members Name change to European Bioplastics Bioplastics incl. biobased & biodegradable Europe ~ 85 Members Advocacy and knowledge hub for all bioplastics 1993 2005 2025 About European Bioplastics European Bioplastics: 30⁺years of bioplastics experience •European Bioplastics represents the interest of the bioplastics industry along the entire value chain in Europe. •Our top priority is to build and strengthen a supportive EU policy framework that enables bioplastics to thrive, by fostering a strong network and engaging in dialogue with all relevant stakeholders. 6 Our vision: Bioplastics drive the evolution of plastics Our Vision Bioplastics drive the evolution of plastics and contribute significantly to a sustainable society. They save fossil resources by using sustainable biomass, provide the unique potential of carbon neutrality, and/or offer additional options for organic recycling at the end of a product’s life. Our Mission We work to create the right regulatory conditions in Europe for the bioplastics market to thrive. Together with stakeholders, we promote sustainable innovation along the value chain and speed up the large-scale adoption of bioplastics. About European Bioplastics 8 July 2025 Our members 12 Activities and services European Bioplastics serves as both a knowledge hub and a business network for companies, experts, and all key stakeholders in the bioplastics industry. Our activities and services at a glance •Gathering and sharing insights and knowledge about the sector •Formulating and communicating our sector’s key positions, both internally and externally •Representing our members’ policy interests in Europe •Connecting our members with potential business partners •Fostering open and collaborative stakeholder conversations •Raising awareness of bioplastics to a wider audience About European Bioplastics 17 SAVE THE DATE 02 –03 DEC 2025 Taking place at the Titanic Hotel Berlin and online For more information and tickets: www.ebc.european-bioplastics.org 2. Background •The plastic packaging segment is the biggest plastic consumer absorbing 39,6% of the plastic produced. However, despite the great demand, plastic waste still represents an important environmental problem in Europe. •Average recycling rates of packaging waste in Europe, in fact, do not exceed 40%, while the rest is sent to landfill. •The European Commission, acknowledging the issue, set two recycling targets for plastic packaging for the years to come: 50% by 2025 and 55% by 2030. •Sustainable alternatives to petroleum-based plastics on the other hand, have the flaw of being on average, more expensive than traditional plastic, with lower performance or less versatile. 4 3. Objectives 5 Increase the use of renewable resources (beer spent grains) for PHA formulations up to >85% Integration of plasma technology throughout the value chain for the pre-treatment of brew spent grains, packaging treatment and finally, for the pre-treatment of packaging waste Development of a system able to identify and sort BioSupPack waste (>90% of BioSupPack materials identified) Demonstrate end-user validation and acceptance of the new BioSupPack products Maximization of impact after the end of the project by exploiting results Creation of the new value chain by managing both brewery and packaging waste flows Upscale the production of new PHAbased products to demonstration level Ensuring BioSupPack recyclability. Mechanical and enzymatic recycling processes to reintroduce materials in the production step and/or recover carbon sources for the fermentation process (>30% carbon source supply) Crafting highly-performing PHA-based rigid packaging with properties like those of conventional petrochemical plastics present in the market Sustainability and EU-standards compliance assessment 4. Demo products 6 4.1. Demo products. Bottles for cosmetics. 7 Pilot scale production: 125 mL Large scale production: 300 mL Body-peeling & sunscreen Validation & consumer acceptance studies 4.2. Demo products. Secondary packaging 8 Design and mould making Injection moulding production: 50 parts ready for validation 4.3. Demo products. Prepared food-trays 9 Flexoprinting •Overview Tray forming •Overview step 1 step 2 Partners involved: ASU, CENTEXBEL, GPI 10 Innovation without action is just an idea —let’s make it real. THANK YOU!! The project is supported by the Circular Bio-based Europe Joint Undertaking and its members. Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or CBE JU. Neither the European Union nor the granting authority can be held responsible for them. NEXT GENERATION CIRCULAR BIOBASED FLAGSHIP PACKAGING: A CATALYST FOR THE GREEN TRANSITION The project is supported by the Circular Bio-based Europe Joint Undertaking and its members. Funded by the European Union under Grant Agreement N. 101157635 TERRIFIC Next Generation Circular Bio-Based Packaging Coordinator 1 Biomaterials producer and Biotech Company 9 Technology Providers 5 End-users (demonstrators) 2 NGOs 1 NFPO TERRIFIC will reform the packaging sector with bio-based solutions that enhance performance, circularity, and resource efficiency throughout the entire value chain. The project is supported by the Circular Bio-based Europe Joint Undertaking and its members. Funded by the European Union under Grant Agreement N. 101157635 •SUSTAINABLE 2G FEEDSTOCK •BIOBASED (RRM >95%) •ADVANCED BARRIER MATERIALS AND TECHNOLOGIES •MULTIPLE EoL TO MATCH THE WASTE AND COLLECTION INFRASTRUCTURE ACROSS EU •CONSOLIDATED MARKET POTENTIAL •NO ACCUMULATION IN OPEN ENVIRONMENT BIOBASED FLAGSHIP PACKAGING SOLUTIONS WOVEN TEA BAGS EXPANDED THERMOBOXES LAMINATED BARRIER STICK PACK MULTILAYER BARRIER FLEXIBLE FILM PACKAGING THERMOFORMED CUPS INJECTION MOULDING COFFEE CAPSULES FOOD TRAYS LAMINATED BARRIER STICK PACK TERRIFIC Next Generation Circular Bio-Based Packaging Our goals and objectives In the REPurpose project, local postconsumer waste is upcycled into new functional Recyclable Elastomeric Polymers (REP) destined for the highvalue market of thermoplastic elastomers that today face recycling problems. New building blocks derived from biomass, or enzymatically degraded organic or plastic waste will be incorporated, giving REP polymers unique characteristics: •tunable elastomeric properties avoiding the need for additives •production, processing and recycling on existing equipment •- controllable degradation in different habitats •- unprecedented indefinite recycling, surpassing fossil carbon at each recycling stage Partners Involved How will we reach the goals? New building blocks derived from biomass or enzymatically degraded plastic waste, or paper and cardboard waste will be incorporated, giving the polymers unique characteristics of recyclability, ecology, and unlimited recycling, surpassing fossil carbon at each recycling stage. The polymers will be tested by relevant stakeholders and dedicated user groups, including global consumer goods producers. BioMat@Copenhagen, based at Aalborg University, focuses on exploring innovative solutions for future sustainable architecture and the building industry. BioMat adopts a design philosophy that integrates material properties as a core design tool. This approach bridges the fields of Material Research, Architectural Design and Digital Fabrication. The goal is to develop feasible and sustainable applications for the built environment. Role in the EU Horizon Project – REPurpose As part of the EU Horizon Project REPURpose, BioMat@Copenhagen leads Work Package 6 (WP6): REP Product Development and Prototyping. BioMat@Copenhagen at Aalborg University Responsibilities and Focus Areas: •Design and Fabrication of REP Products •Bridging REP material development with REP product design and production •Post-processing and physical forming of semi-finished REP materials. (Sheets, Pellets) •Exploring innovative applications for REP polymers (Rigid and Flexible) in following targeted sectors. •Targeted Markets •Building and Construction •Automotive •Consumer goods/ Sports Tasks of Work Package 6 The Maker Space for Sustainability is a versatile production laboratory based in Aalborg University Copenhagen dedicated to supporting a wide range of production and digital fabrication methods, including CNC cutting, Thermal forming and 3D printing technologies. The lab also include a professional plastic production facility that enables high-quality plastic material prototyping, fostering innovation in sustainable product development and material research. Several product samples have been tested in the lab, as will be shown in the following posts. Makerspace for Sustainability