Periodic Reporting for period 2 - PAWN (PAWN - Full Biodegradable Disposable Baby Diapers)
Berichtszeitraum: 2022-03-01 bis 2023-05-31
About 40% of modern disposable baby diaper consist of super absorbent polymer (SAP), a component that is neither skin friendly nor biodegradable. As a result, each year 21 bn used diaper generate 10M tons of plastic waste in Europe. This waste ends up either in incinerations, where it does not provide a good calorific value due to the high liquid content of the used diapers, or in landfill (about 2.6M tons yearly). The industry as well as the consumers have been searching for eco-friendly alternatives for years, but the material mix in diapers and the high quality and safety requirements for baby products have made this undertaking impossible so far. There are biodegradable alternatives for the outer non-woven fabrics of the diaper, but these do not yet reach the comfort and skin-friendliness of standard PP-based materials. The situation is even worse for the superabsorbent core, for which no fully biodegradable alternative with satisfying absorbency is available. The PAWN project successfully developed the first disposable diaper that meets industry requirements, thanks to the collaborative efforts of the consortium led by Polygreen (Israel), Abgol (Israel), Celltex (Slovakia), Wilogis (Germany), and Novis (Germany). The strong demand for a biodegradable diaper meeting industry standards became evident, as no company had achieved this milestone before. Over 5 years, the PAWN project will generate €136M of revenues and €30M of profit. The project is highly profitable and will deliver a ROI of 6.66.
TECHNICAL WORK
- Pilot scale 10 Kg/batch - large scale equipment for polymerization was installed and runs were conducted to determine work protocols. A dramatic increase in the production rate – more than ten-fold – was achieved.
- SAP Syrup development- Continuous work throughout the project has yielded significant results in SAP Syrup production. Trials of syrup eSAP densities were tested during the development: 80, 90, 100 g / m2
Trials of syrup eSAP densities were also conducted on nonwoven. Trials for loading 40-100 gr / m2 on nonwoven PP have been successful. Experiments showed even 130gr / m2 of SAP loaded on a 22 gr / m2 carrier.
Production capabilities have been discovered on different fabrics, in different weights and patterns and we continue to test and develop these capabilities in order to achieve maximum success.
- Start of SAP tests anaerobically and aerobically.
- Pitch parameters to ensure free absorbency (20g / g), AUL (12g / g). Free absorbency (of 0.9% saline solution) has been reached, procedure to achieve values of 22gr / gr and more is now a known process.
-Trails for absorbency capabilities has been conducted as well. Tests were carried out on the printed fabrics, using a non-woven pp permeable bag as a container for the SAP. The result showed absorbent capacity of 15-25gr/gr, that is a typical range for a hygiene product, depending on end use need. Total absorbency per m2 can range from 1.5 to 5 litres depending on the product use.
- Large scale runs: Develop long run productions (2-4-8 hours) without pit stops. Using a continuous SAP addition pump system allowed for continuous printing with no sign of stopping, runs of 500-meter rolls have been made almost 2 hours.
- Testing biodegradable materials. All materials were tested separately to ensure that every part of the diaper works and to see the difference in laboratory tests.
- Mechanical modifications of unwinders in order to be able to cut new material and to run it on the machine.
- Speed tests – to ensure that modifications won’t slow the machine
- Runnability tests – to ensure that modifications won’t change the parameters of a functional diaper
- Assess real flowability and applicability along standard and Bio-PP prototype non-woven. laboratory scale trials showed very positive results of incorporation the eSAP onto the bio-PP carrier, both in printing ease and absorption. AUL tests have been performed and, as expected, the Bio-PP fabric behaved in a similar way to the regular PP.
-Refinement of the syrup material and the drying + grinding process.
- Operating procedures have been developed. These allow the plant to work with much greater efficiency than before.
- Manufacturing process for PAWN eco-diaper- A physical meeting at the CELLTEX plants was held at the end of April to test the SAP (granules and printed) in the production line of the diapers.
- Preparation for LCA and certification
DISSEMINATION AND COMMERCIALISATION WORK
- Actual results of our panel survey showing that number of people who will spend more money for products of daily use if it is “good” environmental friendly product.
- Discussions with several producers from the diaper production industry, including a big producer of adult diapers and a powerful start-up for the manufacturing of intelligent diaper design
- Process of biodegradability becomes more important.
- Customers want to understand what we are doing, what is the difference to state-of-the-art product by equal performance.
- Many customers requested to get first samples.
- Preparations for biodegradability tests in a pilot scale biogas plant, which is part of a large-scale public relations project for bioeconomy in Baden-Württemberg with broad interest from regional Ministries and policy-makers, research institutions and the public
- PAWN dissemination by contacts to the Ministries of Environment and Agriculture in Baden-Württemberg
- Using our knowledge and contacts to our existing clients who can sell these diapers in bigger quantities in Slovakia and abroad.
