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Polycarbonates from renewable hydrocarbons

Polycarbonates from renewable hydrocarbons 1700 1266 Tecnon OrbiChem

It’s no secret that plant-based polycarbonate (PC) can be problematic. Not only does the plastic demonstrate complex technical properties, developing alternative chemical intermediates with the performance potential of petrochemical-based PCs can be a time-consuming process.

The wider polymer industry is already beginning to shift towards renewable carbon feedstocks such as biomass and COto reduce GHG emissions – driven by incentives and legislative penalties.

But we are also seeing more traditional producers of polycarbonates use waste carbon feedstock and/or the mass balance approach to bring certified renewable products made from biobased hydrocarbons to market.

 


‘If crude oil values remain persistently high, it is possible that biobased plastics will become increasingly competitive

Jennifer Hawkins, Tecnon OrbiChem Business Manager


‘Consumers are becoming increasingly environmentally savvy in their buying habits,’ says Tecnon OrbiChem Business Manager Jennifer Hawkins. ‘…But even more so in the automobile sector, where polycarbonate features heavily.’

‘As sales of electric cars continue to grow in a bid to meet cleaner air targets, more focus is being drawn on the materials being used to make them. It defies logic that the world continues to burn fossil fuels while trying to make green, environmentally friendly vehicles.

‘Until now, the cost of high performing biomaterials has limited their use in car production, but if crude oil values remain persistently high, it is possible that biobased plastics will become increasingly competitive, and viable for large scale industrial production use.’

Image shows a schematic diagram of the commercial polycarbonate value chain including chemicals that can be swapped for renewable feedstocks

Class: high heat polymers

An unusual and useful class of high heat polymers, polycarbonates (PC) demonstrate toughness and optical clarity. The most-used polycarbonate is produced by condensation polymerisation using Bisphenol A (BPA) along with either carbonyl chloride – also known as phosgene – or diphenyl carbonate.

Increasingly however, polycarbonates are being made with diphenyl carbonate – which removes the poisonous gas phosgene from the process. The phosgene free diphenyl carbonate (DPC) process – also known as the melt process – is cost-effective. Commercialised by Asahi Kasei in partnership with CHIMEI Corp, the pair opened a plant in Taiwan in 2002. Asahi started developing its non-phosgene aromatic for PC production 50 years ago.

CO2 copolymerisation

Aliphatic polycarbonates are synthesised by the copolymerisation of CO2 and propylene oxide – or other epoxides. It’s a process that has been commercialised but on a limited scale only.

Asahi reacts ethylene oxide with COto yield ethylene carbonate, then reacts that with methanol to give dimethyl carbonate (DMC) and monoethylene glycol. It isn’t alone in laying claim to this CO2-based DMC technology but other producers use propylene oxide, or synthesise propylene carbonate instead of ethylene carbonate before reacting with phenol.

Aromatic versus aliphatic…

When it comes to CO2-based PCs, it’s the aromatic variety that remains among the most available. But aliphatic polycarbonates (APC) – polypropylene carbonate (PPC) and polyethylene carbonate (PEC) – are increasingly available. Fast-approaching a century in existence, APCs were first manufactured by a DuPont lab around the 1930s.

PPC is synthesised from direct copolymerisation of CO2 and propylene oxide. It is said to have good barrier properties and can be used in food packaging applications

PEC uses an ethylene oxide feedstock. Because it is extrudable, it can be a suitable barrier film for multilayer construction. In terms of its end of life profile, PEC decomposes completely above 200oC and biodegrades in specific conditions.

The German research organisation the nova-Institute has reported PEC and PPC-based products to demonstrate 50% weight for aliphatic-type polymers.

High molecular mass aliphatic PCs

Ideal for injection moulding, high molecular mass aliphatic PCs have been developed. In these materials, starch-derived diol isosorbide replaces BPA. Mitsubishi Chemical Corporation developed its biobased PC DurabioTM using Roquette’s isosorbide.

In 2021, Samyang Innochem – a subsidiary of South Korea-based PC producer Samyang Group – announced construction was underway for a 1000 ktpa isosorbide plant in Gunsan, Jeollabuk-do Province, China. The company’s intent was to incorporate the biobased intermediate into its PC manufacturing.

