Periodic Reporting for period 3 - FlexFunction2Sustain (Open Innovation Ecosystem for Sustainable Nano-functionalized Flexible Plastic and Paper Surfaces and Membranes)
Período documentado: 2023-04-01 hasta 2024-07-31
Plastic and paper based flexible materials and films are used in a wide range of daily life products e.g. in packaging, furniture surface finish, consumer electronic devices, architecture or in car windows. Key Enabling Technologies for a majority of these applications are based on nano-enabled functionalization of the surfaces. Today, Plastics Processing Industry faces game-changing, critical challenges for societal acceptance and economic competitiveness: (1) Overcome plastic waste pollution and follow the European Strategy for Plastics in a Circular Economy; (2) Keep pace with digitisation and get products ready for integration of smart systems and intelligent products.
FlexFunction2Sustain (FF2S) is the first European Initiative to support the Industry in overcoming these challenges through a sustainable Open Innovation Ecosystem. FF2S developed dedicated services to boost innovation for nano-functionalised flexible plastic and paper surfaces and membranes and offer those services to users, in particular SMEs, in all EU countries through a single entry point (SEP) model with regional presence. FF2S connects complementary pilot lines to a set of 9 connected lab-2-fab facilities covering all major nano-surface processing techniques for (flexible) plastic and paper surfaces and membranes. The facilities and novel surface functionality were demonstrated in six relevant industrial application scenarios. 17 pre-commercial pilot case projects have been selected and performed n open calls to demonstrate the Services of the FF2S Open Innovation Test Bed (OITB).
FlexFunction2Sustain (FF2S) is the first European Initiative to support the Industry in overcoming these challenges through a sustainable Open Innovation Ecosystem. FF2S developed dedicated services to boost innovation for nano-functionalised flexible plastic and paper surfaces and membranes and offer those services to users, in particular SMEs, in all EU countries through a single entry point (SEP) model with regional presence. FF2S connects complementary pilot lines to a set of 9 connected lab-2-fab facilities covering all major nano-surface processing techniques for (flexible) plastic and paper surfaces and membranes. The facilities and novel surface functionality were demonstrated in six relevant industrial application scenarios. 17 pre-commercial pilot case projects have been selected and performed n open calls to demonstrate the Services of the FF2S Open Innovation Test Bed (OITB).
A business model and the legal structure of the FF2S OITB was set up. A non-profit association will secure the societal impact of the OITB and will establish standing technical committees to address expressed needs of the industry for accelerating the time to market for new products which use nano-functionalised plastic and paper surfaces and membranes. The technical committees will cover activities such as (a) standardisation of characterisation procedures or system designs, (b) maintaining a knowledge base and identifying future technology trends and roadmaps, (c) joint dissemination activities, (d) tune the OITB members’ services and technologies to market needs, (e) maximize efficiency in collaborative research and innovation projects, and (f) interact with the whole European Open Innovation Ecosystem. The Association will establish strategic partnerships with regionally active technology consultants and sales partners to establish a European network of access points for industry that act as single point of contact (called “Single Entry Point - SEP”). The key tasks of the SEP are consulting the customers in technology selection and planning, managing and realizing innovation projects based on the services of the OITB members. In February 2023 the ESNA - European Sustainable Nanotechnologies Association as the FF2S OITB association was created as non-profit association. By that the association became operational by Month 36 of the project. Based on a call for tender KETMarket has been selected and contracted by ESNA to act as the SEP from summer 2023.
In parallel FF2S upgraded the technical facilities of the consortium members for processing of novel bio-based, bio-degradable and/or recyclable plastic and paper based materials that shall replace the state-of-the-art mineral oil based plastic products in e.g. packaging applications. The upgrades of the facility include winding systems to enable the use of materials with low young’s modulus and dimensional stability; modified process stations to reduce process temperatures or to increase productivity and efficiency; and inline quality control solutions to improve yield and quality in pilot processing. Furthermore, FF2S, in particular the consortium partners IPC and Fraunhofer IVV, enhanced their capabilities for recycling of plastics, and for verifying the recyclability and biodegradability. In december 2022 IPC acquired the TÜV Austria certification for evaluating all relevant biodegradability levels (from industrially compostable to marine degradable).
Finally, dedicated characterisation workflows to evaluate physiochemical properties, application performance and safety approval (e.g. for food contact) were prepared. A catalogue of FF2S characterisation services has been published through the project’s website.
All facilities and technological solutions developed within FF2S are verified in six industrial use case scenarios that cover food and non-food packaging, biodegradable security labels, switchable water filter membranes and innovative multifunctional electronic surfaces in automotive applications. Partners successfully demonstrated roll-to-roll processing of bio-degradable micro-structured surfaces for security labels; roll-to-roll manufacturing of conductive PET based membranes for filter applications; demonstrators of fully recyclable drink pouches and operational organic solar cells that were deposited on recycled PET films.
