Hi All,
I notice people are waking up to Biotec now, so I give you some info to digest, and then you might see the part of the big picture for Biotec, and its collection of IP ....
Right-click and save the PDF, then open it, it's better than in a browser :)
Bioplastics PDF
EXECUTIVE SUMMARY
The market for plastics in the United States and Europe is about 73 million tons and is growing
at an annual rate of 3 5%. The major end uses are packaging (about 25% in the US and 36% in
Europe) and construction (about 22% in the US and 20% in Europe). Other important markets
include transportation, furniture and furnishings, electrical and electronics, adhesives, inks and
coatings.
There are two basic types of plastics. Thermoplastics like polyethylene (PE), polypropylene
(PP), and polyvinyl chloride (PVC) make up the greatest share of plastics used in packaging.
They can be softened by heat and shaped by extrusion, moulding, or pressing into any form
required. They are also recyclable. Thermosets are plastics that can be softened when heated, but
cannot be converted back to their original form. Thermosets are valued for their durability and
strength and are used primarily in automotive and construction applications, although they can
also be used in adhesives, inks and coatings. Examples of thermosets include polyurethanes,
unsaturated polyesters, and epoxies.
Plastics can also be divided into commodity polymers (e.g., PE, PP, PVC), which sell for under
CAN$2.82 per kilogram; mid-range and transitional polymers (e.g., PET, Nylon), which sell for
CAN$2.82 to $5.64 per kilogram; performance engineering polymers, which sell for US$5.64 to
$28.22 per kilogram; and high performance plastics at greater than US$28.22 per kilogram.
Canadas plastics industry focuses mainly on commodity plastics. Engineered plastics are
typically imported from the US. At present, the performance limitations of most bioplastics
restrict their applications to commodity plastics. However, new technological developments are
allowing bioplastics (e.g., PLA) and bioplastic/synthetic blends (e.g., PEIT, PTT, or 3GT) to
penetrate the mid-range and transitional polymer category.
Biodegradable plastics are gaining market momentum in Europe as a result of government
regulations promoting the composting of biodegradable materials.
The EU market for bioplastics
in 2000 was 23,000 tonnes and is expected to grow to 454,000 to 907,000 tonnes by 2010, and 3
5 million tonnes by 2020.
Polymers made from renewable resources derived from starch and
sugar are expected to account for 60% of the market for EU biodegradables in 2010, in part
because of their greater cost advantage over biodegradable synthetic polymers made from
petrochemicals. Films (50%), foams (20%), and a variety of others, e.g., fibres and functional
additives (30%) will account for most of the product types. Market segments will include
packaging, textiles/nonwovens, horticulture/agriculture, and as well as non-biodegradable
products. By 2020, the share of polymers from renewable sources is expected to increase to 70
80% of the EU biodegradable market.
At present, starch-based bioplastics (either unmodified or modified and complexed with other
polymers) account for most of the production capacity in Europe. The major centres of
production are Novamont (Italy) and National Starch Company (UK), which have a capacity of
32,000 tonnes, and Rodenburg BioPolymers (Netherlands), which has recently constructed a
36,000-tonne facility that converts waste potato starch into bioplastics. Packaging materials
(food, loosefill, shopping bags, fruit and vegetable wrap, catering service ware, composting bags,
and agricultural film) have penetrated most Western European markets including England,
France, Germany, Italy, Scandinavia, Switzerland, and Austria.
The US markets are also expanding, but they are being driven more by traditional economic
drivers such as price and performance. Production capacity in the US is dominated by Cargill
Dow LLC, which has built a 140,000 tonne per year polylactic acid (PLA) plant in Blair,
Nebraska.
PLA is being used to make food packaging (e.g., bio-oriented films, thermoformed
trays and lids), fibre applications (apparel, industrial fibres, nonwovens) and fibrefill
(comforters, pillows).
Cargill Dow has identified market opportunities for 4.3 billion kilograms
of PLA, valued at over $12.8 billion.
At present, other renewable sources of bioplastics like polyhydroxy alkanoates (PHAs/PHBs),
proteins, and cellulose derivatives represent only a minor fraction of the market, although this
could change dramatically as a result of new research and development. For example, Proctor &
Gamble has made great progress and hopes to commercially produce PHBs by 2004.
Current market projections for bioplastics in Europe and the US do not appear to threaten food
markets.
The 3 5 million tonnes of bioplastics predicted for the EU by 2020 would require an
estimated 2.5+ million acres. The total identified market opportunities for PLA worldwide would
require about 6% of the US corn production, well under annual ending stocks (back-up supply)
of 10.3%.
Bioplastics production is also expected to reduce greenhouse gas (GHG) emissions. As a rule of
thumb, starch-based plastics can save between 0.8 and 3.2 tonnes of CO2 per tonne compared to
one tonne of fossil fuel-derived plastic. The range reflects the share of petroleum-based
copolymers used in the plastic. The lifecycle GHG savings (in CO2 equivalents) for oilseedbased
plastic alternatives has been estimated to be 1.5 tons per ton of polyol made from rapeseed
oil.
The International Biodegradable Polymers Association & Working Group estimates that
CO2
savings potential would be 9 27 million tonnes if the EU market for biodegradable plastics was
to reach 3 5 million tonnes by 2020, assuming renewable raw materials were to comprise a 70
80% share of that market, and 50% was compostable.
Cargill Dow LLC has compared the life cycle CO2 emissions from various plastics and found a
very favourable profile for PLA, significantly better than cellulose, nylon-6,6, PET, polystyrene,
and polypropylene.
Based on the data currently available, it appears that bioplastic production is a sustainable activity.
A wide range of natural biopolymers can be used to make plastics. In general, these biopolymers
come from livestock, crops, forests, marine life (e.g., shell fish and algae), insects, bacteria, and
fungi. These biopolymers can be used for a vast range of applications, including but not limited
to, adhesives, coatings, high performance fibres, plastics, cosmetics, pharmaceuticals, and
medical and surgical devices. This study focuses on industrial-scale applications using
biopolymers derived from agricultural feedstocks. Bioplastics represents one of the largest
potential application areas.
The current market (2002) for starch-based bioplastics accounts for about 23,000 tonnes per
year, although production capacity has now increased to about 68,000 tonnes per year. This
increased capacity will allow further market expansion. Until the Cargill Dow PLA plant was
built, starch-based plastics accounted for about 75 80% of the global market for bioplastics.
About 75% of the starch-based plastic resins are used for packaging applications. The main
advantage of starch-based plastics is their lower cost compared to other synthetic biodegradbale
plastics. Their weakness is their water sensitivity, although this issue can be addressed in
numerous ways, e.g., by blending starch with biodegradable synthetic polymers. The price of
starch-based bioplastics in Europe ranges from $2.04 to $6.52 per kilogram.
A number of companies are now producing starch-based plastics including:
Biotec GmbH
(Germany), VTT Chemical Technology (Finland), EverCorn, Inc. (US), Novamont (Italy),
EarthShell (US), AVEBE (US), Rodenburg BioPolymers (Netherlands), StarchTech, Inc. (US),
and Vegeplast (France). Perhaps the main player in Europe at the moment is Novamont (Italy),
which owns 80 patents and related extensions.