at Aalborg University From REP Polymer Development to Product Design and Prototyping The Strategy of Reuse, Repair and Recycle for REP Products Semi-finished Product: Filament Application: Car Transmission Handle Manufacturing Methods: 3D Printing Market: Automotive/Consumer Goods Semi-finished Product: Filament Application: Car pedal cover Manufacturing Methods: 3D Printing Market: Automotive/Consumer Goods Semi-finished Product: Sheet Application: Car Airbag Cover Manufacturing Methods: Thermal Forming Market: Automotive/Consumer Goods Semi-finished Product: Sheet Application: Interior Panel Manufacturing Methods: Heat Pressing Market: Automotive/Consumer Goods Prototype 1 Prototype 2 Prototype 3 Prototype 4 REP Product Samples & Prototypes Semi-finished Product: Filament Application: Car Transmission Handle Manufacturing Methods: 3D Printing Market: Automotive/Consumer Goods Semi-finished Product: Filament Application: Handlebar Manufacturing Methods: 3D Printing Market: Automotive/Consumer Goods Semi-finished Product: Sheet Application: Card Holder Manufacturing Methods: 3D Printing Market: Consumer Goods Semi-finished Product: Sheet Application: Screwdriver Head Manufacturing Methods: 3D Printing Market: Consumer Goods Prototype 4 Prototype 5 Prototype 6 Prototype 7 REP Product Samples & Prototypes MoeBIOS project has been funded by the EU and the CBE-JU under grant number 101157652. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or CBE JU.Neither the European Union nor the CBE JU can be held responsible for them. Novel bioplastics applications: design breakthroughs and recycling pathways Industrial Stakeholder Workshop K Fair-Düsseldorf: 10/10/2025 Carmen Sánchez ITENE-Technical Director 2 Demonstrating the integration of the bioplastics BIOs End of Life value chain from collection, recycling, upcycling in Packaging (Spain), Textiles (Italy) and Agriculture (Germany) MoeBIOS-Project General Figures IMprOving wastEmanagement of BIObased plastics and the upcycling in packaging, textile and agriculture sectors Consortium of 21 partners + 2 Affiliated Entities led by ITENE Research Centre Waste streams containing BIOs as a feedstock 3 upcycled demonstrators from developed value chains (packaging, Agriculture and Textile) Reduce waste, lower environmental impact, providing a sustainable alternative to fossil resources Creation of a novel model for the BIOs End of Life in Europe focused in 3 sectors: packaging, textile and agriculture 5 MoeBIOS Project CONSORTIUM Project lead: ITENE The overall objective of MoeBIOSis to demonstrate novel recycling processes for bioplastics waste streams (BIOs) along the EoL within 3 value chains, towards new upcycled high-value products Context/main challenges: -Bioplastic (BIOs) presence in the waste streams is expected to dramatically grow in textile, packaging and agriculture -Non-effective value chain has been currently implemented for the BIOs EoL (including collection, sorting, recycling and upcycling) -3 Final demonstrators will be developed WASTE STREAM VALUECHAIN COLLECTION WP1 SORTING WP1 TREATMENT WP2 UPCYCLING WP3 VALIDATION WP3WP4 Safe and Sustainable by Design -LCA –LCC-WP5 How the challenge is addressed: PACKAGING WASTE STREAM AGRICULTURAL WASTE STREAM TEXTILE WASTE STREAM Decision Support System -Best Practices-WP4-WP5 WASTE MANAGERS MSW Separate collection WASTE MANAGERS Post-use Post-industrial WASTE MANAGERS Post-use Post-industrial SORTING EXPERTISE MACHINERY PARTNER Mechanical recycling Bio-recycling Chemical recycling Thermochemical recycling VALIDATOR OF R-PRODUCT FOR PACKAGING VALIDATOR OF AGRICULTURE R-PRODUCT MANUFACTURER VALIDATOR OF TEXTILE R-PRODUCT MANUFACTURER BRAND OWNER BRAND OWNER BRAND OWNER WP4-WP6 C&D&E MAA Stakeholder engagement Benefits to society and the environment Target groups 10 MoeBIOS Project BENEFITS •Environmental Organizations and Advocacy •Consumers and the General Public •Plastics Manufacturers and Producers •Retailers and Distributors •Waste Management and Recycling Companies •Supply Chain Partners •Regulatory Authorities and Governments •Investors and Financial Institutions •Academic and Research Institutions •Local Communities and citizens Local impacts 11 MoeBIOS Project LOCAL IMPACTS Specialized-high skilled job creation (related with recycling technologies