Biodegradable and compostable foamed packaging from renewable resources
Given their ubiquitous nature, the typically synthetic origin of many packaging materials has raised important environmental concerns. The EU-funded project REBIOFOAM developed a sustainable process to make biodegradable packaging from renewable materials, (i.e.starch and water). Energy consumption is minimised by using efficient microwave heating to induce expansion and foaming of a starch-based biopolymer through vaporisation of the water content in the polymer itself. Expansion occurs within the microwave mould cavity such that the biopolymer achieves the desired 3D shape. REBIOFOAM, thanks to the involvement of the whole supply chain, produced two demonstrators, a port hole spacer for washing machines and a corner piece for packaging applications. Both achieved target densities and demonstrated good physical and mechanical properties when compared to reference expanded polystyrene (EPS). A fully automated semi-industrial pilot line has been developed, which is able to produce foamed samples with density 40-45 kg/m3. REBIOFOAM materials can be used as protective packaging materials and its adoption and commercialisation are expected to have major environmental and economical benefits related to decreased energy consumption and when the complete biodegradability and compostability, in combination with the specific mechanical properties of the materials, is an added value for the selected applications.