Renewable tech on the rise

UK-based bioplastic startup Teysha Technologies developed a new biobased polycarbonate platform called AggiePol based on polyhydroxyl monomers – for example saccharides and quinic acid.

The transformations of these polyhydroxyl monomers can produce a wide range of linear and hyperbranched polymers and copolymers. Based on a plug-and-play system, the biopolymer can be tuned physically, mechanically and chemically as well as its degradation rate to suit the needs of its intended applications.

And Sabic’s LexanTM PC engineering thermoplastic resin – produced at its Cartagena, Spain, PC plant – uses certified renewable feedstock. The Saudi Arabia-headquartered company also produces mass balanced-based benzene at its steam cracker in Europe. Sabic’s process combines UPM’s renewable BioVerno bio-naphtha with fossil-based naphtha with the biobased benzene then used to produce phenol for PC feedstock. For each kilogram of PC produced based on certified renewable feedstock, around 61% of CO2 emission is reduced, Sabic claims.

Covestro has enlisted the help of Neste to replace the several thousand tons of fossil- based raw materials in its polycarbonates with Neste’s renewable hydrocarbons – biobased naphtha and bio-propane. The company markets a PC made from biobased phenol and makes PC grades from post-consumer recycled content.

With traditional chemicals producers and startups increasingly moving into the biobased space, plastics are set to become more sustainable in the future.

Tecnon OrbiChem provides insight, analysis, data and commentary on technologies emerging in the biomaterials sector.

new statista graph

Source: Statista/Covestro

This blog post was inspired by Doris de Guzman’s white paper Developing renewable polycarbonates – A balancing act.

Biopolymer specialist works with NIAB to tackle plastic pollution

Biopolymer specialist works with NIAB to tackle plastic pollution 700 336 Agronomist Arable Farmer

Biopolymer innovator Teysha Technologies has joined NIAB to research, test and develop bioplastics for the agricultural industry in the UK. The opportunity will allow Teysha to expand as the start up further commercialises in the UK, utilising the Eastern Agritech Innovation Hub near Cambridge. The Hub will be the focal point for developing and testing new sustainable materials and bioplastics to tackle growing plastic pollution as well as investigating waste feedstock options within British agricultural operations.

The first innovation to be delivered from the new Teysha laboratory will be a series of new polyester composite materials. Their purpose will be to replace some products that are currently based on petrochemical plastics, as well as improve the biodegradability of existing bioplastics such as polylactic acid. Unlike other polymer manufacturing processes, the synthesis of Teysha’s materials generates zero chemical by-products for disposal. Its properties make it susceptible to microbial breakdown, a desirable benefit for applications like packaging.

Teysha’s new polyester composites show promise as plastic alternatives across industries like agriculture and horticulture. For example, British gardeners go through 500 million plastic plant pots a year that are either incinerated or sent to landfills. On average they take an estimated 450 years to degrade and in the process may release toxic additives, dyes and microplastics into the environment. To address this, Teysha is targeting the development of alternatives using polyester composites. The goal is to prototype alternative options that provide additional plant nourishment while also having the ability to either biodegrade or be composted.

“This opportunity to work with the NIAB will allow us to further develop innovative, sustainable materials that can replace harmful plastics in industries like agriculture, as well as examine waste feedstocks for our range of biopolymers.” Said Matthew Stone, Managing Director of Teysha Technologies. “Working with such an important UK institution will also accelerate commercialisation in the UK.”

Teysha Technologies was established to solve the problems surrounding the production and use of plastics. In partnership with Texas A&M University, Teysha have developed novel second generation bioplastics based on sugar polycarbonates. Now, Teysha is extending its commercial operations to the UK where it is establishing a laboratory facility and a relationship with the NIAB.

The NIAB Group is the UK’s fastest-growing crop science organisation, addressing the challenges of food security, climate change and sustainable development in agriculture. The group works with local and national businesses at the hub to carry out commercial scale pilot studies that aid the development of the agricultural and horticultural industries in the UK.

To find out more about Teysha Technologies and its research into tuneable biodegradable biopolymers, visit the Teysha Technologies website.

