BIOPLAS PRO
BIOPLAS PRO, a Horizon 2020 project for the production of bio-based composite materials
BIOPLAS PRO is the line of composite materials of Sineco International made with 100% eco-friendly and recyclable bioplastics. A new formulation of biopolymers and a unique extrusion process.
We have invested in the production of (bio) composite materials based on feedback from our customers, who are increasingly interested in purchasing green items to respect the environment and are aware of the damage that incorrect plastic disposal can cause to the planet.
What makes the BIOPLAS PRO range unique are:
- maintaining behaviors and performances similar to synthetic products
- superior performance compared to existing natural solutions
The application sectors? Multiple, both in the civil sector and in the advanced composites industry.
The BIOPLAS-PRO project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 807215.
Civil Industry and Advanced Composite Materials: The Plastic Problem
Plastic has shaped society in many ways, making life easier and safer. It can be found everywhere : in pipes, insulation, composite products for cars, airplanes, ships, and sports equipment, in mats for soil drainage, soil stabilization, and water and humidity control in buildings.
However, this synthetic material also has a serious effect on the environment. It contributes to a number of situations including:
- The depletion of oil resources. To produce 1 kg of plastic, on average 1-2 kg of oil (raw material) are needed. At the current rate of consumption, it is estimated that global oil reserves will be exhausted within 50 years (Source: BP Statistical Review of World Energy June 2016, British Petroleum – BP, 2016).
- The increase in greenhouse gas emissions. The average CO2 emissions – from the production phase of plastic materials to the management of their waste – are significant: estimated at 3,4 kg of CO2 per kg of plastic produced. (Source: The impact of plastics on life cycle energy consumption and greenhouse gas emissions in Europe, denkstatt GmbH, 2010).
- The waste of natural resources. Limited reuse and poor recyclability of plastics lead to large amounts of post-consumer waste. In 2008, the civil and automotive sectors alone generated 2,6 million tons of plastic waste, of which only 12% was recycled (Source: Plastic Waste in the Environment, European Commission DGENV, April 2011). 64% of the waste was disposed of in landfill and 24% was used for energy recovery, thus wasting 88% of the initial raw material, namely oil.
European legislation on plastics
Today, EU legislation is stricter . Examples include:
- la Waste Framework Directive (2008/98/EC Waste Framework Directive – Regulations and 2020 targets on waste prevention, reuse, recycling and other forms of recovery)
- la Landfill Directive (1999/31/EC Intermediate and long-term objective for the gradual reduction of biodegradable waste in landfills)
- i End-of-Life Vehicle Regulations (ELV)
All this, combined with increasing environmental awareness and the constant decrease in oil reserves, means that companies around the world are increasingly willing to use eco-friendly alternatives to synthetic plastics and invest in bioplastics.
The bioplastic alternative: the challenge and the opportunities
In recent decades, companies and researchers have sought different solutions to the predominant use of conventional plastic, but also to natural products (such as, for example, coconut, straw, sisal, jute) of limited use and poor performance.
A considerable amount of research has concerned bioplastics , materials developed by incorporating entirely or partially resources derived from renewable biomass (such as, for example, oil and natural fibres obtained from plants).
Undoubtedly, they present clear advantages :
- they have one structure and properties similar to traditional plastics, while being 100% eco-friendly and with additional end-of-life options (recycling and degradability)
- boast better performance than natural alternatives as they are 500% lighter and have 300% greater control over biodegradation time.
However, despite the numerous environmental benefits, the diffusion of bioplastics stops at only 0,1-0,2% of the European plastics market , with most of its applications limited to packaging and waste collection bags (86%).
The reason is simple. Even though consumers are demanding eco-friendly products and manufacturers are now ready to integrate them into their business operations, the costs are still there.
Today the main challenge is to provide innovative bioplastics at reasonable costs, while maintaining high performance.
BIOPLAS PRO: High-performance bioplastic products
Our solution: an eco-friendly line that doesn't compromise
BIOPLAS PRO represents our green answer to the use of plastic.
It is based on a technology that combines unique chemical formulations, composed of a mix of biopolymers (bio) and synthetic polymers. In Sineco International we worked on a innovative process to create BIOPLAS PRO, giving life to a bioplastic version of the synthetic products currently existing in the catalogue.
Regarding the technological maturity of the product – as defined by the European Commission in the document “ Technology readiness levels (TRL), HORIZON 2020 ” – today BIOPLAS PRO has reached the TRL6 level.
We want to reach the highest level : the TRL9 grade . To do this, we have set several specific objectives, divided into technical and commercial areas.
Technical objectives
- Optimization and qualification (TRL9) of BIO-MAT, BIO-DRAIN and BIO-CORE products
- Up-scaling of BIOPLAS PRO, from the current single process by extrusion and moulding of multifilaments by means of the pilot plant (TRL6) to the industrial one with production capacity of 15 Mm2 /year (TRL9).
- Integration of BIO-MAT, BIO-DRAIN, BIO-CORE into the product range Sineco International.
Business objectives
- Product introduction to the market in 2020
- Estimated sales: 13kton of products in the first 5 years, which will reduce plastic waste by 10kton and CO2 emissions by 32kton.
- Increased turnover: + 30 million euros of revenue in the fifth year of exploitation of the technology (with a ROI of 5,28).
- International dissemination of the BIOPLAS PRO project results among existing and potential customers, using our local and international network, to enable high market penetration of new products.
BIOPLAS PRO: the impact on our company
In Sineco International we strongly believe in this project. We think that BIOPLAS PRO will allow us to strengthen our market position and brand value, as it offers consumers a sustainable and concrete response.
Our business plan indicates that 13 tons of products will be produced and sold between 2020 and 2024. This will generate €30 million in revenue and at least 20 full-time positions in our company . At the same time, using biopolymers (bio) will reduce the amount of plastic waste by 10 tons and CO2 emissions by 32 tons.
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