Algae based biodegradable packaging materials

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This project's focus is to develop a truly sustainable solution for food and other primary packaging based on algae. Thematic focusAnnual global plastic production reached 454 million tons in 2018, of which 50% is attributable to single-use plastic packaging. Plastic packaging of all kinds contains plasticizers which make it more flexible, but on the other side are poisonous to us. This means that recycling plastics cannot be a long-term solution as the tiny plastic particles peel off the items as we consume them and trigger diseases. However, legislation to eliminate plastics and plastic packaging becomes increasingly stringent. Even large companies are being forced to disentangle their economic growth from both environmental impact and resource exhaustion. More and more firms are turning to bioplastics, which has put market penetration well on the way. Currently, there is a great demand for plastics made from corn or sugar cane. However, this seems to be accompanied by some disadvantages. First of all, there seems to be a moral problem, since corn is mostly sourced from countries where there is a high poverty rate, and the population suffers from hunger problems. Secondly, the already existing monocultures are getting even bigger, thirdly, 90% of the corn production belongs to two corporate giants that use transgenics for planting, and lastly, the end product can only be decomposed industrially, which in turn requires a great amount of energy.As the facts demonstrate, today's packaging is not sustainable - either it is based on fossil resources or even if it is bio-based or biodegradable, in reality it takes a very long time and a lot of energy to degrade, which means that it ends up in landfills and incinerators anyway. This project's focus is to develop a truly sustainable solution for food and other primary packaging based on algae as none of these problems mentioned above occur with seaweed. First of all, algae are one of the most plentiful biomass sources on earth. They don’t compete with arable land, as they grow within water without any need of fertilizer. We don't need to worry about exploiting the plant, as there is always a little left in the water, which means that the harvest is ethical. In addition, only natural ingredients are being used, so the end product could even be edible. After being used, the final product can decompose on the compost, like a fruit, without any energy input within two months, returning its nutrients back to the nature. And finally, the ingredients even keep bacteria away, which is a good extra component for food packaging.The startup NORIWARE (https://www.noriware.com/) will be supported by FHNW (https://www.fhnw.ch/de/die-fhnw/hochschulen/ht/institute/institut-fuer-kunststofftechnik/) with the development of an algae-based polymer which is not only 100% bio-based but as well 100% biodegradable. The objective is to apply design thinking, starting with the requirements for sustainable packaging materials, moving on to polymer formulation and sustainable packaging solutions. Degree of innovationThe technological novelty of the idea is to address the current problem of plastic waste that destroys the environment and the resulting harmful microplastic by completely rethinking the function of packaging. With this idea, we are trying to take into account the relationship between the usage time and the lifetime of a package, giving it a completely new value. We make truly sustainable plastic packaging from seaweed, which is made from 100% natural materials and is therefore even edible. Their edibility implies that they decompose like a fruit just by exposure to the air. This way, our future packaging waste can be disposed of on the compost instead of costing the waste industry additional energy. Unfortunately, the two project parties FHNW and Noriware met after the Co-Creatin Workshop. EffectNoriware is in the process of launching a plastic cup that will be used in takeaway businesses, catering businesses at major events, on airlines, in hospitals, and in dental practices, replacing inconvenient reusable cup systems or disposable cardboard cups. Market analysis in the above-mentioned areas has revealed a demand in Switzerland of 6 billion cups. The cost of producing a cup in the laboratory is currently CHF 0.1017 per cup. Together with FHNW, a suitable manufacturing process is to be developed to enable production to be scaled up in an economically preferable manner. Furthermore, Noriwares' packaging solutions are not only another bio-based plastic packaging, but also sequester CO2 during their growth phase and ensure a balance in the marine biosphere.This means that compared to, for example, a polystyrene cup, a negative CO2 balance is already generated during the production of the raw material, which increases after use, as the cup, unlike a conventional polystyrene cup, can be disposed on the compost and does not consume any further energy during proper disposal. Another big advantage exists with the not professional disposal. While a conventional plastic cup causes severe damage to the environment over hundreds of years, our product decomposes after 1-2 months in ambient air and leaves nothing but nutrients for the environment. Furthermore, Noriwares' packaging solutions are not just another bio-based plastic packaging but unfold as an ecological benefit for the marine ecosystem. Algae bind CO2 during their growth phase and ensure a balance in the marine biosphere. Through photosynthesis, marine algae convert dissolved CO2 and sunlight into organic matter and oxygen. Also, nearshore marine systems can absorb up to 50 times more carbon than forestry on land. This means that compared to, for example, a polystyrene cup, a negative CO2 balance is already created during the production of the raw material, which is doubled after use, as the cup, unlike a conventional polystyrene cup, can be disposed of on the compost and does not emit any further CO2 during proper disposal. In addition, the disposal of our packaging speaks for itself as an innovation. While a conventional plastic cup causes severe damage to the environment over thousands of years, our product leaves no trace in the environment as it decomposes in the air after 6 weeks. On the contrary, it becomes a source of nutrients for the environment. Methodological qualityThe funds will be used by FHNW to further develop the polymerization and compounding process to make the algae approach scalable. The developed formulations will be characterized using DSC, TGA, rheometer, and MFI to determine the process parameters and compare them to the requirements of a plastic cup. A positive decision can be the starting point for an innovation project and sustainable collaboration between Noriware and FHNW. Gender and DiversityThe project includes the following contact points and respects both genders. · Jessica Farda, Co-Founder Noriware· Julius Thoma, Co-Founder Noriware· Stefan Grieder, Co-Founder Noriware· Prof. Dr. Markus Grob, Head of the FHNW Institute of Polymer Engineering· Prof. Dr. Christian Brauner, Head of competence field lightweight design and composite technologies at the FHNW Institute of Polymer Engineering Scope and TasksThe scope will be to characterize and polymerize selected materials. Prototypes will be produced from the characterized materials and tested for their industrial implementation.The work packages will be: WP1: Definition of specification and formulation (Noriware)WP2: Selection of raw materials, additives, and stabilizers (Noriware, FHNW)WP3: Polymerization and characterization of different algae polymers (Noriware, FHNW)WP4: Prototype manufacturing of cups and films (Noriware, FHNW)WP5: Summary of results, comprehensive planning for further algae polymer development (Noriware) Budget and Co-FundingWe would ask to get support for CHF 25’000 seed money, which will be used by FHNW (for WP 2,3, 4). We choose to get support for the mandatory assessment of the CO2 reduction potential for a lump sum of CHF1’000. 20% of the seed money will be contributed by Noriware. Of which 10% will be used to purchase the required materials. Noriware will additionally cover their labor costs in the amount of approximately CHF10’000 within this project.

