Periodic Reporting for period 3 - BIONANOPOLYS (OPEN INNOVATION TEST BED FOR DEVELOPING SAFE NANO-ENABLED BIO-BASED MATERIALS AND POLYMER BIONANOCOMPOSITES FOR MULTIFUNCTIONAL AND NEW ADVANCED APPLICATIONS)
Período documentado: 2024-01-01 hasta 2024-12-31
The BIONANOPOLYS project aims to contribute to the EU's climate-neutral goal by 2050 through the development of bio-based nano-enabled materials (NEBM) that outperform fossil-based materials in various sectors such as packaging, textiles, agriculture, and healthcare. By transforming biobased materials to the nanoscale, the project enhances their properties like surface area, mechanical strength, and barrier capabilities.
BIONANOPOLYS will strengthen the circular economy by launching an Open Innovation Test Bed (OITB) to develop and promote bionanocomposites. The project involves 14 pilot lines across Europe and includes 15 technological institutes and 8 industrial partners to validate nearly 20 case studies.
The project’s goal is to create a network of pilot plants and services to accelerate the introduction of bio-based materials into the market via a Single-Entry Point (SEP). This network will provide essential support for industrial companies, startups, and research centers, helping to develop sustainable, competitive bio-based materials with advanced properties for broader industry use.
BIONANOPOLYS will strengthen the circular economy by launching an Open Innovation Test Bed (OITB) to develop and promote bionanocomposites. The project involves 14 pilot lines across Europe and includes 15 technological institutes and 8 industrial partners to validate nearly 20 case studies.
The project’s goal is to create a network of pilot plants and services to accelerate the introduction of bio-based materials into the market via a Single-Entry Point (SEP). This network will provide essential support for industrial companies, startups, and research centers, helping to develop sustainable, competitive bio-based materials with advanced properties for broader industry use.
In WP1, regular meetings monitored task progress, addressed issues, and managed risks. Six general and one extraordinary assembly were held, along with three amendments.
In WP2, the OITB management structure, Open Call conditions, and service portfolio were defined. Promotion activities led to 27 Open Call applications, and the SEP was established at M22. A business model was defined as a service broker between providers and customers.
In WP3, upgrades to production processes for nanoadditives resulted in increased production capacity.
In WP4, improvements in production processes for bionanocomposites and the modification of nanoadditives increased productivity and adapted processes to biopolymers.
In WP5, upgrades to various pilot plants (PP) involved in bionanoproducts were validated with commercial biopolymers and bionanocomposites from WP4. These upgrades improved process productivity by increasing production capacity, reducing material consumption, and minimizing validation time. N
In WP6, strategies were implemented to enhance pilot lines through transversal technologies. In-line monitoring systems using NIR technology effectively measured biopolymer permeability and nanoparticle dispersion. Other methods, including ED-XRF and NIR, were explored for measuring thin layers' thickness and homogeneity. Mathematical modeling using Finite Element Method and simulation models optimized trial numbers, and rapid prototyping through 3D printing reduced the need for multiple experiments. Finally, benchmarked technologies like radiography and tomography helped partners select the best techniques for characterizing bio-based nanocomposites.
In WP7, improvements in various pilot plants were validated through 21 user cases proposed by 8 industrial partners. Ten of the 21 user cases were successful in achieving the required properties. Notable successes include:
- UC1_P2: Cleaning wipes with 85% viscose and 15% chemically modified PLA showed industrial compostability.
- UC3: Paper-based materials reinforced with CNF achieved an over 80% improvement in barrier properties and around 40% improvement in mechanical properties.
- UC4_P2: Paper-based materials coated with hydrophobic CNF showed a 17% improvement in water barrier properties.
- UC6: PBS-co-PLA block copolymers as additives in film packaging improved stress at break (+47%), elongation (+133%), and elastic modulus (+250%).
- UC9: Modified clays reinforced biodegradable film in non-food packaging, achieving improvements in stress at break (+26%), elongation (+133%), and elastic modulus (+16%).
- UC10: Sunscreen with CNF and CNC showed enhanced sun protection factor, helping reduce fossil-based additives and UV filters.
- UC11/12: Active nanocapsules for cosmetics and food with antioxidant properties showed comparable performance to commercial products.
- UC15: Thermoformed foamed trays reinforced with organoclays showed a 23.2% density reduction, 50% improvement in tensile strength, and 36% reduction in oxygen transfer rate.
- UC17: Foamed prototypes for the automotive sector using bionanocompounds showed similar density to commercial products, with a 30% improvement in modulus.
WP8 included safety, regulation, and environmental assessments. Toxicity tests showed most user cases were safe, with some exceptions like UC4_2. Exposure measurements revealed inadequate ventilation, suggesting improvements for safety. LCA results identified the most environmentally promising user cases, with process upgrades reducing environmental impact by up to 70%. LCC showed cost improvements, and S-LCA revealed reduced social risks across pilot plants. Recyclability and compostability tests confirmed positive results for several user cases.
In WP9, Business Services developed a portfolio focused on investment and business services. Key activities included workshops on business models, investment readiness, pitching sessions, tailored mentoring, and legal workshops. The service portfolio was structured into technical, process parametrization, and non-technical services.
WP10 launched the Open Call, selecting six test cases, and received positive feedback. Final test cases showed high satisfaction, leading to improvements in the OITB for future clients.
WP11 focused on dissemination, creating the project website, holding national stakeholder events, and participating in 45 conferences. Nine success stories were promoted, with two patents and three peer-reviewed papers submitted.
