Periodic Reporting for period 4 - BIOSNAP (SMART, SUSTAINABLE & CONVENIENT UNIT DOSE PACKAGING)
Período documentado: 2022-11-01 hasta 2023-10-31
85% of marine litter consists of plastic, with single-use plastics accounting for over half of this litter. This plastic material mostly derives from non-renewable sources such as fossil fuel. Recycling plastics has been presented as the solution to the problem. However, only the 14% of the plastics used worldwide is collected and of this only one-third can be really recycled.
To overcome the problems presented by fossil fuels, many companies are investing in bioplastics. Despite the excellent progress, bioplastic is still a young technology. Current bio-packaging applications on the market have high potential for improvement related to their environmental sustainability as well as functionality.
Through this project, we developed a novel unit dose packaging that is made of bio-based and bio-compostable plastic material, meeting the requirements to apply for "OK Industrial Compost" certification by TÜV Austria.
In addition, food contact compatibility tests have been performed based on current EU legislation on food contact materials and EU REG. N. 10/2011 on plastic materials. Specific food products were formulated and produced following the processing conditions and the facilities requirements of the food industry, with the aim to evaluate if the materials developed achieve adequate shelf-life and sensory characteristics.
To evaluate the behavior of BIOSNAP with food, and to learn about consumer acceptability, we carried out two sensory analysis, evaluated by an expert panel and a consumer panel.
Finally, through an innovative tool (MUNDO SABOR), information from real potential consumers was obtained to carry out a consumer concept test, that is to make a market study of the packaging solutions of BIOSNAP, and through the application “Home Use Test” (HUT), consumers had the chance of assessing the products at home.
To overcome the problems presented by fossil fuels, many companies are investing in bioplastics. Despite the excellent progress, bioplastic is still a young technology. Current bio-packaging applications on the market have high potential for improvement related to their environmental sustainability as well as functionality.
Through this project, we developed a novel unit dose packaging that is made of bio-based and bio-compostable plastic material, meeting the requirements to apply for "OK Industrial Compost" certification by TÜV Austria.
In addition, food contact compatibility tests have been performed based on current EU legislation on food contact materials and EU REG. N. 10/2011 on plastic materials. Specific food products were formulated and produced following the processing conditions and the facilities requirements of the food industry, with the aim to evaluate if the materials developed achieve adequate shelf-life and sensory characteristics.
To evaluate the behavior of BIOSNAP with food, and to learn about consumer acceptability, we carried out two sensory analysis, evaluated by an expert panel and a consumer panel.
Finally, through an innovative tool (MUNDO SABOR), information from real potential consumers was obtained to carry out a consumer concept test, that is to make a market study of the packaging solutions of BIOSNAP, and through the application “Home Use Test” (HUT), consumers had the chance of assessing the products at home.
From the start of the project to the end of the project, the following activities have been carried out:
• Scouting of PHA suppliers worldwide.
• Purchasing of PHA grades from some suppliers.
• Starting characterization of PHA grades and evaluation of performances: comparison with the current Easysnap solution.
• PHA-blends: selection of biocompostable grades to be added to PHA matrix to make blends in order to best adapt PHA fil to the Easysnap solution.
• Extrusion of PHA-based blends in pellet.
• Cast film extrusion of PHA-blends, characterization and comparison with current Easysnap materials. Selection to the best(s) candidate(s).
• Determination of the degree of disintegration on the selected candidates according to UNI EN ISO 20200.
• Printing trials with biocompostable inks on biocompostable films to be coupled with PHA-based films.
• Purchasing of a new extrusion cast line to be installed in Gualapack dedicated to PHA extrusion.
• Adaptation of Easysnap machine to the bio-based material:
- Test of the new Dosing System and design of the pump control circuit
- Design of external blades with different cutting-edge profiles
- Analysis, study and design of a new pre-cut group with towing and 90° cutting orientation compared to the traditional pre-cut previously used
- Definition of the technical specifications for the stand-alone cutting group to carry out future tests.