Project Idea Metadata

• Project Idea Name: Algae based biodegradable packaging materials
• Date: 6/7/2022 11:34:49 AM
• Administrators:
  • Christian Brauner

Project Idea Description

Thematic focus

Annual global plastic production reached 454 million tons in 2018, of which 50% is attributable to single-use plastic packaging. Plastic packaging of all kinds contains plasticizers which make it more flexible, but on the other side are poisonous to us. This means that recycling plastics cannot be a long-term solution as the tiny plastic particles peel off the items as we consume them and trigger diseases.

However, legislation to eliminate plastics and plastic packaging becomes increasingly stringent. Even large companies are being forced to disentangle their economic growth from both environmental impact and resource exhaustion. More and more firms are turning to bioplastics, which has put market penetration well on the way. Currently, there is a great demand for plastics made from corn or sugar cane. However, this seems to be accompanied by some disadvantages. First of all, there seems to be a moral problem, since corn is mostly sourced from countries where there is a high poverty rate, and the population suffers from hunger problems. Secondly, the already existing monocultures are getting even bigger, thirdly, 90% of the corn production belongs to two corporate giants that use transgenics for planting, and lastly, the end product can only be decomposed industrially, which in turn requires a great amount of energy.

As the facts demonstrate, today's packaging is not sustainable - either it is based on fossil resources or even if it is bio-based or biodegradable, in reality it takes a very long time and a lot of energy to degrade, which means that it ends up in landfills and incinerators anyway.

This project's focus is to develop a truly sustainable solution for food and other primary packaging based on algae as none of these problems mentioned above occur with seaweed.

First of all, algae are one of the most plentiful biomass sources on earth. They don’t compete with arable land, as they grow within water without any need of fertilizer. We don't need to worry about exploiting the plant, as there is always a little left in the water, which means that the harvest is ethical. In addition, only natural ingredients are being used, so the end product could even be edible. After being used, the final product can decompose on the compost, like a fruit, without any energy input within two months, returning its nutrients back to the nature. And finally, the ingredients even keep bacteria away, which is a good extra component for food packaging.

The startup NORIWARE (https://www.noriware.com/) will be supported by FHNW (https://www.fhnw.ch/de/die-fhnw/hochschulen/ht/institute/institut-fuer-kunststofftechnik/) with the development of an algae-based polymer which is not only 100% bio-based but as well 100% biodegradable.

