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    Material Biopolymers

    Biopolymers are polymers that are

    generated from renewable naturalsources, are often biodegradable, andnot toxic to produce.

    They can be produced by biologicalsystems (i.e. micro-organisms, plantsand animals), or chemically synthesizedfrom biological starting materials (e.g.sugars, starch, natural fats or oils, etc.).

    Biopolymers are an alternative topetroleum-based polymers (traditionalplastics).(Bio)polyesters have properties similarto traditional polyesters.

    Starch-based polymers are often a blendof starch and other plastics (e.g PE),which allows for enhancedenvironmental properties.

    PolyestersBiopolymer type

    Price(DKK/kg)

    Density(kg/liter)

    Aliphatic-aromatic

    copolymer - -

    Aliphatic polyesters - -

    CPLA 25-50 1.25

    PCL - -

    PHA 15-60 1.25

    PLA 30-70 1.26

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    Starch-based

    polymers Biopolymer type Price (DKK/kg)Density(kg/liter)

    10 % Starch - -

    50 % Starch - -

    90 % Starch 20-40 -Foamed starch - -

    OthersBiopolymer type

    Price(DKK/kg)

    Density(kg/liter)

    Casein

    formaldehyde- 1.33

    Celluose acetate - -

    Horn - -

    Environ-

    mentals

    notes

    Some polymers degrade in only a few weeks, whileothers take several months.Biodegradability and other plastic propertiesstrongly depend on the polymer structure. By

    changing the structure, these properties can bealtered.

    Price The above-mentioned prices are from December1997.The price of biopolymers is still fairly highcompared to oil-based polymers. This is due tolower production-volumes than petroleum-basedpolymers.However, the growing environmental

    consciousness and the application of life-cycleevaluations in the material circuit may helpbiomass-based raw materials to becomemass-produced and cheaper, replacing traditionalplastics in a number of applications.Significant price reductions can be expected withinthe next two years.

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    References Links:Biodegradable Polymers and Plastics in Japan

    DTI, Centre for Product Development

    GBF - Enviromental Biochemical Engineering

    Proterra - International Centre for Agro-based

    MaterialsHow green are green plastics?

    Companies:Biotec GmbH

    National Starch & Chemical

    Books, Magazines & Papers:

    Biopolymers (journal)Biopolymers (paper)

    Photo Thomas Nissen (Computer graphics)

    Copyright 1997-2001 Torben LenauThis page is part ofDesign inSite

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    Horn

    Return tomaterials description

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    Material Aliphatic-aromatic copolymer

    This copolymer combines the excellentmaterial properties of aromatic PET, andthe biodegradability of aliphaticpolyesters. It is soft, pliable (producinglow noise) and has a good touch.Melting-points are high for a degradablematerial (around 200C).

    Depending on the application, up to three

    aliphatic monomers are incorporated intothe PET structure. The monomers createweak spots in the polymeric chains,thereby making them susceptible todegradation through hydrolysis.

    Applications include disposal bags,

    diapers and eating utensils. It can be usedto create geo-textiles and plant pots, andit is suitable for thermoformed blownbottles and injection moulded objects.

    Category Biopolymers

    Processes Blow mouldingInjection moulding

    Extrusion

    References DupontGBF - Enviromental Biochemical Engineering

    Price It is only marginally more expensive to produce thanPET itself because it can be manufactured withexisting equipment using existing bulk monomers.Currently available degradable materials can cost

    twice as much.

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    Environmen-

    tal notes

    Disposal: It can be recycled, incinerated or landfilled,but is intended mainly for disposal composting andin-soil degradation. If properly disposed, it degradesin eight weeks.The large polymer molecules are cleaved by moisture

    into smaller molecules, which are then consumed bynaturally occurring microbes and converted to carbondioxide and water.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material Aliphatic polyesters

    Aliphatic polyesters have propertiessimilar to those of PE and PP. They areodorless and can be used for trash bags,diapers, and cosmetic and beveragebottles.

    They can be processed on conventionalprocessing equipment at 140-260 C, inblown and extruded films, foams, and

    injection moulded products.

