Issue 04/2016
bioplasticsMAGAZINE_1604
bioplasticsMAGAZINE_1604
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News<br />
BASF extends its portfolio of innovative foam<br />
solutions with ecovio EA<br />
BASF is expanding its range of high performance foam<br />
products with ecovio EA, an expandable, closed-cell foam<br />
material which is biobased and certified compostable.<br />
Largely biobased, it is made of BASF’s biodegradable<br />
polymer ecoflex and PLA, which is derived from corn or other<br />
sugar-generating plants such as manioc. This innovative<br />
patented particle<br />
foam offers properties<br />
similar to those of EPS<br />
and boasts outstanding<br />
energy absorption and<br />
very good resilience,<br />
even when subjected<br />
to multiple impact<br />
loads. This makes it<br />
particularly suitable for<br />
transport packaging<br />
applications, especially for high-value or delicate goods<br />
requiring a high level of impact resistance and robustness.<br />
To produce ecovio EA, expandable granules are charged<br />
with the blowing agent pentane in an innovative process. This<br />
step enables trouble-free pre-expansion of the material on<br />
conventional EPS pre-expanders and subsequent moulding.<br />
The granules are pre-expanded with the addition of steam to<br />
produce closed-cell beads with an adjustable minimum bulk<br />
density of 25 g/l. A short prefoaming time contributes to a low<br />
energy consumption in this production step.<br />
The expanded granules can subsequently be processed into<br />
a variety of different moulded parts on existing EPS or EPP<br />
production machines – no conversions or modification of the<br />
production process required.<br />
Its processing strongly resembles the processing of EPS. It<br />
is, however, necessary to adapt the process parameters. This<br />
is reflected in a shorter steaming time while the cycle time in<br />
the forming step remains overall the same. Due to a shrinkage<br />
rate of approximately 1.5 %, the mould geometries will need<br />
to be adapted. To ensure a very high quality of moulded part<br />
and dimensional stability it is advisable – similar to EPP<br />
processing – to carry out component conditioning in a heating<br />
oven after the shaping.<br />
Its lower rigidity – ecovio EA is somewhere between EPS and<br />
EPP when it comes to its energy absorbing capacity – make<br />
it perfect for use in the E&E sector, as well, in particular for<br />
heavy and delicate packaged goods such as washing machines<br />
or televisions that are easily damaged during transport. The<br />
material offers a minimum thermal conductivity of 0.034 W/<br />
mK, and is therefore also outstandingly suited to all thermal<br />
insulation applications in the transport sector. ecovio EA<br />
helps to maintain the cold chain at all times for temperaturesensitive<br />
goods such as packaged vegetables, fruit, meat,<br />
frozen goods or even medicines, preventing spoilage.<br />
Its inherent properties also allow storage at temperatures of<br />
up to 100 °C over a period of several hours, which means that<br />
Ecovio EA is also suitable for hot-melt adhesive applications.<br />
And, while displaying good resistance to solvents such as<br />
acetone, as a certified compostable product, it contains no<br />
flame retardants.<br />
BASF is currently developing an ecovio EA grade approved for<br />
food contact applications. The material is constantly durable<br />
under normal environmental conditions. Special conditions,<br />
as are found in industrial composting plants, are required to<br />
initiate the biological degradation process. In places where<br />
appropriate waste disposal channels are available through<br />
local composting plants, it is easy to dispose of the foam. The<br />
certified compostability means that it is possible to dispose of<br />
it along with leftover food waste – without needing to separate<br />
the materials beforehand.<br />
Due to the high porosity and the specific surface area of<br />
the foam beads, ecovio EA degrades very quickly in industrial<br />
composting plants. Composting tests have shown that, for<br />
example, cubes of ecovio EA with an edge length of 5 cm and<br />
densities of 28 – 47 g/l break down within the space of five<br />
weeks to form water, CO 2<br />
and biomass. Prior to composting,<br />
the material can also be recycled in grades in customary<br />
recycling processes. MT<br />
www.basf.com<br />
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bioplastics MAGAZINE [<strong>04</strong>/16] Vol. 11 9