Exploitation activities in WP11 established an updated exploitation plan, identifying key exploitable results and developing an exploitation roadmap for each industrial sector. These efforts contributed to building an eco-friendly network of pilot plants, offering assessment and innovation services to support the development of bio-based materials with enhanced properties.
In WP2, the OITB management structure, Open Call conditions, and service portfolio were defined. Promotion activities led to 27 Open Call applications, and the SEP was established at M22. A business model was defined as a service broker between providers and customers.
In WP3, upgrades to production processes for nanoadditives resulted in increased production capacity.
In WP4, improvements in production processes for bionanocomposites and the modification of nanoadditives increased productivity and adapted processes to biopolymers.
In WP5, upgrades to various pilot plants (PP) involved in bionanoproducts were validated with commercial biopolymers and bionanocomposites from WP4. These upgrades improved process productivity by increasing production capacity, reducing material consumption, and minimizing validation time. N
In WP6, strategies were implemented to enhance pilot lines through transversal technologies. In-line monitoring systems using NIR technology effectively measured biopolymer permeability and nanoparticle dispersion. Other methods, including ED-XRF and NIR, were explored for measuring thin layers' thickness and homogeneity. Mathematical modeling using Finite Element Method and simulation models optimized trial numbers, and rapid prototyping through 3D printing reduced the need for multiple experiments. Finally, benchmarked technologies like radiography and tomography helped partners select the best techniques for characterizing bio-based nanocomposites.
In WP7, improvements in various pilot plants were validated through 21 user cases proposed by 8 industrial partners. Ten of the 21 user cases were successful in achieving the required properties. Notable successes include:
- UC1_P2: Cleaning wipes with 85% viscose and 15% chemically modified PLA showed industrial compostability.
- UC3: Paper-based materials reinforced with CNF achieved an over 80% improvement in barrier properties and around 40% improvement in mechanical properties.
- UC4_P2: Paper-based materials coated with hydrophobic CNF showed a 17% improvement in water barrier properties.
- UC6: PBS-co-PLA block copolymers as additives in film packaging improved stress at break (+47%), elongation (+133%), and elastic modulus (+250%).
- UC9: Modified clays reinforced biodegradable film in non-food packaging, achieving improvements in stress at break (+26%), elongation (+133%), and elastic modulus (+16%).
- UC10: Sunscreen with CNF and CNC showed enhanced sun protection factor, helping reduce fossil-based additives and UV filters.
- UC11/12: Active nanocapsules for cosmetics and food with antioxidant properties showed comparable performance to commercial products.
- UC15: Thermoformed foamed trays reinforced with organoclays showed a 23.2% density reduction, 50% improvement in tensile strength, and 36% reduction in oxygen transfer rate.
- UC17: Foamed prototypes for the automotive sector using bionanocompounds showed similar density to commercial products, with a 30% improvement in modulus.
WP8 included safety, regulation, and environmental assessments. Toxicity tests showed most user cases were safe, with some exceptions like UC4_2. Exposure measurements revealed inadequate ventilation, suggesting improvements for safety. LCA results identified the most environmentally promising user cases, with process upgrades reducing environmental impact by up to 70%. LCC showed cost improvements, and S-LCA revealed reduced social risks across pilot plants. Recyclability and compostability tests confirmed positive results for several user cases.
In WP9, Business Services developed a portfolio focused on investment and business services. Key activities included workshops on business models, investment readiness, pitching sessions, tailored mentoring, and legal workshops. The service portfolio was structured into technical, process parametrization, and non-technical services.
WP10 launched the Open Call, selecting six test cases, and received positive feedback. Final test cases showed high satisfaction, leading to improvements in the OITB for future clients.
WP11 focused on dissemination, creating the project website, holding national stakeholder events, and participating in 45 conferences. Nine success stories were promoted, with two patents and three peer-reviewed papers submitted.
Exploitation activities in WP11 established an updated exploitation plan, identifying key exploitable results and developing an exploitation roadmap for each industrial sector. These efforts contributed to building an eco-friendly network of pilot plants, offering assessment and innovation services to support the development of bio-based materials with enhanced properties.
The BIONANOPOLYS project has demonstrated the successful performance of nano-enabled bio-based materials using European biomass feedstocks, developed at both pilot and industrial scales. The biobased products achieved comparable performance to conventional fossil-based ones, offering safe, recyclable, and compostable alternatives. This reduces the EU's dependency on fossil resources and helps tackle plastic waste. The increased production capacity and upgrades in pilot lines within the BIONANOPOLYS OITB will support faster market introduction of biomaterials in high-demand applications like packaging, textiles, and consumer goods.
The environmental and technical success of the bionanoproducts will help gain industry and consumer acceptance of biomaterials and nanoadditives as viable alternatives to fossil-based materials, contributing to GHG emission reductions and fossil resource conservation, aiding the EU's goal of climate neutrality by 2050.
In addition to environmental benefits, the development and implementation of new technologies could stimulate job creation in research, manufacturing, and commercialization, attracting investment and boosting EU economic growth, especially in regions with high unemployment. The OITB, by supporting sustainable industries and reducing waste, can also create green jobs, benefiting long-term economic and societal well-being.
The environmental and technical success of the bionanoproducts will help gain industry and consumer acceptance of biomaterials and nanoadditives as viable alternatives to fossil-based materials, contributing to GHG emission reductions and fossil resource conservation, aiding the EU's goal of climate neutrality by 2050.
In addition to environmental benefits, the development and implementation of new technologies could stimulate job creation in research, manufacturing, and commercialization, attracting investment and boosting EU economic growth, especially in regions with high unemployment. The OITB, by supporting sustainable industries and reducing waste, can also create green jobs, benefiting long-term economic and societal well-being.