March 2021

In our first BIOnTop newsletter issue, we are covering the latest developments of our research project, recent deliverables and publications, as well as other relevant news and events of the European bioplastics research community.

BIOnTop aims to develop novel bio-based and compostable packaging and textiles through experimental research on copolymers and compounds with customized biodegradability and multifunctional coating solutions. The project receives funding from the Bio Based Industries Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 837761.

The 4-year research project is carried out by 21 teams and a total of almost 170 experts from research institutes, the mechanical engineering sector, food and packaging companies, and trade bodies from 8 EU countries. After the start of the project in 2019, the initial 18 months of the project have already produced promising preliminary findings. Rafael Alonso Ruiz of the Chemical Technology Group at AIMPLAS, BIOnTOP’s project coordinator and consortium lead, gives a brief overview of what the project partners are working on in 2021.

The EU research project BIOnTop (Grant Agreement Number GA 837761) aims to develop innovative, fully bio-based and recyclable packaging and textiles as a more sustainable alternative to current plastic packaging made from crude oil. The 4-year research project is carried out by 21 teams and a total of almost 170 experts from research institutes, the mechanical engineering sector, food and packaging companies, and trade bodies from 8 EU countries.

The initial 18 months of the project have already produced promising preliminary findings: An extensive review on the state-of-the-art of currently available biodegradable household packaging and textiles was carried out to define the specifications for these products. Additionally, information on commercially available biopolymers, additives, and monomers, including suppliers and prices, was compiled in a second extensive report, in order to select the right source materials for the project research. Both reports laid the groundwork for the next phase of the project’s experimental trials on PLA-based products with customized end of life and properties, which are currently ongoing.

“Since the beginning of the project in 2019, the consortium partners have defined the specifications and aims for the packaging demonstrators, and have started their research on the development of the copolymers, composites, coatings and materials that will provide BIOnTop products with the desired properties, with the special goal of obtaining tuneable end-of-life options depending on the final application of the package”, says Rafael Alonso Ruiz of the Chemical Technology Group at AIMPLAS, BIOnTop’s administrative project coordinator and consortium lead.

Dr Rafael Alonso Ruiz, Chemical Technology Group AIMPLAS

Rafael Alonso Ruiz also offers a brief overview of what the project partners are working on in 2021: “At the beginning of 2021, we are at the point where we are finishing to define the final formulations at laboratory scale, and we are up-scaling them to semiindustrial scale. Furthermore, first steps towards the fabrication of the final products will be taken during 2021, following two paths that will run in parallel in two separated work packages. On the one hand, we aim to fabricate mono- and multi-layer packaging for fruits and vegetables, dairy, as well as personal care products. On the other hand, the goal is to obtain bio-based nets for fruits and vegetables as well as bio-based textiles for food wraps and tea bags. At the end of 2021 and mainly in 2022, BIOnTop will focus on the validation of the final products, both for the aimed applications as well as their envisioned end-of-life options.”

The initial 18 months of the project have already produced promising preliminary findings. The initial results have been published in two technical deliverables and one scientific paper:

• Deliverable 1.1: "Report on the state-of-the art review". A report including up to date literature (that will feed into review paper(s)), patent and commercial information on home compostable bio-based packaging and textiles. DOWNLOAD
• Deliverable 1.2: "Survey of commercial biopolymers, additives & monomers and strategy for further improvement needed". DOWNLOAD
• Bio-Based Packaging: Materials, Modifications, Industrial Applications and Sustainability, published in the international scientific journal Polymers (ISSN 2073-4360). VIEW 

More coverage on the project and current developments can be found on the project website https://biontop.eu

BIOnTop’s research teams are pursuing various strategies to optimise biopolymers with a specific focus on protein-based coatings. These new coating technologies are being developed by the research group for Biopolymer Processing and Functionalization BPF headed by Dr Corina Reichert at the Sustainable Packaging Institute SPI of the Albstadt-Sigmaringen University (ASU). Her team works on the development of coatings made from bio-based materials such as fatty acids and proteins.