    Aliphatic polyesters are biodegradablebut often lack in good thermal andmechanical properties. Vice versa,aromatic polyesters, like PET, haveexcellent material properties, but are

    resistant to microbial attack.Category Biopolymers

    Products Pot for plants

    Processes Blow mouldingInjection moulding

    Extrusion

    Similar

    materials

    PET (aromatic polyester)

    References Showa Highpolymer Co. Ltd. (Bionolle)

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    Environmen-

    tal notes

    Creation: Made from polycondensation reaction ofglycol and aliphatic dicarboxylic acids. Bothcomponents can be obtained from renewableresources (e.g. glycol from glycerol by fermentation).

    Disposal: It biodegrades to water and carbon dioxidein soil as well as fresh and ocean water areas.The rate of degradation depends on grade, shape ofthe product, and level of microbiological activity.Typically, degradation of a 0.04 mm thick film takestwo months.When coated with coconut-shell powder, and buriedin soil, it decomposes within five days. In fact,coconut-shell powder absorbs water and swells,

    helping microorganisms to live on the biodegradablefilm.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material CPLA - Polylactide aliphatic copolymer

    Biodegradable CPLA is a mixture oflactide and aliphatic polyesters. It can beeither a hard plastic (similar to PS) or asoft flexible one (similar to PP)depending on the amount of aliphaticpolyester present in the mixture.

    Possible applications will includecompost bags, cushioning materials, food

    wrapping materials, fishing nets, etc.It is easy to process with stability up to200 C.

    Category Biopolymers

    Processes Most conventional plastic processes like:Blow moulding

    Injection moulding

    Extrusion

    Vacuum forming

    Fibre spinning

    Similar

    materials

    Aliphatic polyesters

    References Dainippon Ink and Chemicals Inc. (DIC)

    Price DIC plans to produce several tons per year at a priceranging from 25 to 50 DKK/kg.

    Environmen-

    tal notes

    Creation: CPLA is made by copolymerising lactide(made by fermenting cornstarch, cheese whey, etc.)with aliphatic polyester (e.g dicarboxylic acid orglycol made from fermentation of glycerol). All arerenewable resources.

    Disposal: If incinerated, no toxic substances aregenerated.The heating value and carbon dioxide generatedduring combustion are lower, by almost half thelevel, of that generated by PE or PS.

    Although CPLA has a high molecular weight and

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    high melting-point, it begins breaking down into alow-molecular weight polymer, in naturalenvironments, after 5-6 months. Completedecomposition after 12 months.When composted with food garbage, it beginsbreaking down into a low-molecular weight after 2weeks.

    Additional

    Info

    CPLA does not dissolve in alcoholic solvents, oils,and diluted solution of strong acids. It does dissolvein aromatic hydrocarbon, concentrated acids, andcaustic soda.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material PCL - Polycaprolactone

    Polycaprolactone is a biodegradablethermoplastic polymer derived from thechemical synthesis of crude oil. Althoughnot produced from renewable rawmaterials, it is fully biodegradable.

    Polycaprolactone has good water, oil,solvent and chlorine resistance. It has alow melting-point (58-60 C) and low

    viscosity, and it is easy to process.

    It is used mainly in thermoplasticpolyurethanes, resins for surface coatings,adhesives and synthetic leather andfabrics. It also serves to make stiffenersfor shoes and orthopedic splints, and fully

    biodegradable compostable bags, sutures,and fibres.

    Category Biopolymers

    References Solvay Caprolactones (CAPA)Union Carbide Corp. (Tone)

    Environmen-

    tal notes

    Disposal: Fully biodegradable.

    The low melting-point makes the material suited forcomposting as a means of disposal, due to thetemperature obtained during composting routinelyexceeding 60 C.

    Degradation time is very short. In Sweden there hasbeen an attempt to produce PCL bags, but theydegraded before reaching the customers.

    Additional

    Info

    Polycaprolactone is often mixed with starch to obtain

    a good biodegradable material at a low price (~20DKK/kg lower than other aliphatic polyesters).The mix has been successefully used for making trashbags in Korea (Yukong Company).

    Photo Thomas Nissen (Computer graphics)

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    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material PHAs - Polyhydroxyalkanoates

    PHAs are linear polyesters produced innature by bacterial fermentation of sugaror lipids.More than 100 different monomers canbe combined within this family to givematerials with extremely differentproperties.

    They can be either thermoplastic or

    elastomeric materials, withmelting-points ranging from 40 to 180C.The most common type of PHAs is PHB(poly-beta-hydroxybutyrate). PHB hasproperties similar to those of PP, howeverit is stiffer and more brittle.

