A new offer of plant-based resins for the

plastics industry
L. MENTINK
Product Manager ROQUETTE

6th EUROPEAN BIOPLASTICS CONFERENCE

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Content

About ROQUETTE Group

Gaalene : a new starch-based resins range

Carbon footprint and environmental properties

Main technical properties of these resins

Applications and uses

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

About Roquette Group

Roquette - Lestrem (France)

Employees :

6 600

Turnover :

2.5 Billion

Worldwide :

Presence in more than 100 countries

Natural Raw Materials :

7 Million tons / year (100% plant based)

Product range :

700 types of products from starch

Production sites:

18 (Europe, United State, Asia)

R&D :

300 researchers

R&D Budget :

More than 50 Million

Roquette is one of the world leaders in starch industry

Human Nutrition

Pharmaceuticals / Cosmetics

Animal Feed

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Paper & Specialties

New products portofolio resulting

from Roquette innovation programs

Green Chemistry

New monomers and

biotech processes

New plant-based resins

for the plastic markets

Nutrition & Health

New functional ingredients

for food and pharmaceutical
markets

New microalgae-based
additives and ingredients

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Roquette new offers for the plastics industry

Renewable Plant Productions

Wheat, Maize, Potato, Pea

Bio-refined starch products

Natural Polymers

Monosaccharides

(Native or modified)

(glucose, dextrose, polyols)

Green Chemistry,
Functionalization

Green Chemistry,
White biotechnology

Starch-based monomers

Gaalene

( isosorbide, succinic acid )

Thermoplastic resins

Plastic converters

Starch-based plasticizers

Chemical companies

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

. in response of customers needs for

more ecofriendly products

Case of Sustainable consumption in France

Study Ethicity / Ademe - March 2011

Buy a sustainable product, is first:

A product produced localy : 51%
A product that respects the environment : 34%
A product with a low cost during use : 31%
A product that meets a real need : 29%

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

 and as source of innovation for brand owners

Coca-Cola Plant-Based Journey

Coca-Cola November 2009

Volvic September 2010

Sundown 2011 / 2012

Brand owners communicate on plant origin rather than end of life

Plant-based is used in press / media rather than bioplastic
A medium level of bio-based content in the products is retained.

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Availabity of arable land in the world

Study conducted in 2009

(French Gouvernment request)
''The amount of land used in cultivation and not yet
cultivated are extensive across the world, especially in
South America and Africa.''
The world's arable land appears much higher than the
area needed to ensure food security of humanity.''

Availability of arable
land for the security
of mankind
2009

''This conclusion remains true even in adopting the

assumption of relatively slow growth in yields, according
to a scenario of a sustainable green revolution", even
excluding the cultivation of all forests and all the areas
currently protected and even taking into account the
plausible effects of global warming.'

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

What is Gaalene ?

PLANT-BASED PLASTICS

Durable

Biodegradable

(Recyclable)

(Compostable)

Green PE
Green TPU, Green PET
PA11, PA6-10
PTT

PLA
Compounds PLA
Compounds Amidon
Compounds cellulose
PHB / PHBV

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

What is Gaalene ?

TECHNICAL

SUSTAINABLE

LOCAL

NATURAL
6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

22

Starch : the second most abondant polymer in Nature

Starch = Energy storage form in plants thanks to photosynthesis

Starch = Polymer of Glucose ((2R, 3S, 4R, 5R)- 2, 3, 4, 5, 6-pentahydroxyhexanal).
Starch = Natural mixture of 2 types of :

AMYLOSE :
[p~0, n~300] Mw ~ 0.1 million daltons

AMYLOPECTINE : [p,n]A,B,C
Mw ~ 50-500 millions daltons

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

today used to produce different types of bioplastics

Starch from Renewable Plant Productions

Blends by extrusion
(granular starch or TPS)

Functionalisation
Grafting

Hydrolysis

Glucose
Starch compounds
and
Starch blends

Gaalene
resins

Green Chemistry
White biotechnology

Building blocks

Bacterial Polymers

(lactic acid, succinic acid)

Polymerisation

Extraction
Purification

PLA , PBS, PC

PHB , PHBV

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Gaalene resins : fully integrated in Roquette portofolio