Most sensitive foods are packaged in multi-layer composite films to ensure sufficient flavour, water vapor, and oxygen barriers to maintain products’ quality and increase its shelf life. However, most of these composite materials cannot be recycled. BIOnTop aims to develop fully recyclable and bio-based packaging materials in order to provide more sustainable packaging alternatives that offer optimised barrier properties and new end-of-life options. For this purpose, the project research currently focusses on polylactic acid (PLA)-based films. PLA is produced from renewable biomass and offers various end-of-life options, including mechanical as well as organic recycling (composting). Furthermore, PLA-based plastics can be produced on an industrial scale and already account for a considerable share of the global bioplastics production. The optical and mechanical properties of PLA films are comparable to those of conventional petrochemical polyester films. Yet, they are less suitable for fresh products with a medium to long shelf life due to lower oxygen and water vapour barrier properties. In order to achieve better barrier properties, PLA-based films can be modified by new coating technologies.

To this end, BIOnTop’s research teams are pursuing various strategies to optimise biopolymers with a specific focus on protein-based coatings. The research builds on the results of a number of previous EU research projects in this field, namely Wheylayer and Thermowhey – two completed projects that were able to show that certain biopolymers are very well suited as coating materials to provide sufficient barrier properties for different types of packaging such as trays and blisters. For example, it has been shown that trays coated with whey protein have improved oxygen barrier properties to meet the requirements of modified atmosphere fresh meat packaging.

Within BIOnTop, these new coating technologies are being further developed by the research group for Biopolymer Processing and Functionalization BPF headed by Dr Corina Reichert at the Sustainable Packaging Institute SPI of the Albstadt-Sigmaringen University (ASU). Her team works on the development of coatings made from bio-based materials such as fatty acids and proteins. Thermoplastic PLA films are coated with whey protein and a surface functionalization by an innovative fatty acid grafting technique is performed to make the film water repellent and to decrease the water vapor transmission. A protein coating layer is used to provide sufficient reactive groups for the fatty acids to be coated onto the PLA film. Additionally, the protein coating increases the oxygen barrier properties of the films. If successful, the developed bio-based multilayer films will be scaled up to pilot plant and industrial scale, and the physical and sensory parameters will be evaluated in packaging and storage tests. Different endof-life options will be researched within the BIOnTop consortium in order to ensure that the developed packaging can be processed in existing waste recycling plants. Read the full article published in the International Dairy Magazine 05/2020.

BIOnTop was part of the 15th European Bioplastics Conference 2020, the world’s leading conference of the bioplastics industry, at the end of 2020. The virtual conference was a unique opportunity to present the project and its efforts to around 350 experts from the industry, R&D, brands, and policy makers from 36 countries. AIMPLAS’ Rafael Alonso Ruiz took part in a panel discussion on how EU research projects like BIOnTop can shape the future of bio-based plastics in Europe.

Watch the full presentation and panel discussion here.

BIOnTop is conducting a survey on the consumer perception of bio-based products in order to ensure that research and development within the project are aligned with real world market and consumer needs and expectations. Through an online questionnaire we aim to get more detailed insights on consumers’ purchasing choices and the influence of the type of packaging, type of materials, sustainability and recyclability of the packaging, shelf life, as well as their views on bio-based/renewable origin of resources and different end-of-life options.

Take the survey

The survey is being conducted by BIOnTop consortium member Movimento Consumatori (MC), an independent non-profit consumers’ rights association based in Italy. Results will be published in a survey report later this year.

• The circular economy can help save the planet –? if we start innovating now (World Economic Forum)
• VTT Tests cellulose-based Food Packaging Film with Thermoplasticity (Omnexus SpecialChem News)
• European REFUCOAT Project develops recyclable, active packaging food systems (Bioplastics Magazine)
• TIPA and PerfoTec collaborate to create compostable packs that extend shelf-life (Packaging Europe)
• 31 May – 13 June 2021 | EU Green Week 2021 “Zero Pollution for Healthier People and Planet” (European Commission)
• Save the date: 30 November-1 December 2021| 16th European Bioplastics Conference 2021 (EUBP European Bioplastics e.V.)

For more relevant news, have a look on the BIOnTop tech watch.