    A PHB copolymer called PHBV(polyhydroxybutyrate-valerate) is lessstiff and tougher, and it is used aspackaging material.

    Category Biopolymers

    Products Bone plateRazor, biodegradable (PHA)

    Shampoo bottle, biodegradable (PHBV)

    Surgical sutures

    Processes Blow mouldingInjection moulding

    Extrusion

    Keywords PHBPHBV

    References Monsanto Company (BiopolTM)PHB production

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    Price The price (1997: 15-60 DKK/kg) is very highcompared to other oil-derived polymers.Prices are thus falling down (1993: 100-140 DKK/kg)and, in a couple of years they could reach a levelwhich would enable mass-production (2-6 DKK/kg).

    Environmen-

    tal notes

    Creation: Made from renewable natural sources likesugar.

    Use: It is biocompatible and therefore can beimplanted in the body without causing inflammations.The producer claims that is not toxic.

    Disposal: It biodegrades in microbially activeenvironments in 5-6 weeks.

    The action of some enzymes produced by microbssolubilises PHB which is then absorbed through thecell wall and metabolised.

    PHB is normally broken down to carbon dioxide andwater when degraded in aerobic conditions. Inabsence of oxygen the degradation is faster, andmethane is also produced.PHB is not degraded in biologically inactive systemssuch as sanitary landfills.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material PLA - Polylactide

    PLA is a biodegradable thermoplasticderived from lactic acid.

    It resembles clear polystyrene, providesgood aesthetics (gloss and clarity), but itis stiff and brittle and needs modificationsfor most practical applications (i.e.plasticizers increase its flexibility).

    It can be processed like mostthermoplastics into fibres, films,thermoformed or injection moulded.Used for compost bags, plant pots,diapers and packaging.

    Category Biopolymers

    Products Compostable bag

    Processes Most conventional plastic processes like:Blow moulding

    Injection moulding

    Extrusion

    Vacuum forming

    Fibre spinning

    References Neste Corporate TechnologyCargill Dow Polymers LLC

    Price Current prices (1997) are between 40 and 70DKK/kg.

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    Environmen-

    tal notes

    Creation: Lactic acid can be obtained on the basis ofrenewable starch containing resources (e.g. corn,wheat or sugar beat) by fermentation, or by chemicalsynthesis of non-renewable resources.

    Disposal: If composted properly it takes 3-4 weeksfor complete degradation.The first stage of degradation (two weeks) is ahydrolisis to water soluble oligomers and lactic acid.The latter, as a naturally occurring substance, is arapid metabolisation into CO2, water and biomass bya variety of micro-organisms.

    Additional

    Info

    The future tendency is towards a sharp decrease ofthe price, thanks to the introduction of plants capable

    to mass-produce the material. Future prices areexpected to fall to few times the price of PP (15-20DKK/kg).

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material 10 % Starch

    Starch can be used as biodegradableadditive or replacement material intraditional oil-based commodity plastics.

    If starch is added to petroleum derivedpolymers (e.g. PE), it allowsdisintegration of the blend, but not itsbiodegradability.

    CategoryBiopolymers

    Products Compostable bags

    Environmen-

    tal notes

    Disposal: Starch can in theory accelerate thedisintegration or fragmentation of the syntheticpolymer chains.Microbial action consumes the starch, therebycreating pores in the material, which weaken it andenable it to break apart.

    Disintegration of starch-plastic blends is not the sameas biodegradation.Their breakdown, also under optimal conditions, isquite slow. Starch content needs to exceed 60%before significant material breakdown occurs.

    Additional

    Info

    In 1993 LDPE-starch blends were commercializedunder the trade name Ecostar

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material 50 % Starch

    Also called plastified starch materials.They exhibit mechanical propertiessimilar to conventional plastics such asPP, and are generally resistant to oils andalcohols, however, they degrade whenexposed to hot water.

    Properties of these materials can bevaried as the content of starch and other

    materials changes.They are fully biodegradable andcompostable, and they can replacetraditional plastics in food service, foodpackaging, personal health care, etc.

    Their basic content (40-80%) is corn

    starch, a renewable natural material. Therest is performance-enhancing additivesand other biodegradable materials.

