The future of Bio-based Circular Plastics
By Stefaan Vanhalle - R&D Manager
Introduction
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As part of the European Green Deal and the new Circular Economy Action Plan the European Commission proposed a revision of Directive 94/62/EC on Packaging and Packaging Waste. On 24 April 2024 the EU Parliament adopted new measures to make packaging more sustainable and reduce packaging waste in the EU. The EU Council needs formally to approve the agreement before it can enter into force. Once approved, the regulation will include an 18-month preparation period for member states and industries to align with the new rules. Nevertheless in an effort to reduce the environmental impact of plastic waste and promote the circular economy, the Dutch government has announced in a National Circular Plastics Standard that starting in 2027, all plastics produced in the Netherlands must consist of 15% recycled or bio-based plastic. The NCPN concerns plastic polymers that are processed in the Netherlands (by converters or parties that make partial or end products (including packaging) from these polymers). This new Dutch standard aims to reduce the use of fossil resources, minimize waste, and increase the deployment of sustainable materials. The standard was available in a concept version and open for consultation until May 31, 2024. Further elaboration of the standard will be announced in 2025. This white paper focuses specifically on bioplastics, explaining the different types and their characteristics, along with considerations for special packaging requirements in cleanrooms. |
Definitions:
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Bioplastics: the term bioplastics is used on the one hand for plastics that are completely or partially made from biological materials and on the other hand for plastics that are biodegradable. Conventional plastics which are biodegradable are thus also called bioplastics, making it very confusing! In 2023, bioplastics accounted for only 1% to 3% of total plastic use, while 97% to 99% of plastics are still fossil-based. The goal is to achieve 100% renewable plastics by 2050. Bioplastics can be divided into three main categories: |
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Bio-based plastics (not te be confused with bioplastics):
The term 'bio-based' describes what the product is made from. These plastics are made from renewable (meaning they grow back in a short period) biological sources such as plants, sugars, and starch. In short, it includes all materials that come directly from nature. Some are used directly, such as insulation materials in construction. Others are used as raw materials for bio-based products, such as PLA, bioplastic, or bio-based resin. The use of bio-based plastics would be a significant step forward compared to plastics from non-renewable sources. It reduces the contribution to greenhouse gas (CO2eq) emissions from the combustion of fossil resources, thereby lessening the pressure on the climate. Additionally, bio-based materials have the significant advantage of sequestering CO2.
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| These plastics can be broken down by micro-organisms into water, carbon dioxide (or methane), and biomass under natural conditions. Biodegradable plastics can be bio-based or fossil-based. The term 'biodegradable' describes the end of the product's lifecycle: how it is processed afterward. If something is biodegradable, it means that fungi and bacteria can break down the material until nothing remains. However, the rate of degradation varies by material. It can take years for bio-based plastic to decompose fully. Waste processing facilities are not always equipped to handle these extended breakdown periods, resulting in biodegradable waste sometimes being incinerated. Compostable plastics: |
Examples of bio-based plastics
PLA, or Polylactic Acid, is a biodegradable and bioactive thermoplastic derived from renewable resources such as corn starch, sugarcane, or cassava roots. PLA is typically produced by fermenting sugars derived from renewable plant sources into lactic acid. This lactic acid is then polymerized to form polylactic acid. PLA is recyclable, biodegradable and compostable. It degrades into water and carbon dioxide over time.
PHA’s (Polyhydroxyalkanoates) are a class of recyclable and biodegradable polymers produced by certain microorganisms as a storage material in response to nutrient limitations. PHAs are synthesized by various bacteria and archaea through fermentation processes, where these microorganisms convert sugars, lipids, or other carbon sources into PHA as an energy reserve.
