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