- New algorithms were studied for the automation and development of the packaging machine software from a 4.0 perspective and specifically, the objectives pursued concerned a new machine management software with a new operator interface
• Adaptation of Easysnap machine to the bio-based material:
- Test of the new Dosing System and design of the pump control circuit
- Design of external blades with different cutting-edge profiles
- Analysis, study and design of a new pre-cut group with towing and 90° cutting orientation compared to the traditional pre-cut previously used
- Definition of the technical specifications for the stand-alone cutting group to carry out future tests.
- New algorithms were studied for the automation and development of the packaging machine software from a 4.0 perspective and specifically, the objectives pursued concerned a new machine management software with a new operator interface
-Machine design of the new machine BIOSNAP
-Verification of projects and sending new design to suppliers
-Verification of incoming materials and BIOSNAP machine assembly
-First initial phase of machine testing of the materials sent by Gualapack
-Validation of the machine
• Carried out quality control tests, weldability, sensory (organoleptic) and consumer (market study) analyzes.
• Carried out tests required to apply for "OK Compost" certification: Biodegradability (completed), Chemical characterization (completed), Disintegration (completed), and Eco-toxicological (completed) analyses.
• Carried out and evaluated tests on compostability and food contact compatibility based on current EU legislation EU REG. N. 1935/2004 on food contact materials and objects and EU REG. N. 10/2011 on plastic materials and articles intended to come into contact with food.
• As the adhesives used to fix top layer to bottom layer need to be compostable, it is necessary to ensure that the adhesive strength (or resistance) is properly achieved to avoid layers peeling apart. Sealing resistance tests according to ASTM F88 were carried out by Easysnap through an external laboratory (CSI)
• Website of BIOSNAP project created (EASYSNAP).
• Online surveys with MUNDOSABOR platform to analyze consumer patterns and preferences completed (CTIC CITA).
• “Home Use Test” (HUT) studies of PAPERSNAP solution completed (CTIC CITA).
• 2x workshops carried out in Spain (CTIC CITA).
• Communication and dissemination activities (events, fairs and trips) to promote the project carried out. (CTIC CITA) in part from EASYSNAP.
• Intensification of awareness-raising activities in the areas covered by the project (contact with the producers of the Food Companies). (CTIC CITA).
• Optimized and Manufactured material – not yet in industrial production but made.
• Intellectual Property Management and Patent generation To be defined on the basis of the birth of the first industrial productions as the material at the time undergoes the process of existing patents
• Scouting of PHA suppliers worldwide.
• Purchasing of PHA grades from some suppliers.
• Starting characterization of PHA grades and evaluation of performances: comparison with the current Easysnap solution.
• PHA-blends: selection of biocompostable grades to be added to PHA matrix to make blends in order to best adapt PHA fil to the Easysnap solution.
• Extrusion of PHA-based blends in pellet.
• Cast film extrusion of PHA-blends, characterization and comparison with current Easysnap materials. Selection to the best(s) candidate(s).
• Determination of the degree of disintegration on the selected candidates according to UNI EN ISO 20200.
• Printing trials with biocompostable inks on biocompostable films to be coupled with PHA-based films.
• Purchasing of a new extrusion cast line to be installed in Gualapack dedicated to PHA extrusion.
• Adaptation of Easysnap machine to the bio-based material:
- Test of the new Dosing System and design of the pump control circuit
- Design of external blades with different cutting-edge profiles
- Analysis, study and design of a new pre-cut group with towing and 90° cutting orientation compared to the traditional pre-cut previously used
- Definition of the technical specifications for the stand-alone cutting group to carry out future tests.
- New algorithms were studied for the automation and development of the packaging machine software from a 4.0 perspective and specifically, the objectives pursued concerned a new machine management software with a new operator interface
• Adaptation of Easysnap machine to the bio-based material:
- Test of the new Dosing System and design of the pump control circuit
- Design of external blades with different cutting-edge profiles
- Analysis, study and design of a new pre-cut group with towing and 90° cutting orientation compared to the traditional pre-cut previously used
- Definition of the technical specifications for the stand-alone cutting group to carry out future tests.
