BUGWORKERS

New tailor-made PHB-based nanocomposites for high performance applications produced from environmentally friendly production routes

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 Obiettivo del progetto (Objective)

'The project aims to develop a new cost-competitive and environmentally friendly bionanocomposite material based on the combination of a polyhydroxybutyrate (PHB) matrix with new chemical, structure produced by new fermentation culture technology with two types of nanofibres,cellulose whiskers and lignin-based, in order to have a true alternative to engineering materials in two main sectors: household appliances, computers & telecommunications. To fulfil this global objective, current limitations of PHB polymers and their composites will be overcome using a synergic combination of different approaches: •A tailor-made PHB biopolymer structure obtained using new fermentation culture conditions, i.e, by synergic combination of different media and precursor feedings (specific sugar blends) obtained from hydrolyzed bio-mass, being able to select a structure to provide a PHB with enhanced functionalities (improved thermal and chemical properties, cellulose compatibility, processing, higher impact,..) in comparison with commercial ones. •To improve the cost competitiveness of PHB biopolymer by optimization of the fermentation process (increasing yield) and the use of lingo-cellulose biomass and other industrial by-products as fermentation feedstock. It will be no competition with food supply. •Development of cellulose whiskers and lignin nanofibres using enzymatic production routes with new functionalities (antimicrobial, flame retardant and self-assembly) from wood waste. •Compounding of new PHB with a synergic combination of both types of nanofibres and long natural fibres, using the planetary multi-screw extruder for improved nanofibres distribution, reducing thermal degradation,improve matrix-nanofibre interphase and introduction of coupling agents by reactive extrusion. •Development of multilayer structures (co-extrusion and co-injection) in order to obtain multifunctional material properties to improve the final performance of plastic parts in select sectors.'

Introduzione (Teaser)

Polyhydroxybutyrate (PHB) is a biodegradable polymer formed from renewable resources, namely fermentation processes in several kinds of bacteria. Scientists have now overcome the main obstacle to using PHB: poor mechanical properties.

Descrizione progetto (Article)

Plastics are made from petroleum that is in increasingly shorter supply. They are not biodegradable and, although they are largely recyclable, recyclation is not always energy efficient. Scientists significantly improved the functionalities of the promising biopolymer PHB through modifications in the fermentation process and reinforcement with bio-based nanofibres.

Work on the EU-funded http://www.bugworkersproject.eu/ (BUGWORKERS) (New tailor-made PHB-based nanocomposites for high performance applications produced from environmentally friendly production routes) project led to a cost-effective and environmentally friendly bio-nanocomposite targeted for household appliances, computers and telecommunications devices.

Investigators successfully developed a route to a tailor-made PHB biopolymer structure with improved functionalities compared to commercially available PHB. These include enhanced thermal and chemical properties, better compatibility with cellulose fibres, greater ease of processing and higher resistance to impact.

The precursor sugar blends that were fed to the bacteria played a critical role. They were obtained from hydrolysed wheat straw as agricultural waste, both cost effective and non-competitive with food production. Optimising the combination of culture media and precursor feeds led to high yield of improved PHB.

Researchers also developed economically feasible processes to yield cellulose nanowhiskers and lignin nanofibres with new functionalities from lignocellulosic wood waste. Enzymes are nature's catalysts and the team used green enzymatic processes to separate out the wood biomass components and produce nanofibres with antimicrobial, flame retardant and self-assembly properties.

Using standard extrusion and injection processes, the team successfully produced complex multi-layer parts using PHB and both types of fibres. The parts demonstrated significant improvements in mechanical properties. Demonstrator components for four different industrial case studies were produced.

Rising petroleum prices along with the need for sustainable alternatives to conventional plastic could ensure faster commercialisation of BUGWORKERS bio-nanocomposites. These fully biodegradable eco-friendly products made from renewable non-food resources could find wide-ranging applications that include packaging and biomedical systems. Major benefits are expected for manufacturers, consumers and the environment.