    Category Biopolymers

    Products Pen, biodegradableGolf teesTrash bags

    Processes Most conventional plastic processes like:Blow moulding

    Injection moulding

    Extrusion

    Thermoforming

    References Novamont S.p.A. (Mater-Bi)

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    Environmen-

    tal notes

    Creation: Made of renewable natural sources(starch).

    Disposal: When disposed in biologically activeenvironments such as composte facilities and

    wastewater treatments systems, they displaydegradation characteristics similar to leaves, woodchips and paper.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material 90 % Starch

    Usually referred to as thermoplasticstarch.They are stable in oils and fats, however,depending on the type, they can varyfrom stable to unstable in hot/cold water.They can be processed by traditionaltechniques for plastics.

    These materials consist mainly (>90%) of

    starch obtained from renewable naturalsources. Colouring and flame retardantadditives are possible.

    Category Biopolymers

    Products Starch-based tubeDegradable compost bagsAgricultural mulch filmGolf tees

    Processes Most conventional plastic processes like:Blow moulding

    Injection moulding

    Extrusion

    Thermoforming

    References Biotec GmbH (Bioplast)

    NOVON International (NOVON)

    Price Prices vary from 20 to 40 DKK/kg

    Environmen-

    tal notes

    Creation: Made of renewable natural sources.

    Disposal: Depending on the grade, thermoplasticstarch can degrade completely within five days inaqueous aerobic testing and in 45 days in a controlled

    compost, or can even decompose in water.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material Foamed starch

    Starch can be environmentally friendlyblown into a foamed material using watersteam.

    Foamed starch is antistatic, insulating andshock absorbing, therefore a goodreplacement for polystyrene foam.

    It can be used as packaging material or

    can be pressed into starch-based sheet forthin-walled products, such as trays,disposable dishes etc.

    Category Biopolymers

    Products Loose-fillDisposable cup

    Processes Water steam foamingExtrusion

    Cutting

    Moulding

    Similar

    materials

    Foamed PS

    References Biotec GmbH (Biopur)

    National Starch & Chemical (Eco-Foam)Norel (EnvirofillTM)

    Environmen-

    tal notes

    Creation: Foamed starch is 99% starch, which is arenewable resource found in corn, wheat, rice,potatoes, etc.Foaming is performed using water steam instead ofhydrocarbon-based blowing agents used for blowingPS.

    Disposal: It dissolves when soaked with waterleaving just a dilute corn starch solution. The solutionis not toxic and is consumed by microbial life inabout ten days, leaving only carbon dioxide andwater.

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    It can also be re-used, recycled, incinerated, orcomposted along with other organic materials, sinceit decomposes very quickly.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material Casein formaldehyde

    Casein formaldehyde is a plastic ofnatural protein origin, made from organicsubstances such as milk, horn orvegetable products such as soy beans,wheat, etc.

    It can be made to look like celluloid,ivory, or artificial horn.It is odourless, insoluble in water, and

    only with difficulty inflammable.

    In the first decades of this century, caseinformaldehyde was used to make buttons,pins, cigarette-cases, fountain pens,umbrella handles and radio cabinets.

    Category Biopolymers

    Products Button for clothesGramophone box

    References Plastic museum

    Environmen-

    tal notes

    Creation: Made from chemical modification ofcasein, which is a natural renewable resource.

    AdditionalInfo

    Casein formaldehyde was commercialised under thetrade names Galalith and Erinoid.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material CA - cellulose acetate

    Cellulose acetate (CA) is used fortransparent, translucent and opaqueobjects (e.g. typewriter keys, calculators,switches, car wheel coverings).

    Furthermore, it is especially suitable forcoatings applications requiring highmelting-point, toughness, clarity, andgood resistance to ultraviolet light,

    chemicals, oils, and greases.

    Cellulose acetate is an amorphousthermoplastic material belonging to thecellulosic resin family. It is obtained byintroducing the acetyl radical of aceticacid into cellulose (as cotton or wood

    fibres) to produce a tough plasticmaterial.

    Danish Name CA - celluloseacetat

    Category Biopolymers

    Products Knife-handleShoe-heel

    Lamp shadePenUmbrella handle

    References Plast og gummi stbi

    Environmen-

    tal notes

    Creation: Made from chemical modification ofcellulose, which is one of the most diffuse organicsubstances in nature.

    Use: Cellulose acetate is inflammable and burns witha yellowish flame producing a smelling smoke.Additive are often used to decrease its inflammabilityand to give the material self-estinguishing properties.