M

AI
ZE

GERM CAKE

BRAN

T
EA

WHEAT GLUTEN
CORN STEEP
LIQUOR

OIL
FIBRE
AND GUMS

MODIFIED
CYCLODEXTRINS

CYCLODEXTRINS
CORN

FIBRE

XYLITOL

LIQUID
SORBITOL

GLUTEN FEED

MANNITOL

STARCH SLURRIES
GLUCONO-DELTALACTONE

MAIZE
GLUTEN MEAL
HYDROLYSATE

GLUCONATES
AND LACTATES
MANNOSE

PROTEIN

PREGELATINISED
STARCHES

GLUCONIC
ACID

PULP

LACTIC ACID
NATIVE STARCHES

SORBITOL
POWDER
EXTRUDED
STARCHES

MODIFIED

TO
TA
PO PEA

LIQUID
SORBITOL

DEXTRINS

STARCHES
GRAFTED
STARCHES

GLUCOSE

MALTO DEXTRINS

SYRUPS
CATIONIC AND

CARAMEL COLOUR

GAALENE
RESINS

ANIONIC STARCHES
OXIDISED
GLUCOSE SYRUPS

LYCASIN
MALTITOL
SYRUPS
MALTITOL
POWDER

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

DEXTROSE

ISOSORBIDE

A contribution towards a better environment

Gaalene starch-based resins means :

1.

Non GMO bio-based origin,

2.

Local farming from plants well adapted to our climates (wheat) without irrigation,

3.

Excellent yields of production (low farmland used) allowing crop rotations beneficial to the soil,
flora and fauna,

4.

Joint production of very high nutritional value products (proteins, fibers) for use in human food
(bread, pasta, etc.) and animal feed :
1 ton of Gaalene allows the joint production of 0.3 tons of nutritional products

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Comparative ecoprofil of plastics

0,45

Including photosynthesis, the Carbon footprint of Gaalene resins is very

interesting (less than 0.45 kg CO2 eq./kg )
This is a great reduction of CO2 emissions compared to usual plastics
( -70% compared to polyolefins and - 90% compared to ABS).

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Gaalene : fully recyclable in polyolefin streams

The production scraps can be recycled directly after

grinding in industrial units.

At end of life, Gaalene resins can be sorted easily with NIR technology
(demonstration conducted with company Pellenc Technologies)

Resins recovered can be reused alone or

mixed with polyolefins.
In this case, the mechanical properties remain
good even after at least 5 cycles of injection.

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Value creation with Gaalene resins

Gaalene resins have specific

properties and offer new
functions.

Va

lue
c

rea
tio

New properties
Environmental
benefits
Basic properties

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Gaalene resins allow important

environmental benefits.

Gaalene resins have adapted

mechanical properties.

Gaalene resins main properties

Gaalene resins
Density

1.10 to 1.12

MVR (190
C / 10kg)

40 to 110 cm3/10min

Flexural modulus

7,80
2,80

1,30

400 to 1300 MPa

Elongation at break

1,24

1,20

1,15

1,10

1,07

1,05

70 to 900 %

Charpy notched impact strength

5 to 13 KJ/m2

HDT B (0,45MPa)

50 to 90 C

Cristallinity (DSC)

15 20 %

Biobased content

52% min

A wide range of properties.

A rheology adapted to the main conversion processes
Low density (- 30% compared to PLA or starch compounds)

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

0,91

Mechanical properties of Gaalene resins

4000

PLA

3500

PHB
PS

Modulus (Mpa)

3000

2500

2000
GAALENE
734 PJ

1500

PP

1000
PBS

GAALENE
906 PF

HDPE

500
PCL

LDPE

0
0

100

200

300

400

500

600

700

Elongation at Break (%)

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

800

900

1000

Many opportunities for finishing

Visual finish possibilities :

Tactile possibilities :

Coloration
Paint

Soft touch
Grip

Printing
Gluing,

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Shock absorber

Gaalene resins range for various applications

Gaalene resin references are compatible with :

Thin films from mono to multi-layers by extrusion blowing
Molded parts by injection, directly of after compounding,
Bottles by extrusion blow molding.

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Bio-based films with Gaalene resins

Monolayer or Multi-layer
Carrier bags

Printed shrink films

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Multilayer Laminated
Stand-up packaging

Injection molded parts with Gaalene

Technical parts based on

Gaalene /glass fiber compounds

Injection molded containers

with Gaalene

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Bottles produced with Gaalene resins

Extruded and Co-extruded Bottles

with Gaalene

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

Waste basket designed with Gaalene

Elise by Starck,
The professional solution for sustainable development

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011

THANK YOU
FOR YOUR ATTENTION
www.gaialene.com
Gaalene Awarded

NOVA INSTITUTE COPERION - March 15th 2011

6th EUROPEAN BIOPLASTICS CONFERENCE- November 2011