implementation-EEA) Improved local environmental conditions: reduced pollution, cleaner ecosystems due to better waste management practices, contributing to the overall well-being Community engagement initiatives and social consciousness Local bio-economy deployment MAPPING THE BIOS 7 WP approach Value chain approach-dedicated workshops Call for materials within the MoeBIOS project First Results: Upcycling and recycling Agriculture Packaging Textile Recyclability study, visibility, networking and project results achievement Waste manager Clear definition of current situation of bioplastics Recycler Best recycling routes and techniques by bioplastic and blend Validator Evaluation of the products with the best properties MoeBIOS project has been funded by the EU and the CBE-JU under grant number 101157652. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or CBE JU.Neither the European Union nor the CBE JU can be held responsible for them. 8 Thank you for your attention! Miriam Lorenzo Navarro [email protected] ReBioCycle A new European blueprint for circular bioplastics upcycling solutions Kevin O Connor UCD and BiOrbic HORIZON-JU-CBE-2023 Innovation action (IA) Project: 101156032 Project duration -4 years 01/10/2024 –30/09/2028 ReBioCycle -Partners Closing the loop to make bio-based plastics circular Int roduct ion t o t he PROSPER project CBE JU contribution: €7.5 million Duration: S e p t e m b e r 2 0 2 4 –Augus t 2028 Feedstock: used biobased plastics Main products: sorted and recycled bio-based plastics PROSPER will demonstrate the techno-economic feasibility of the sorting and recycling of bio-based plastics in 4 actual waste sorting plants in Spain, France and Italy to generate new packaging from the recycled bio-based plastics Our partners Wageningen University & Research Contract Research Organisation Highly engaged, proficient experts Governments, NGO’s, institutional funders, industrial companies World-class facilities and laboratories Visit us at Hall 7 SC09 PROSPER Vision Sorting plant 1 (BE) Sorting plant 2 (BE) Sorting plant 1 (Fr) Sorting plant 1 (NL) The ‘new’ biobased sorting refinery PLA recycling PBAT recycling PHA recycling Sorting plant X PS recycling? 500 ton PLA, PBAT 750 ton PLA, PHA 350 ton bioplastic blends 650 ton starch based plastics X kton of mixed bioplastics waste • Plastic waste that does not get sorted, will not be recycled • Plastic products without scale, will not get sorted 3 European Recyling Pilots PROSPER approach Progress: Sorting trial with bioplastic spiked streams PLA rigid Purity: 95% Biopolyester rigid Purity: 83% Biopolyester film Purity: 70% Progress: Processing and product development Compounding of flakes Production of granulate Sheet casting Production of first demonstrators; s h o w c a s e d at Hall 7SC0 9 Progress: First Mode l re sult s Current PLA sorting is indeed too expensive (>1200€per ton compared to 180-200 €per ton for other polymers. If PLA achieves a market penetration of 2,4% it would be cost competitive to sort (similar toother polymers) Co nclus io n a nd o ut lo o k • Due to the relatively small volumes bio-based plastics are currently not being recycled, which blocks their scale-up. • PROSPER aims to think out of the box at system level to get bioplastics out of the catch 22 • Strong consortium with actors all over the value chain • Not only solving the bioplastic recycling issue, but the question: ‘ how to set up cost-competitive sorting and recycling schemes for minor polymer fractions in packaging’? • PROPSER will demonstrate in 3 EU pilots the proper sorting, recycling and reuse in new plastic packaging products • First project results oncost-effective post consumer recycling of biobased plastics are promising PLASTIC PACKAGING RECOVERY Unwanted materials Sorting Final storage Press Paronese 2 PLASTIC PACKAGING RECOVERY Paronese 2 5.000 t/y Plastic bales Unwanted materials 95% 5% Energy recovery Sent to Paronese 1 for Solid recovered fuel (SRF) production INPUT WASTE Recycling Sent to north of Italy for plasmix production THANKS FOR YOUR ATTENTION Francesco Baldi (Alia Servizi Ambientali Spa) MoeBIOS is funded by the Circular Bio-Based Europe Joint Undertaking under the European Union’s Horizon Europe research and innovation programme under grant agreement No.101157652