Periodic Reporting for period 1 - PAWN (PAWN - Full Biodegradable Disposable Baby Diapers)
Période du rapport: 2020-12-01 au 2022-02-28
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. In the PAWN project, we will bring to the market the first disposable baby diaper that fulfils al requirements. For this aim, the consortium brings together Polygreen (Israel), a start-up company that has developed a biodegradable SAP, Avgol (Israel), a marketleader in non-woven materials, who will integrate a technology to make PolyPropylene materials biodegradable, Celltex (Slovakia), a producer of baby diapers, Wilogis (Germany), a distributor of eco-friendly hygiene products and Novis (Germany), specialists in waste valorization and life cycle analysis. 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, absorbing
-Refinement of the syrup material and the drying + grinding process. Tests and improvements have been made to improve drying and grinding processes. For example, increasing the capacity for continuous running of the printing machinery, increasing the carrier support length. Machinery for post-drying processes was developed, to enable continuous treatment for long printed SoN products.
- 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, absorbing
-Refinement of the syrup material and the drying + grinding process. Tests and improvements have been made to improve drying and grinding processes. For example, increasing the capacity for continuous running of the printing machinery, increasing the carrier support length. Machinery for post-drying processes was developed, to enable continuous treatment for long printed SoN products.
- 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
PAWN is designed as the diaper that will pioneer the real full biodegradability of these disposable garments that generate 10M tons of plastic-based waste yearly. The different EU directives focused on banning the use of plastics will find a full compliance in our diaper: as all of the parts will be recycled/composted, being especially remarkable the biodegradability of the SAP: this is 40% of the final weight of the diaper, and had never been biodegradable before our PAWN diaper. Furthermore, the whole manufacturing process from eSAP and Bio-PP obtention down to final diaper distribution follows a streamlined and adjusted Life Cycle Management to ensure optimized energy consumption, minimum footprint and full biodegradability after diaper use.
PAWN is designed to replace the fluff component in the hygiene industry. Non degradable fluff has a huge environmental impact and with the new product help we can save +12 million Potential Trees per year and +6 million Ton Potential Plastic per Year while helping to preserve our environment.
PAWN is designed to replace the fluff component in the hygiene industry. Non degradable fluff has a huge environmental impact and with the new product help we can save +12 million Potential Trees per year and +6 million Ton Potential Plastic per Year while helping to preserve our environment.