The first non-toxic bio-based polymer resin to revolutionize the wood panel industry

Project Information

SWOP

Grant agreement ID: 878880

DOI

10.3030/878880

Project closed

EC signature date 28 October 2019

Start date 1 November 2019

End date 30 April 2023

Funded under

• Horizon 2020 Framework Programme

Total cost

€ 3 043 857,52

EU contribution

€ 2 249 687,00

Coordinated by

PLANTICS HOLDING BV
Netherlands

Periodic Reporting for period 7 - SWOP (The first non-toxic bio-based polymer resin to revolutionize the wood panel industry)

Reporting period: 2022-11-01 to 2023-04-30

Summary of the context and overall objectives of the project

Across huge industries, like the construction and wood industry, formaldehyde-based polymer resins are used in large volumes as binders to keep together materials and components to produce stable and durable products. Such oil-based resins, however, pose a large societal and environmental burden, as these are toxic, carcinogenic, non-recyclable, and have a large CO2 footprint. Due to increased problem recognition and recently introduced regulations, these industries actively seek for alternatives. However no safe, bio-based and cost-competitive resins are currently available that meet the functional requirements for a strong and durable material, until now. Plantics has developed a strong, 100% bio-based, recyclable and safe (no formaldehyde or other toxic components) alternative with a carbon footprint that is 5 to 7 times lower compared to existing resins. This new group of bio-resin are biopolymers of which the raw materials are abundantly available, making production of the resin cost-competitive to existing oil-based resins. It is ready to replace toxic and polluting resins, starting with binders in the wood industry. The SWOP consortium, consisting of 3 industrial parties and 1 NGO, has been established to realize and accelerate market entry of revolutionary wood panels with the resin as a binder. As a result of this project, these wood panels will be commercialized by a leading wood panel manufacturer, and used by a Dutch circular furniture manufacturer, for formaldehyde-free kitchens. A research and consulting organization for the wood industry will perform studies to measure the health and environmental effects of a shift to using the Plantics bio-resins. This 3,5-year project will accelerate market entry (2023), stimulate the European economy and while doing so address European health and environmental goals.

Objectives:
1. Finalize development and production scale-up of the Plantics bio-resins,
2. Finalize development and production scale-up of the -Plantics bio-resin wood panels
3. Test the product in a complex end-product setting – kitchen furniture
4. Conduct health assessment to evaluate the production safety and life-cycle of Plantics bio-resin wood panels
5. Fast initiation of commercialization of Plantics wood panels and perform related dissemination activities to potential customers and other stakeholders.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The production process for the base resin has remained unchanged since its initial development in the early stages of the SWOP project. Several additional batches of resin have been produced using the procedure established at the start of the project. Progress has been made in recycling off-spec resin, with the implementation of a 200L pilot reactor. This pilot reactor serves as the final step before incorporating the recycling process into full-scale 7t resin production. However, as the pilot reactor test was conducted at the end of the SWOP project, no results are currently available regarding how this recycled resin behaves in wood applications.

Plywood can now be produced at Koskisen thanks to developments made on the resin and the process. Several batches of plywood with both wet glue and impregnated paper have been produced at Koskisen. The mechanical properties of the panels are reaching the right specification. Plywood panels have been used in the kitchens. The last steps are being taken to get the product ready for market.

Two types of Plantics Wood panels have been used in kitchens: particle boards for the corpus, finished with a 2mm hemp composite, and unfinished plywood panels for the kitchen back walls. One of the major challenges encountered in kitchen production was achieving tolerance in thickness within a chipboard and between chipboards. To address this, panels were sorted by thickness, and new CNC production drawings were created based on the three most common thicknesses of panels.

A new formaldehyde measurement campaign was conducted to further investigate the results obtained in the previous measurement campaign. Additionally, the life-cycle analysis (LCA) of chipboards and plywood has been completed, resulting in the writing of the LCA report. Furthermore, the policy landscape analysis has been finalized, and the final report has been written.

Efforts were made to connect consortium partners with potential users, update the business plan, and establish commercialization agreements. Furthermore, novel spin-off opportunities developed within the project were leveraged.

Quarterly meetings and recurring teleconferences were organized. Regular reports were submitted to ensure continuous communication and progress tracking within the project.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The unique technical solution of the Plantics bio- resins provides superior safety and environmental effects when compared to all competitive techniques. These features are provided by the world’s first thermoset biopolymer that is 100% bio-based. The resin provides multiple features meeting the market demands. The product is safe (no toxic gases when manufactured or burned), environment-friendly (reduction of CO2 emission and recyclable) and cost-competitive (abundant raw materials), thereby having the potential to realize widespread implementation in the wood panel industry. We are delivering a sustainable alternative for which customers are willing to pay a “green-premium” and still it competes economically with conventional fossil-based resins. The technology used in the wood panels represents a unique innovation and beyond-state-of-the-art solution, that provides:
• Safety - For occupational health (wood industry employees) and end-product users
• Sustainability – In production (oil independent, not infringing with food industry) and breakdown (recyclable). Investing in the technology will also pave the way for expansion of the technology into the floriculture-, packaging-, and insulation-markets in the future.

The consortium and its vision