- New algorithms were studied for the automation and development of the packaging machine software from a 4.0 perspective and specifically, the objectives pursued concerned a new machine management software with a new operator interface
-Machine design of the new machine BIOSNAP
-Verification of projects and sending new design to suppliers
-Verification of incoming materials and BIOSNAP machine assembly
-First initial phase of machine testing of the materials sent by Gualapack
-Validation of the machine
• Carried out quality control tests, weldability, sensory (organoleptic) and consumer (market study) analyzes.
• Carried out tests required to apply for "OK Compost" certification: Biodegradability (completed), Chemical characterization (completed), Disintegration (completed), and Eco-toxicological (completed) analyses.
• Carried out and evaluated tests on compostability and food contact compatibility based on current EU legislation EU REG. N. 1935/2004 on food contact materials and objects and EU REG. N. 10/2011 on plastic materials and articles intended to come into contact with food.
• As the adhesives used to fix top layer to bottom layer need to be compostable, it is necessary to ensure that the adhesive strength (or resistance) is properly achieved to avoid layers peeling apart. Sealing resistance tests according to ASTM F88 were carried out by Easysnap through an external laboratory (CSI)
• Website of BIOSNAP project created (EASYSNAP).
• Online surveys with MUNDOSABOR platform to analyze consumer patterns and preferences completed (CTIC CITA).
• “Home Use Test” (HUT) studies of PAPERSNAP solution completed (CTIC CITA).
• 2x workshops carried out in Spain (CTIC CITA).
• Communication and dissemination activities (events, fairs and trips) to promote the project carried out. (CTIC CITA) in part from EASYSNAP.
• Intensification of awareness-raising activities in the areas covered by the project (contact with the producers of the Food Companies). (CTIC CITA).
• Optimized and Manufactured material – not yet in industrial production but made.
• Intellectual Property Management and Patent generation To be defined on the basis of the birth of the first industrial productions as the material at the time undergoes the process of existing patents
Currently, PHA grades represent a very small percentage of the total bioplastics market, despite their promising performances in terms of bio-compostability. Consequently, they have been used in a very limited way by the packaging industry.
Through the BIOSNAP project we are developing a novel unit dose packaging.
- Green Environmental Impact
The new sachets will be made from polyhydroxy acids (PHA) and polylactic acid (PLA) bioplastics which are both 100% biodegradable and compostable and resonate with the EC’s Proposal for a Directive of the European Parliament and of the Council on the reduction of the impact of certain plastic products on the environment.
- Easy to use performance
BIOSNAP is an innovative & smart packaging manufactured from a patented and certified Easysnap technology that will be manufactured by Easysnap machinery. The smart opening on our sachets allows product dispensing in a clean and easy way with just one hand.
Its pioneering design defeats the problem of conventional sachets of having to tear away products tops or using two hands to struggle and open a package. Easysnap Technology is currently the ONLY packaging company worldwide offering such innovative technology and unit dose packaging.
Through the BIOSNAP project we are developing a novel unit dose packaging.
- Green Environmental Impact
The new sachets will be made from polyhydroxy acids (PHA) and polylactic acid (PLA) bioplastics which are both 100% biodegradable and compostable and resonate with the EC’s Proposal for a Directive of the European Parliament and of the Council on the reduction of the impact of certain plastic products on the environment.
- Easy to use performance
BIOSNAP is an innovative & smart packaging manufactured from a patented and certified Easysnap technology that will be manufactured by Easysnap machinery. The smart opening on our sachets allows product dispensing in a clean and easy way with just one hand.
Its pioneering design defeats the problem of conventional sachets of having to tear away products tops or using two hands to struggle and open a package. Easysnap Technology is currently the ONLY packaging company worldwide offering such innovative technology and unit dose packaging.