Developing the LCA methodology for bio-based plastics

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In order to correctly assess the negative emissions potential of bio-based plastics and if their use leads to overall environmental benefits compared to fossil materials, a case study of coffee machine production is conducted. The life cycle assessment (LCA) methodology is applied to compare bio-based and fossil plastics and assess possible shortcomings on the methodology side and the environmental benefits on the material side. Thematic focusThermoplan develops and produces fully automatic coffee machines in the highest Swiss quality for professional use in restaurants and businesses. The family enterprise is globally active and supplies customers in 80 countries. At the Swiss headquarters in Weggis (Canton Lucerne) there are approximately 450 employees. Worldwide more than 200 certified distribution and service partners make up the Thermoplan network.The company has a strong commitment towards sustainable development. One of the many sustainability-oriented projects targets the substitution of plastic components of coffee machines with a biogenic raw material produced from recycled coffee grounds.Bio-based plastics are assumed to present a sustainable alternative to fossil-based plastics, but due to a lack of data it is not possible to evaluate the actual potential of this future material to increase the sustainability performance of the product.The life cycle assessment methodology is an ideal tool to analyse and quantify the environmental potential (incl. CO2eq emission reduction and circular economy potentials) of this innovative material compared to its fossil alternative. However, due to the comprehensive data requirements, new products and processes represent a challenge for the LCA methodology as well as for life cycle inventory databases.Thermoplan and the FHNW plan to team up in order to tackle the challenge of quantifying the sustainability of coffee machines using bio-based plastics on one side and understanding the methodological shortcomings linked to data availability and current LCA modelling techniques. The results of this project will improve LCA-best practice of bio-based materials in general and provide value also to other participants of the Inno-Booster and further stakeholders.Degree of innovation and EffectThe interest towards bio-based plastics and composites is growing, as alternatives to fossil-based materials are sought. The present case study should lead to a better understanding of environmental benefits linked to the use of bio-based plastics and identify methodological shortcomings and data gaps in plastic LCAs. The degree of innovation is high and can benefit all stakeholders aiming at a more sustainable plastic industry.Methodological qualityThe results of the study will create an added value, assured by the complementary expertises that the project partners (Thermoplan AG and FHNW) bring to the project. Thermoplan AG is expert in the development and manufacturing of professional coffee machines and has a strong sustainable awareness. The FHNW brings a powerful LCA background and expertise, which will be used to identify methodological weaknesses and help address them. PSI brings expertise in the use of the Brightway LCA software, which provides powerful functionality for analysing greenhouse gas emissions over time, comparing different implementations of global warming indicators, supplementing existing background databases (e.g. ecoinvent) with data on missing industry sectors, and flexibility in changing assumptions regarding recycling, waste treatment, and circular usage patterns.Scope and tasksThe work will be carried out in the following work packages (WP) by the FHNW as a research project, in close collaboration with Thermoplan AG and PSI. The number (%) next to the WP represent the planned allocation of the budget to each WP.WP1: Goal and scope definition (6%)- Definition of the system boundaries and functional unit- Definition of scenariosWP2: Database analysis and life cycle inventory (53%)- Analysis of the data situation for bio-based and fossil-based plastics- Development of datasets for bio-based plastics, corresponding best-practice and uncertainties (if possible)- Life cycle inventory for the products and processes defined in WP1WP3: Life Cycle Impact Assessments (16%)- Quantification of the environmental impacts linked to the scenarios defined in WP1WP4: Sensitivity Analysis and interpretation of the results (13%)- Conduction of a sensitivity analysis to test the robustness of the results- Interpretation of the resultsWP5: Report (9%)- Findings will be integrated into a final reportWP6: Meetings, site visits (3%)- Kick-off meeting- Site visit- Final meeting, presentation of resultsBudgetBased on the budget table below, the total project costs amount to CHF 24’948, from which 90% (CHF 22’453) should be funded by the seed money and 10% (CHF 2’495) by the co-funding contribution. The allocated budget to each work package can be seen above.