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Polyethylene Furanoate (PEF) is a biobased polymer that is gaining attention as a sustainable alternative to traditional petroleum-based plastics like PET (Polyethylene Terephthalate). PEF is derived from renewable resources, primarily plant-based materials. The key monomers for PEF are furandicarboxylic acid (FDCA) and ethylene glycol. FDCA is produced from fructose, which can be sourced from corn, sugarcane, or other biomass. The polymerization process involves condensing FDCA with ethylene glycol to form PEF. PEF is less biodegradable as PLA or PHA but is recyclable. However developing an effective recycling infrastructure for PEF is essential to maximize its environmental benefits. Existing recycling systems are primarily designed for PET and other conventional plastics. |
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Bio-based Polypropylene (Bio-PP) is a sustainable alternative to traditional polypropylene, a widely used thermoplastic polymer. Bio-PP is made from renewable biological sources, primarily biomass such as sugarcane, corn, and other agricultural residues. The production involves extracting bioethanol from biomass, which is then converted into bio-based propylene through a series of chemical processes. The propylene is polymerized to produce Bio-PP. The process aims to mirror the chemical structure of conventional polypropylene, ensuring comparable properties and performance. Bio-PP is less biodegradable as PLA or PHA but is recyclable in existing recycling systems that are primarily designed for conventional PP. |
Bio-based Polyethylene (Bio-PE) is a sustainable alternative to conventional polyethylene, produced from renewable resources rather than fossil fuels. Bio-PE is derived from ethanol produced from biomass, such as sugarcane, corn, or other agricultural residues. The ethanol is converted to ethylene through a dehydration process, which is then polymerized to produce polyethylene. The production process for Bio-PE mirrors that of conventional PE, ensuring similar properties and performance. Bio-PE, like conventional PE, is not biodegradable. However bio-PE can be recycled.
Bio-based Plastics and end of life processing
As previously discussed, not all bio-based products are automatically biodegradable. Moreover, bio-based plastics are simply too expensive to allow them to degrade after use and it is much more circular to recycle bioplastics just like conventional plastics and give them a second life. The property of being biodegradable should rather be seen that if biodegradable plastic were to unintentionally end up in nature, it can be broken down. Bio-based plastics can be collected via PMD and could then be recycled. Unfortunately the amount of bio-based plastics in this waste stream is currently to low (less than 1%) to set up a separate waste stream for recycling of these bio-based plastics. As a consequence these plastics are currently not sorted out the PMD waste stream and end up with the residual fraction and are finally incinerated, which is a shame for such expensive products. It's a bit of a chicken and egg story. Without a larger share of bioplastics, it will be difficult to set up a profitable recycling process, but on the other hand, the lack of a profitable recycling process does hold back the further development of bioplastics.
Biodegradable (bio-) plastics cannot be collected with organic waste (GFT or organic waste) in the Netherlands because the waste processing industry is not yet equipped to handle the long breakdown times of the plastic. Unfortunately, much biodegradable plastic is still incinerated.
Bio-based Plastics for Cleanroom Consumables Packaging
Cleanroom consumables like mops, wipes, disposable garments and goggles used or worn by cleanroom operators must also be packed in cleanroom-compatible plastic packaging. The packaging must provide the following:
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Protection during Transportation and Storage: The packaging must be suitable for holding the consumable during transportation and storage. Contamination Prevention: The packaging safeguards the consumable from contamination and various external factors such as light, heat, and moisture. Information Display: The packaging displays essential manufacturing information, including the lot number, manufacturing date, expiry date, as well as chemical protection levels and usage guidelines. |
Due to these stringent requirements, there is a probability that exceptions might be made for cleanroom consumables packaging regarding the 2027 standard. Ensuring that the packaging meets cleanroom standards while integrating recycled or biobased content presents unique challenges that might necessitate specific allowances to maintain the integrity and safety of sensitive products.
Benefits and Challenges of bio-based plastics
Benefits
- Environmental Benefits: Reduction in fossil fuel dependency, decrease in GHG emissions, and potentially reduced waste problems
- Circular Economy: Promotion of recycling and reuse of materials.
- Biological Cycle: Ability to integrate biological waste streams into a closed loop.
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Challenges
- Infrastructure: Adapting existing recycling and waste processing infrastructure to effectively handle bioplastics.
- Cost: Higher production costs of bioplastics compared to conventional plastics.
- Consumer Awareness: Need to educate consumers on the proper use and disposal of bioplastics.
- Availability
- Special Requirements for Cleanroom Packaging: Balancing the need for contamination-free packaging with the integration of recycled or biobased materials.
Conclusion
Bio-based plastics offer significant potential, but it is essential to understand the differences between bioplastics and bio-based, biodegradable, and compostable plastics to maximize their benefits. Effective implementation will depend on improved infrastructure, economic feasibility, and widespread awareness and education. Additionally, special considerations may be necessary for cleanroom consumables packaging to ensure that the high quality standards required for contamination-sensitive products are maintained.