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    Additional

    Info

    First plastic to be injection moulded.Cellulose acetate becomes brittle at temperatureunder the freezing point.It is an insulator material and shows only a littletendency to electrostatic charging.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Material Horn

    It is an organic material containing 80%keratin. It is thermoplastic and can beworked after dry heating or immersion inboiling water or alkaline solutions.

    After softening it can be pressedobtaining objects and various laminas,such as tobacco containers, boxes,buttons, pens and combs. It was

    successfully applied, especially inEngland, before the advent of plastics.

    Danish Name Horn

    Category Biopolymers

    Environmen-

    tal notes

    Creation: Horn is natural organic material.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1998-2001 Torben LenauThis page is part ofDesign inSite

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    Aliphatic-aromatic copoly

    Return tomaterials description

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    Aliphatic polyesters

    Return tomaterials description

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    CPLA - Polylactide aliphacopolymer

    Return tomaterials description

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    PCL - Polycaprolactone

    Return tomaterials description

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    PHAs - Polyhydroxyalkan

    Return tomaterials description

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    PLA - Polylactide

    Return tomaterials description

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    Starch-based biopolymers% starch)

    Return tomaterials description

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    Starch-based biopolymers(40-80 % starch)

    Return tomaterials description

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    Starch-based biopolymers% starch)

    Return tomaterials description

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    Foamed starch

    Return tomaterials description

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    Casein formaldehyde

    Return tomaterials description

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    CA - cellulose acetate

    Return tomaterials description

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    Biopolymers are usuallyproduced from plants andoften biodegradable.

    Back

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    Products Compostable bag

    This compostable lawn and leaf bag ismade of PLA.It is designed expressly for collecting yardwaste as part of municipal compostingprogrammes, and offers an alternative tokraft paper collection bags.

    Like kraft paper lawn and leafs bags, thebiopolymer bags eliminate the need to

    separate bags from their contents atcompost sites. Both degrade and are easyto print on.

    Compared to paper bags advantages are:improved wet strength, better punctureresistance, visibility of content, ease of

    handling and closing, as well ascompactness which minimises storagerequirements.

    Category Outdoor equipment

    Materials PLA

    Processes Blow moulding

    References Cargill Dow Polymers LLC

    Keywords BiopolymerBiodegradableCompostingTransparent

    Price Competitive with the price of paper bags.

    Environ-mental

    notes

    Use: Bags designed only for degradation throughcomposting, and only for carrying leaves, grass etc.They should not be used for waste such as ashes etc.

    Disposal: The bag biodegrades along with the leaves,grass and wood chips inside it to create a rich, organichumus that can be used as a soil nutrient.

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    Similar

    products

    Pot for plants

    Copyright 1998 Torben Lenau

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    Process Blow moulding

    Used for hollow parts of all sizes. A tube ofmolten plastics is extruded into an openmould.The mould closes and thereby the bottomof the part welds.

    Hot air is blown into the tube and it is blown upuntil it fills out the mould cavity.

    Parts can be produced in small and large

    quantities, since setup cost is low andtools/moulds are often made of aluminium andcheap.

    Danish

    Name

    Blsestbning

    Category Mass conserving processes, Plastic moulding

    Materials PS ABS SAN PVC PC PE PP

    Typical

    products

    Bottle for motor oil

    Bottle for organic solvents

    Tubing for a car

    Competing

    processes

    Injection blow moulding

    References Dudek Plast A/SGravenhorst Plast A/SKornerup Plast Trading ApSRosti A/S

    Price

    notes

    Moulds can be produced at a relative low price. Setup times arelow.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1997, 1998 Torben Lenau

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    Process Injection moulding

    For parts of all sizes which require accurate andcomplex geometry.Granular plastic or pellets are melted by frictionwith a rotating screw and actual heating, and theninjected into the mould.

    Normally, the process is reserved tothermoplastics, but it can be used for shapingfibre reinforced thermoplastics or thermosettings.

    When shaping composites, parts with goodmechanical properties cannot be produced as thecontent of fibres must be limited.Production volumes are medium to large, and thecycle time per part is very short.

