Symphony Environmental July 2008

As explained in the previous presentation there are different types of polymers. We want to apply d2w to the simplest and most abundant types :- Polyethylene and Polypropylene. 66 million tonnes of polyethylene per annum 60 million tonnes of polyprpylene per annum 35% used in packaging. That’s just 44 million tonnes to go for! Polymer Structure

Flexible packaging:- Commodity plastic packaging -bags and sacks- EASY Non food packaging - NOT SO EASY Food packaging - EVEN LESS EASY But the rewards are higher:- Repeat business Based on specification Print content

The Benefits of Plastic Packaging Lightweight Flexible Strong/Durable Heat sealable Impervious to moisture Printable Recyclable By-product of Oil Refinery

Crude components LPG 2% Naptha 3% Lubricants 5% Aviation Fuel 15% Petrol 45% Diesel 15% Heating Oils10% Bitumen 5%

Crude Oil Naptha is a by-product of crude oil extraction. We produce about 87 million barrels per day It is about 3% of all global crude extraction. 50% is used to produce plastic products.

But… Not degradable

The Plastic Problem Consumers and Environmental Activists Drive Politics Consumers want their waste picked up from them, but not put down anywhere near them. Consumers believe that household waste is predominantly plastic packaging Plastic packaging is considered to be a mayor environmental pollution problem.

Solution Oxo-Biodegradable Plastic Complete degradation 2 – 5 years after the end of the pre-set service life* * Depends on product type and exposure conditions

d2w additive put into basic polymer resin at the production stage (Normally 1%) Breaks molecular chain Plastic starts degrading at end of pre-set service life How does it work? Bio-degradation completed by micro-organisms Process of Oxidation – caused by light, heat and stress

How does it work? C C C C C C H HH HH HH HH HH H Long chains Flexible material oxidation microbial degradation CO 2 + H 2 O + biomass   degradation is affected by heat, light, stress and air C C HH HH C C HH HH C C HH HH Short chains / brittle oxidation

Residues Water CO 2 Biomass NO ‘‘HEAVY METALS’’

How it works

It is well accepted that polyolefins that have undergone oxidative degradation provide hydrophilic surfaces having greatly reduced molecular masses. Reduction of the molecular weight of the polyolefin to around 40,000 combined with the introduction of oxygen containing functional groups leads to bio-degradation. These images are taken from a pieces of fragmented oxo-degraded d2w film. They were subjected to immersion in water and a compost mixture. They were then examined in a Leo variable pressure scanning electron microscope. In an area of extensive cracking colonies of bacteria have arrived. A closer look at the area highlighted in blue shows…..

How it Works

How it works Numerous bacterial cells and fungal spores colonising the cracked area and the whole depth of the film through the crack is showing areas of microbial attack.

How it works The transition metal salt generates free radicals that in turn produce hydro- peroxides in the form of aldehydes, ketones, esters, alcohols and carboxylic acids. It is these that are bio degradable.

How it works Transition metals:- Cobalt, iron, manganese, copper,zinc, cerium, nickel.

Food contact Test

Food contact test

Recycling of Degradable Plastics The Recycling of oxo- degradable materials is not a problem.

EU funded BRITE-EURAM research project Aston University in collaboration with Blaise Pascal University “no change in melt flow index was observed on reprocessing” Process aid stabilisation is finite and exhausted during manufacturing. Transition metal salt is susceptible to shear temperatures. Recycling introduces at least two more heat histories. Recycling of Degradable Plastics

Bio-degradable plastic It is important to distinguish between the different types of biodegradable plastic as their costs and uses are very different Oxo-biodegradable plastic is made from a by-product of oil refining Hydro-biodegradable plastic is usually made from a food crop such as starch, derived from agricultural crops

Why not Hydro-biodegradable plastic? These are very much more expensive and less durable. Some of these plastics have a high starch content and it is claimed that they are therefore made from renewable resources. However many of them contain more than 50% of synthetic plastic derived from oil, and others are entirely based on oil derived intermediates. “Based on”? Process aids? In the depths of a landfill, these plastics can generate copious amounts of methane A disproportionate amount of land will be required to produce the raw material to replace conventional plastic and also a huge amount of water. Already the use of crops to make bio fuels is driving up the cost of feed to chicken farmers, pig farmers and other livestock industries. Hydro-biodegradable plastics will emit methane and release carbon dioxide into the atmosphere at a greater rate than oxo-biodegradable plastics.

Hydro degradables Mater-Bi from Novamont Eco-Flex from BASF Bionelle from Showa Denko Biomax from Dupont PVOH- various sources PCL / Capa from Solvay Nature-Works from Cargill PLA Nature-Flex from Innovia

Disposal Typically there are Five Options:- Incineration Landfill Compost Recycle Litter

Disposal Incineration;- refined oil Landfill;- breakdown -aid settlement Compost;- will work in in-vessel Recycle;- will recycle Litter;- will disappear

Advantages of Oxo-biodegradable plastic Oxo-biodegradable film is certified safe for contact with any food type and is ideal for frozen food packaging. Oxo-biodegradable plastics are made from naptha which is a by-product of oil refining. It makes good environmental sense to use the by-product instead of wasting it by ‘flare- off’ at the refinery Oxo-biodegradable plastics can be recycled and can be made from recycled. They can also be composted, and perform well in-vessel. Oxo-biodegradable sheet is very useful in agriculture because after the harvest many thousands of kilometres of dirty plastic has to be gathered and disposed of.

Manufacturing Oxo-biodegradable plastic No special machinery or workforce No change of supplier or loss of jobs. Compatible with polypropylene PP, polyethylene PE & most consumable plastic packaging. 6 months to 5 years shelf life. Adjustable product life. No compromises in functionality: strength, clarity, barrier properties, seal ability, print. Comprehensively tested and and proven

Standards for Oxo-biodegradable New draft Standard BS 8472 (not complete) ASTM (US) D.6954 testing protocol AFNOR NFU :2005 (France) – Agriculture/Horticulture

Food Contact Safe – tested by RAPRA (US Owned) Soil Safe – tested by OWS, Belgium (EN 13432) Biodegradable – tested by PYXIS, UK Oxo-biodegradable – tested by CSI, Italy; RAPRA, UK and UFSCar / UNESP Brasil Certification

Carrier bags or ‘‘Shopper-bags’’ Refuse sacks Aprons Products Available Bags to contain dog faeces collected in parks, gardens, etc PE, PP, (Not PET) Bin Liners Gloves Bread bags Frozen food bags Wrappers for cigarette packets Shrink-wrap and pallet-wrap ‘‘Bubble-wrap’’ Rigid products such as bottles and cups

Products Available PE, PP, (Not PET, PS or PVC)

Reduce and Re-use Recycle Make from recycled Main Product Features Incinerate Compost (in vessel) Landfill (no methane)

Oxo-biodegradable products and additive technologies