Periodic Reporting for period 6 - PlanticsInside (The first biodegradable thermoset biopolymer to replace single-use plastics)
Reporting period: 2023-02-01 to 2023-07-31
Reducing plastic waste and lowering CO2 emissions is the top priority of the EU when it comes to environmental action. Yearly almost 400 million tons of plastic is produced worldwide. New legislation forces industries to use alternatives to fossil-based plastics. Therefore, a shift to biobased and biodegradable materials is needed.
Current status? Today bioplastics only comprise less than 2% of the plastic production. Why? The functionality of bioplastics is not yet as required, and costs are too high. Based on an invention of The University of Amsterdam, Plantics has developed new cost-competitive thermoset bioresins that meet both requirements. It is safe, 100% bio-based, recyclable, and if it enters in the environment, it is bio-degradable. Moreover, it is strong and has very good binding properties.
The spin-off company Plantics B.V. (founded in 2014) aims to further develop the new bioresin and its production process and develop applications together with strong (market) partners. Plantics resins can be used in combination with moulded paper as an alternative to single use plastics for e.g. packaging and disposables (about 40% of the plastics market). The resulting material is strong, has good barrier characteristics and is biodegradable. Plantics resins can also be used as an alternative to the currently used often toxic and flammable fossil based thermoset plastics (20% of the plastics market) like polyurethane (used in insulation and furniture foams), or formaldehyde-based resins that are used as binders in wood panels.
In this project we focus on the replacement of some specific single use plastic packaging and disposables with products that are made from moulded paper and Plantics resins. We will design, build, and demonstrate an optimized product and resin production process to enable the company to quickly bring a first product to the market, soon followed by other products. We also aim to finalize contracts with customers and suppliers and update our commercialization plan.
Current status? Today bioplastics only comprise less than 2% of the plastic production. Why? The functionality of bioplastics is not yet as required, and costs are too high. Based on an invention of The University of Amsterdam, Plantics has developed new cost-competitive thermoset bioresins that meet both requirements. It is safe, 100% bio-based, recyclable, and if it enters in the environment, it is bio-degradable. Moreover, it is strong and has very good binding properties.
The spin-off company Plantics B.V. (founded in 2014) aims to further develop the new bioresin and its production process and develop applications together with strong (market) partners. Plantics resins can be used in combination with moulded paper as an alternative to single use plastics for e.g. packaging and disposables (about 40% of the plastics market). The resulting material is strong, has good barrier characteristics and is biodegradable. Plantics resins can also be used as an alternative to the currently used often toxic and flammable fossil based thermoset plastics (20% of the plastics market) like polyurethane (used in insulation and furniture foams), or formaldehyde-based resins that are used as binders in wood panels.
In this project we focus on the replacement of some specific single use plastic packaging and disposables with products that are made from moulded paper and Plantics resins. We will design, build, and demonstrate an optimized product and resin production process to enable the company to quickly bring a first product to the market, soon followed by other products. We also aim to finalize contracts with customers and suppliers and update our commercialization plan.
At the start of the project, the focus was on optimizing Plantics resin formulations for molded paper products. Key considerations were enhancing paper barrier properties, making it resistant to water and oil, and ensuring product durability. The resin's applications spanned various needs, and successful scaling of resin synthesis was rapidly achieved. Trial products were produced and tested out in different markets, indicating market readiness and demonstrating that the product performance requirements are met. In addition, preliminary contracts with suppliers and customers were being drafted.
In RP2 the European market landscape for moulded paper products were subject to heavy change. The COVID-19 pandemic propelled demand for paper products, coupled with the transition from plastic to paper packaging. This shift strained the production capacity for molded paper products, leading to supplier disruptions and greenhouse closures. Consequently, the project timeline was extended. Despite delays and tough market conditions, we managed to produce and sell 300k plant pots in Germany. This attests to market readiness. Experience from semi-lab production enriched our multi-purpose pilot plant's design. Additionally, we've acquired expertise in consistent large-scale resin and plant pot production.