    Danish

    Name

    Sprjtestbning

    Category Mass conserving processes, Plastic injection moulding

    Materials PlasticsComposites

    Typical

    products

    Disposable drinking glass

    Hedge cutter

    MilestoneRazor, biodegradable

    Razor, ordinary

    Shaver, rechargeable

    Spoon, clasp type

    Satellite box

    Washing machine drum

    Gear

    Hinge for gramophone lidVideo front-panel

    Competing

    processes

    Extrusion

    Gas assisted injection moulding

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    References A. Johnsen Industri A/SHelarco

    Jotun Danmark A/S

    Molytex A/S

    Pricenotes

    The injection machine and the shaping mould are veryexpensive.

    Additional

    info

    Possible to achieve good dimensional accuracy and surfacefinish.

    Photo Thomas Nissen (Computer graphics)

    Copyright 1997, 1998 Torben Lenau

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    Process Extrusion

    Profiles of all shapes can be produced. In anextruder the material is heated and continuoslypushed by a rotating screw through a die with theshape of the profile. After the die, the profile iscooled by air or water and cut into desiredlengths.

    Production volumes are normally high.

    DanishName

    Ekstrudering

    Category Mass conserving processes, 2d plastic processes

    Materials Most plastics

    Typical

    products

    Garden hoseTubesMetal sheet edge protection

    RailingsIce cube plastic bag

    Potholder

    Competing

    processes

    Injection moulding

    Blow moulding

    Pultrusion

    Calandering

    References DKI Plast A/SVestfos Plast A/SGlim Plastic Industri ApS

    Photo Thomas Nissen (Computer graphics)

    Copyright 1997, 1998 Torben Lenau

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    Products Pot for plants

    This pot for plants is made of aliphaticpolyesters (Bionolle)

    Its biodegradability allows the plant to beplanted in soil with no need to extract itfrom its pot.

    Category Outdoor equipment

    Materials Aliphatic polyesters

    References Showa Highpolymer Co. Ltd.

    Keywords BiopolymerBiodegradableOutdoorRenewable resources

    Environ-

    mental

    notes

    See aliphatic polyesters

    Similar

    products

    Compostable bag

    Photo Showa Highpolymer Co. Ltd.

    Copyright 1998 Torben Lenau

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    Process Vacuum forming

    Well suited for larger plastic parts since toolsinvestments are low. Also used for high volumeproduction of e.g. disposable cups and chocolatepackaging. The surface facing the mould has thebest quality. Material thickness is difficult tocontrol.

    A sheet of thermoplastic material is heated to thesoftening point. The sheet is positioned over a

    mould with small air canals, and a vacuum pullsthe sheet into the mould.

    Vacuum is normally sufficient due to the lowstrength in the material being formed, but for amore complex geometry, additional air ormechanical pressure can be applied.

    Danish

    Name

    Vacuum formning

    Category Mass conserving processes, Plastic shaping

    Materials Most thermoplastics e.g. ABS PC PP PS PE

    Typical

    products

    Dolphin, bicycle trailer base part

    KimBox suitcase

    Appliance housingDisposable cupsCommercial signShaped packagingRefrigerator inside panels

    Competing

    processes

    Rotation moulding

    Blow moulding

    Injection moulding

    References Bramstoft & Wassmann ApSCretex A/SHelge Buch's Eftf. ApS

    Price

    notes

    Low tooling costs

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    Additional

    info

    Difficult to produce small details

    Photo Thomas Nissen (Computer graphics)

    Copyright 1996, 97, 98 Torben Lenau

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    Products Razor, biodegradable

    A double-bladed razor with replaceablehead. Handle and razor heads are made ofbiodegradable plastic.

    Danish

    Name

    Barberhvl, bionedbrydelig

    CategoryPersonal items, Personal care

    Materials PHA (handle and razor head)Stainless steel (blades)PS and paper (packaging)

    Processes Injection moulding (handle)Insert moulding (razor head)

    Packaging:Extrusion

    Vacuum forming

    References Kay Razor

    Keywords Personal accessoriesCutting functionShaveBiodegradablePlastic

    Price Retail price, for 1 handle with 5 razor heads (9/95)DKK 30,-.

    Environ-

    mental

    notes

    Materials / Production: The plastic is made frmrenewable resources.Use / Transport: The razor it self does not use energy,but use require water, soap and energy for heatingwater.Disposal: putrification or inceneration.

    Similar

    products

    Razor, ordinary

    Shaver, rechargeable

    Copyright 1997, 1998 Torben Lenau

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    Products Shampoo bottle, biodegradable

    This shampoo bottle is manufactured frombiodegradable PHBV plastic

    (commercially named BiopolTM).