Project Idea Metadata

• Project Idea Name: Developing the LCA methodology for bio-based plastics
• Date: 4/1/2022 1:18:33 PM
• Administrators:
  • Léonard Marchand

Project Idea Description

Thematic focus

Thermoplan develops and produces fully automatic coffee machines in the highest Swiss quality for professional use in restaurants and businesses. The family enterprise is globally active and supplies customers in 80 countries. At the Swiss headquarters in Weggis (Canton Lucerne) there are approximately 450 employees. Worldwide more than 200 certified distribution and service partners make up the Thermoplan network.

The company has a strong commitment towards sustainable development. One of the many sustainability-oriented projects targets the substitution of plastic components of coffee machines with a biogenic raw material produced from recycled coffee grounds.

Bio-based plastics are assumed to present a sustainable alternative to fossil-based plastics, but due to a lack of data it is not possible to evaluate the actual potential of this future material to increase the sustainability performance of the product.

The life cycle assessment methodology is an ideal tool to analyse and quantify the environmental potential (incl. CO2eq emission reduction and circular economy potentials) of this innovative material compared to its fossil alternative. However, due to the comprehensive data requirements, new products and processes represent a challenge for the LCA methodology as well as for life cycle inventory databases.

Thermoplan and the FHNW plan to team up in order to tackle the challenge of quantifying the sustainability of coffee machines using bio-based plastics on one side and understanding the methodological shortcomings linked to data availability and current LCA modelling techniques. The results of this project will improve LCA-best practice of bio-based materials in general and provide value also to other participants of the Inno-Booster and further stakeholders.

Degree of innovation and Effect

The interest towards bio-based plastics and composites is growing, as alternatives to fossil-based materials are sought. The present case study should lead to a better understanding of environmental benefits linked to the use of bio-based plastics and identify methodological shortcomings and data gaps in plastic LCAs. The degree of innovation is high and can benefit all stakeholders aiming at a more sustainable plastic industry.

Methodological quality

The results of the study will create an added value, assured by the complementary expertises that the project partners (Thermoplan AG and FHNW) bring to the project. Thermoplan AG is expert in the development and manufacturing of professional coffee machines and has a strong sustainable awareness. The FHNW brings a powerful LCA background and expertise, which will be used to identify methodological weaknesses and help address them. PSI brings expertise in the use of the Brightway LCA software, which provides powerful functionality for analysing greenhouse gas emissions over time, comparing different implementations of global warming indicators, supplementing existing background databases (e.g. ecoinvent) with data on missing industry sectors, and flexibility in changing assumptions regarding recycling, waste treatment, and circular usage patterns.

Scope and tasks

The work will be carried out in the following work packages (WP) by the FHNW as a research project, in close collaboration with Thermoplan AG and PSI. The number (%) next to the WP represent the planned allocation of the budget to each WP.

WP1: Goal and scope definition (6%)

- Definition of the system boundaries and functional unit

- Definition of scenarios

WP2: Database analysis and life cycle inventory (53%)

- Analysis of the data situation for bio-based and fossil-based plastics

- Development of datasets for bio-based plastics, corresponding best-practice and uncertainties (if possible)

- Life cycle inventory for the products and processes defined in WP1

WP3: Life Cycle Impact Assessments (16%)

- Quantification of the environmental impacts linked to the scenarios defined in WP1

WP4: Sensitivity Analysis and interpretation of the results (13%)

- Conduction of a sensitivity analysis to test the robustness of the results

- Interpretation of the results

WP5: Report (9%)

- Findings will be integrated into a final report

WP6: Meetings, site visits (3%)

- Kick-off meeting

- Site visit

- Final meeting, presentation of results

Budget

Based on the budget table below, the total project costs amount to CHF 24’948, from which 90% (CHF 22’453) should be funded by the seed money and 10% (CHF 2’495) by the co-funding contribution. The allocated budget to each work package can be seen above.

In order to correctly assess the negative emissions potential of bio-based plastics and if their use leads to overall environmental benefits compared to fossil materials, a case study of coffee machine production is conducted. The life cycle assessment (LCA) methodology is applied to compare bio-based and fossil plastics and assess possible shortcomings on the methodology side and the environmental benefits on the material side.