- Preparations for model project for use, recycling and energy- and fertiliser recovery from eco-diapers for different regions with IHK Oberschwaben as well as the University of applied science Albstadt-Sigmaringen
- Personal marketing with German and international fair visitors and exhibitors on Biofach Nuremberg
- Pilot scale 10 Kg/batch - large scale equipment for polymerization was installed and runs were conducted to determine work protocols. A dramatic increase in the production rate – more than ten-fold – was achieved.
- SAP Syrup development- Continuous work throughout the project has yielded significant results in SAP Syrup production. Trials of syrup eSAP densities were tested during the development: 80, 90, 100 g / m2
Trials of syrup eSAP densities were also conducted on nonwoven. Trials for loading 40-100 gr / m2 on nonwoven PP have been successful. Experiments showed even 130gr / m2 of SAP loaded on a 22 gr / m2 carrier.
Production capabilities have been discovered on different fabrics, in different weights and patterns and we continue to test and develop these capabilities in order to achieve maximum success.
- Start of SAP tests anaerobically and aerobically.
- Pitch parameters to ensure free absorbency (20g / g), AUL (12g / g). Free absorbency (of 0.9% saline solution) has been reached, procedure to achieve values of 22gr / gr and more is now a known process.
-Trails for absorbency capabilities has been conducted as well. Tests were carried out on the printed fabrics, using a non-woven pp permeable bag as a container for the SAP. The result showed absorbent capacity of 15-25gr/gr, that is a typical range for a hygiene product, depending on end use need. Total absorbency per m2 can range from 1.5 to 5 litres depending on the product use.
- Large scale runs: Develop long run productions (2-4-8 hours) without pit stops. Using a continuous SAP addition pump system allowed for continuous printing with no sign of stopping, runs of 500-meter rolls have been made almost 2 hours.
- Testing biodegradable materials. All materials were tested separately to ensure that every part of the diaper works and to see the difference in laboratory tests.
- Mechanical modifications of unwinders in order to be able to cut new material and to run it on the machine.
- Speed tests – to ensure that modifications won’t slow the machine
- Runnability tests – to ensure that modifications won’t change the parameters of a functional diaper
- Assess real flowability and applicability along standard and Bio-PP prototype non-woven. laboratory scale trials showed very positive results of incorporation the eSAP onto the bio-PP carrier, both in printing ease and absorption. AUL tests have been performed and, as expected, the Bio-PP fabric behaved in a similar way to the regular PP.
-Refinement of the syrup material and the drying + grinding process.
- Operating procedures have been developed. These allow the plant to work with much greater efficiency than before.
- Manufacturing process for PAWN eco-diaper- A physical meeting at the CELLTEX plants was held at the end of April to test the SAP (granules and printed) in the production line of the diapers.
- Preparation for LCA and certification
DISSEMINATION AND COMMERCIALISATION WORK
- Actual results of our panel survey showing that number of people who will spend more money for products of daily use if it is “good” environmental friendly product.
- Discussions with several producers from the diaper production industry, including a big producer of adult diapers and a powerful start-up for the manufacturing of intelligent diaper design
- Process of biodegradability becomes more important.
- Customers want to understand what we are doing, what is the difference to state-of-the-art product by equal performance.
- Many customers requested to get first samples.
- Preparations for biodegradability tests in a pilot scale biogas plant, which is part of a large-scale public relations project for bioeconomy in Baden-Württemberg with broad interest from regional Ministries and policy-makers, research institutions and the public
- PAWN dissemination by contacts to the Ministries of Environment and Agriculture in Baden-Württemberg
- Using our knowledge and contacts to our existing clients who can sell these diapers in bigger quantities in Slovakia and abroad.
- Preparations for model project for use, recycling and energy- and fertiliser recovery from eco-diapers for different regions with IHK Oberschwaben as well as the University of applied science Albstadt-Sigmaringen
- Personal marketing with German and international fair visitors and exhibitors on Biofach Nuremberg
The PAWN project has achieved a groundbreaking milestone by introducing the world's first sustainable diaper that demonstrates exceptional performance parity, cost parity proximity, biodegradability, and eco-design capabilities. The sustainable diaper developed ensures a reduced environmental footprint and showcases performance comparable to conventional disposable diapers, ensuring consumer acceptance. The introduction of a biodegradable diaper contributes to waste reduction and landfill diversion, addressing critical environmental concerns and promoting sustainability. By utilizing eco-friendly materials and optimizing production processes, the project aligns with circular economy principles, reducing the strain on natural resource, also creating awareness among consumers about eco-friendly alternatives, potentially leading to increased demand for green products and sustainable practices and encouraging other sectors to explore eco-friendly solutions.
In conclusion, the PAWN project's world-first sustainable diaper represents a significant leap towards addressing environmental challenges associated with conventional diapers. Its potential socio-economic impact and wider societal implications underscore the importance of sustainable innovation in the global market and its potential to create a greener and more environmentally conscious future
In conclusion, the PAWN project's world-first sustainable diaper represents a significant leap towards addressing environmental challenges associated with conventional diapers. Its potential socio-economic impact and wider societal implications underscore the importance of sustainable innovation in the global market and its potential to create a greener and more environmentally conscious future