Due to shortages of recycled paper and moulder paper products in Europe, the plant pots were temporarily purchased from China. New market trials were started in this 4th reporting period in greenhouses, growing different plants under different conditions. A business developer was hired to promote the Plantics’ plant pots, which are promoted under the brand “DOPA plant pots”. In the meantime, tooling design for mould production with a European supplier for paper plant pots was started. Besides plant pots, we started two development projects to introduce our material for (indirect) food contact packaging with two potential partners. Furthermore, the first large investment of the multipurpose pilot production installation was installed and successfully commissioned.
During RP5, the second large investment of the pilot production installation was successfully commissioned. With this installation we have nearly doubled our potential production capacity for standard plant pots. The production capacity was used to maintain a stable stock of plant pots ready for sale. One large cultivation test was completely monitored from growth to transportation to sales in shops, which proved to be a huge success and has also led to a larger follow-up order in the following reporting period.
In the final reporting period, the flexible pilot production installation was fully completed and is used for full-time production. The increased production output is achieved by applying iterations to the design based on learnings in production. With the increased output we maintain a stable stock of plant pots ready to supply the demand by sales. Emphasizing sustainable partnerships, the project steered toward the retail sector, manifesting in increased sales from repeat customers. Notably, the European tooling design from the European supplier persisted as a technical challenge, impeding large-scale production realization.
In RP2 the European market landscape for moulded paper products were subject to heavy change. The COVID-19 pandemic propelled demand for paper products, coupled with the transition from plastic to paper packaging. This shift strained the production capacity for molded paper products, leading to supplier disruptions and greenhouse closures. Consequently, the project timeline was extended. Despite delays and tough market conditions, we managed to produce and sell 300k plant pots in Germany. This attests to market readiness. Experience from semi-lab production enriched our multi-purpose pilot plant's design. Additionally, we've acquired expertise in consistent large-scale resin and plant pot production.
Due to shortages of recycled paper and moulder paper products in Europe, the plant pots were temporarily purchased from China. New market trials were started in this 4th reporting period in greenhouses, growing different plants under different conditions. A business developer was hired to promote the Plantics’ plant pots, which are promoted under the brand “DOPA plant pots”. In the meantime, tooling design for mould production with a European supplier for paper plant pots was started. Besides plant pots, we started two development projects to introduce our material for (indirect) food contact packaging with two potential partners. Furthermore, the first large investment of the multipurpose pilot production installation was installed and successfully commissioned.
During RP5, the second large investment of the pilot production installation was successfully commissioned. With this installation we have nearly doubled our potential production capacity for standard plant pots. The production capacity was used to maintain a stable stock of plant pots ready for sale. One large cultivation test was completely monitored from growth to transportation to sales in shops, which proved to be a huge success and has also led to a larger follow-up order in the following reporting period.
In the final reporting period, the flexible pilot production installation was fully completed and is used for full-time production. The increased production output is achieved by applying iterations to the design based on learnings in production. With the increased output we maintain a stable stock of plant pots ready to supply the demand by sales. Emphasizing sustainable partnerships, the project steered toward the retail sector, manifesting in increased sales from repeat customers. Notably, the European tooling design from the European supplier persisted as a technical challenge, impeding large-scale production realization.
Plantics offers a unique beyond the state-of-the-art solution; our value proposition is that we offer the world’s first thermoset biomaterial that is 100% bio-based, recyclable and if it enters in the environment also fully biodegradable. Importantly, it is safe to use as it contains no toxic components, it is flame retardant and when it burns, no toxic gases are formed. We are delivering a sustainable alternative for which customers are willing to pay a “green-premium” and still it competes economically with conventional fossil-based plastics (Figure 1)
Plantics resins can be used in combination with moulded (recycled) paper as an alternative for single use fossil-based plastics for e.g. packaging and disposables. Replacing these single-use plastics with moulded paper treated with Plantics resins, will reduce the CO2 emissions and will help in reducing plastic waste.
Plantics resins can be used in combination with moulded (recycled) paper as an alternative for single use fossil-based plastics for e.g. packaging and disposables. Replacing these single-use plastics with moulded paper treated with Plantics resins, will reduce the CO2 emissions and will help in reducing plastic waste.