    The biodegradable shampoo bottle is thefirst major product to be produced usingthis material.

    The closure is injection moulded and the

    bottle is blow moulded.

    Category Personal items, Personal care

    Materials PHBV

    Processes Injection moulding (closure)Blow moulding (bottle)

    ReferencesMonsanto Company

    Wella

    Keywords BottleBiodegradableBiopolymerPHBVBiopolTM

    Price Approximately 4 DKK/bottle (retail, 1995)

    Environ-

    mental

    notes

    Creation: The plastic is made from renewableresources using traditional production methods.

    Disposal: The bottle will degrade throughcomposting.

    Similar

    products

    Razor, biodegradable

    Photo Monsanto Company

    Copyright 1998 Torben Lenau

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    Products Pen, biodegradable

    This "green pen", with the exception ofthe ink refill, is made from the corn starchbased material Mater-Bi.

    It is very similar to an ordinary plasticpen, but degrades when disposed in acomposting site or in natural environment.

    Category Dwelling & office appliances, office equipment

    Materials Starch-based biopolymer (Mater-Bi)

    Processes Injection moulding

    References Novamont S.p.A.Enpac

    Keywords BiopolymerBiodegradablePen

    Office equipment

    Price Approximately 11 DKK (retail, 1997)

    Environ-

    mental

    notes

    Creation: The pen is made from renewable resourcesusing traditional production methods.

    Disposal: The pen will disintegrate in about 12months after being disposed.

    Copyright 1998 Torben Lenau

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    Products Starch-based tube

    This tube is made of corn starch, isenvironment-friendly and is designed todecompose in water.

    The tube is a direct alternative toconventional spiral-wound tubepackaging, including flexible plastics andcorrugated paper.The product can also be made in a variety

    of vibrant colours.

    Category Dwelling & office appliances, office equipment

    Materials Thermoplastic starch

    References American Excelsior Company

    Keywords BiopolymerBiodegradableStarchPackagingWater-soluble

    Environ-

    mental

    notes

    Creation: The tube is made from renewable resourcesusing traditional production methods.

    Disposal: The tube is designed to dissolve in waterafter use.

    Copyright 1998 Torben Lenau

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    Products Loose-fill

    This loose-fill for packaging industry ismade of foamed starch.

    It offers numerous disposal alternativesand can be a good substitute ofCFCs-blown PS.

    Category Packaging

    Materials Foamed starch

    Processes Water steam foaming

    References National Starch & ChemicalAmerican Excelsior Company

    Keywords BiopolymerBiodegradableStarchPackaging

    Water-soluble

    Environ-

    mental

    notes

    Creation: Made from renewable materials.Environment-friendly foaming process.

    Disposal: See foamed starch.

    Copyright 1998 Torben Lenau

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    Products Disposable cup

    The cup shown appears very similar tonormal PS disaposable cups, and diaplayssimilar characteristics as far as thermalinsulation and resistance to fluids areconcerned.

    Category Food, Food equipment

    Materials Foamed starch

    Processes Water steam foamingPressing

    References Biotec GbmH

    Keywords BiopolymerBiodegradableStarchPackaging

    Environ-mental

    notes

    Creation: Made from renewable materials.Environment-friendly foaming process.

    Disposal: Once disregarded, the cup will completelydecompose into useful compost.

    Copyright 1998 Torben Lenau

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    Products Button for clothes

    This buttons are made of caseinformaldehyde.They show the different decorationpossibilities that this material can give.

    Category Personal items, Clothes

    Materials Casein formaldehyde

    References Bottonificio Ontano

    Keywords BiopolymerDecoration3D decorationClothes

    Environ-

    mental

    notes

    Creation: See casein formaldehyde.

    Copyright 1998 Torben Lenau

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    Products Gramophone box

    The box housing this gramophone iscoated with a layer of caseinformaldehyde.

    The antique gramophone from 1950shows how casein formaldehyde can givea beautiful surface appearance.

    Category Dwelling & office appliances, Home electronics

    Materials Casein formaldehyde

    References Plastic museum

    Keywords BiopolymerDecorationHome electroniocs

    Environ-

    mentalnotes

    Creation: See casein formaldehyde.

    Copyright 1998 Torben Lenau