The objective is to apply design thinking, starting with the requirements for sustainable packaging materials, moving on to polymer formulation and sustainable packaging solutions.

Degree of innovation

The technological novelty of the idea is to address the current problem of plastic waste that destroys the environment and the resulting harmful microplastic by completely rethinking the function of packaging. With this idea, we are trying to take into account the relationship between the usage time and the lifetime of a package, giving it a completely new value. We make truly sustainable plastic packaging from seaweed, which is made from 100% natural materials and is therefore even edible. Their edibility implies that they decompose like a fruit just by exposure to the air. This way, our future packaging waste can be disposed of on the compost instead of costing the waste industry additional energy.

Unfortunately, the two project parties FHNW and Noriware met after the Co-Creatin Workshop.

Effect

Noriware is in the process of launching a plastic cup that will be used in takeaway businesses, catering businesses at major events, on airlines, in hospitals, and in dental practices, replacing inconvenient reusable cup systems or disposable cardboard cups. Market analysis in the above-mentioned areas has revealed a demand in Switzerland of 6 billion cups. The cost of producing a cup in the laboratory is currently CHF 0.1017 per cup. Together with FHNW, a suitable manufacturing process is to be developed to enable production to be scaled up in an economically preferable manner.

Furthermore, Noriwares' packaging solutions are not only another bio-based plastic packaging, but also sequester CO2 during their growth phase and ensure a balance in the marine biosphere.

This means that compared to, for example, a polystyrene cup, a negative CO2 balance is already generated during the production of the raw material, which increases after use, as the cup, unlike a conventional polystyrene cup, can be disposed on the compost and does not consume any further energy during proper disposal. Another big advantage exists with the not professional disposal. While a conventional plastic cup causes severe damage to the environment over hundreds of years, our product decomposes after 1-2 months in ambient air and leaves nothing but nutrients for the environment.

Furthermore, Noriwares' packaging solutions are not just another bio-based plastic packaging but unfold as an ecological benefit for the marine ecosystem. Algae bind CO2 during their growth phase and ensure a balance in the marine biosphere. Through photosynthesis, marine algae convert dissolved CO2 and sunlight into organic matter and oxygen. Also, nearshore marine systems can absorb up to 50 times more carbon than forestry on land. This means that compared to, for example, a polystyrene cup, a negative CO2 balance is already created during the production of the raw material, which is doubled after use, as the cup, unlike a conventional polystyrene cup, can be disposed of on the compost and does not emit any further CO2 during proper disposal. In addition, the disposal of our packaging speaks for itself as an innovation. While a conventional plastic cup causes severe damage to the environment over thousands of years, our product leaves no trace in the environment as it decomposes in the air after 6 weeks. On the contrary, it becomes a source of nutrients for the environment.

Methodological quality

The funds will be used by FHNW to further develop the polymerization and compounding process to make the algae approach scalable. The developed formulations will be characterized using DSC, TGA, rheometer, and MFI to determine the process parameters and compare them to the requirements of a plastic cup. A positive decision can be the starting point for an innovation project and sustainable collaboration between Noriware and FHNW.

Gender and Diversity

The project includes the following contact points and respects both genders.

· Jessica Farda, Co-Founder Noriware

· Julius Thoma, Co-Founder Noriware

· Stefan Grieder, Co-Founder Noriware

· Prof. Dr. Markus Grob, Head of the FHNW Institute of Polymer Engineering

· Prof. Dr. Christian Brauner, Head of competence field lightweight design and composite technologies at the FHNW Institute of Polymer Engineering

Scope and Tasks

The scope will be to characterize and polymerize selected materials. Prototypes will be produced from the characterized materials and tested for their industrial implementation.

The work packages will be:

WP1: Definition of specification and formulation (Noriware)

WP2: Selection of raw materials, additives, and stabilizers (Noriware, FHNW)

WP3: Polymerization and characterization of different algae polymers (Noriware, FHNW)

WP4: Prototype manufacturing of cups and films (Noriware, FHNW)

WP5: Summary of results, comprehensive planning for further algae polymer development

(Noriware)

Budget and Co-Funding

We would ask to get support for CHF 25’000 seed money, which will be used by FHNW (for WP 2,3, 4).

We choose to get support for the mandatory assessment of the CO2 reduction potential for a lump sum of CHF1’000.

20% of the seed money will be contributed by Noriware. Of which 10% will be used to purchase the required materials. Noriware will additionally cover their labor costs in the amount of approximately CHF10’000 within this project.

This project's focus is to develop a truly sustainable solution for food and other primary packaging based on algae.