At Month 18, FF2S launched an open call to invite SME for pre-commercial pilot case projects. The SME receive subsidized access to the innovation services of the FF2S OITB to support and accelerate development of novel products and technologies for smart and sustainable plastics and paper solutions. 23 applications have been received. 17 of them have been selected as pilot cases and performed and finished well.
The results from industrial demo cases were actively promoted through social media, while each stakeholder involved has carefully considered the exploitation possibilities generated as a result of the project’s achievements.
In parallel FF2S upgraded the technical facilities of the consortium members for processing of novel bio-based, bio-degradable and/or recyclable plastic and paper based materials that shall replace the state-of-the-art mineral oil based plastic products in e.g. packaging applications. The upgrades of the facility include winding systems to enable the use of materials with low young’s modulus and dimensional stability; modified process stations to reduce process temperatures or to increase productivity and efficiency; and inline quality control solutions to improve yield and quality in pilot processing. Furthermore, FF2S, in particular the consortium partners IPC and Fraunhofer IVV, enhanced their capabilities for recycling of plastics, and for verifying the recyclability and biodegradability. In december 2022 IPC acquired the TÜV Austria certification for evaluating all relevant biodegradability levels (from industrially compostable to marine degradable).
Finally, dedicated characterisation workflows to evaluate physiochemical properties, application performance and safety approval (e.g. for food contact) were prepared. A catalogue of FF2S characterisation services has been published through the project’s website.
All facilities and technological solutions developed within FF2S are verified in six industrial use case scenarios that cover food and non-food packaging, biodegradable security labels, switchable water filter membranes and innovative multifunctional electronic surfaces in automotive applications. Partners successfully demonstrated roll-to-roll processing of bio-degradable micro-structured surfaces for security labels; roll-to-roll manufacturing of conductive PET based membranes for filter applications; demonstrators of fully recyclable drink pouches and operational organic solar cells that were deposited on recycled PET films.
At Month 18, FF2S launched an open call to invite SME for pre-commercial pilot case projects. The SME receive subsidized access to the innovation services of the FF2S OITB to support and accelerate development of novel products and technologies for smart and sustainable plastics and paper solutions. 23 applications have been received. 17 of them have been selected as pilot cases and performed and finished well.
The results from industrial demo cases were actively promoted through social media, while each stakeholder involved has carefully considered the exploitation possibilities generated as a result of the project’s achievements.
FF2S created a sustainable network of excellence for nanotechnologies for eco-friendly plastic and paper products. The OITB is prepared to support the client at any point in the innovation chain from TRL4 to TRL7 with and integrated technological, business development and verification/pre-certification service portfolio that helps the client to progress quickly through the innovation chain – accelerating the time to market by 30% and more.
Key innovations comprise:
- open, from the whole EU accessible, “lab-to-fab” facilities for nano-functionalization of plastic and paper surfaces and membranes, being fully prepared for novel – biodegradable or fully recyclable – polymers; covering the whole innovation chain from a lab verification (TRL 4) to pilot and small series production (TRL7);
- a sustainable network of excellence for nanotechnologies for eco-friendly plastic and paper products supporting standardisation activities (together with the whole European Open Innovation Ecosystem); suggesting and consulting regulation activities; and providing market trends and roadmapping activities;
- a fully integrated market- and customer oriented portfolio of joint innovation services covering both technological services (e.g. material design, process development, testing and verification and pilot production) and business services (e.g. IP consulting and securing, due diligence services, support in financing and funding of new ideas, estabilishment of networks and value chains): offered to SME in the whole European Single Market for fair and reasonable conditions through a single point of contact.
Key innovations comprise:
- open, from the whole EU accessible, “lab-to-fab” facilities for nano-functionalization of plastic and paper surfaces and membranes, being fully prepared for novel – biodegradable or fully recyclable – polymers; covering the whole innovation chain from a lab verification (TRL 4) to pilot and small series production (TRL7);
- a sustainable network of excellence for nanotechnologies for eco-friendly plastic and paper products supporting standardisation activities (together with the whole European Open Innovation Ecosystem); suggesting and consulting regulation activities; and providing market trends and roadmapping activities;
- a fully integrated market- and customer oriented portfolio of joint innovation services covering both technological services (e.g. material design, process development, testing and verification and pilot production) and business services (e.g. IP consulting and securing, due diligence services, support in financing and funding of new ideas, estabilishment of networks and value chains): offered to SME in the whole European Single Market for fair and reasonable conditions through a single point of contact.