Masking plastic pollution – How single-use masks are impacting the environment

Masking plastic pollution – How single-use masks are impacting the environment 1000 667 Packaging News

3.4 billion disposable face masks were discarded each day at the start of 2021, according to a study by Benson, Bassey and Palanisami. While a proven safety measure for protecting public health, we must address the environmental impact of facial coverings. Here Dr Ashlee Jahnke, director of research at biodegradable biopolymer research platform Teysha Technologies, discusses the issues surrounding single-use face masks.

Imports of face masks into the European Union (EU) have more than doubled since the start of the pandemic, according to a report by the European Environment Agency (EEA). The general consensus among medical organisations and the scientific community is that masks help to limit the spread of respiratory viruses like COVID-19. One study, looking into secondary transmission of SARS-CoV-2, found that face masks were 79 per cent effective in preventing transmission.

However, while masks have proven effective at limiting the spread of COVID, they could be causing damage elsewhere. The EEA’s report also finds that an uptake in disposable mask wearing has led to an increase in littering, which can harm wildlife and contribute to the spread of microplastics.

Microplastics, major problem
Wearing masks is incredibly important in helping stop the spread of contagions. However, public health does not have to come at the expense of plastic pollution. The release of microparticles and heavy metals into the environment is one of the greatest risks disposable masks pose.

Disposable medical masks are produced from polymers such as polypropylene and polycarbonate to create three protective layers. The inner layer is made up of soft fibres, the middle layer has a melt-blow filter and the outer layer uses dyed, nonwoven fibres that are water-resistant to create a barrier against droplets.

When these masks begin to degrade, over time or through contact with water, they release microplastic fibres. These fibres are under five millimetres in size and can be ingested by humans and other forms of wildlife. Human consumption of microplastics can lead to issues such as oxidative stress, immunotoxicity and metabolic disturbances. Currently, the full extent of microplastic exposure to humans remains unknown.

The future is bioplastics
19 billion face masks are incinerated in the UK each year. The rest end up in landfills, or are littered across our streets. While some businesses have started reusing plastics to create personal protective equipment (PPE), UK Prime Minister Boris Johnson has stated that recycling materials “is not the answer” as it justifies overproduction and encourages the “industrial addiction” to plastic.

Other solutions include making reusable masks from materials such as cotton. However, there is an argument that these masks do not offer the same level of protection as medical grade options. Priorities need to be devised, handling the pandemic and stopping its spread is the most important thing at the moment. But in the long term, as mask wearing becomes the norm, there needs to be a full investigation into the impact of disposable masks.

The 2019 directive agreed by EU states and Norway to restrict single-use plastics from being produced and sold in the EU came into effect in July 2021. As more anti-plastic legislation is passed around the world, we could see further interest and investment in the bioplastics industry.

Some bioplastic companies, like Teysha Technologies, are going further than developing a single polymer system through investment and working with world leading research scientists.

Teysha’s unique IP is a platform technology that uses sustainable feedstocks in the form of various modified natural-product monomers and co-monomers to generate polycarbonate material. A key feature of this platform is that the material’s physical, chemical and mechanical properties can be tuned. One example of this is developing a system where the main mechanism of polymer degradation is water driven. This allows for the formation of a wide variety of final products with multiple applications.

This technology allows us to remain agile and responsive to unanticipated product demands, such as the sudden need for billions of disposable masks caused by the global pandemic.

Continued use of face-masks is incredibly important to limit the spread of respiratory viruses. However, we must push for further research and development into face-masks if we want to protect the planet as well as public health.

Masking plastic pollution

Masking plastic pollution 1000 667 Automation Update

~ How single-use masks are impacting the environment ~

3.4 billion disposable face masks were discarded each day at the start of 2021, according to a study by Benson, Bassey and Palanisami. While a proven safety measure for protecting public health, we must address the environmental impact of facial coverings. Here Dr Ashlee Jahnke, director of research at biodegradable biopolymer research platform Teysha Technologies, discusses the issues surrounding single-use face masks.

Imports of face masks into the European Union (EU) have more than doubled since the start of the pandemic, according to a report by the European Environment Agency (EEA). The general consensus among medical organisations and the scientific community is that masks help to limit the spread of respiratory viruses like COVID-19. One study, looking into secondary transmission of SARS-CoV-2, found that face masks were 79 per cent effective in preventing transmission.

However, while masks have proven effective at limiting the spread of COVID, they could be causing damage elsewhere. The EEA’s report also finds that an uptake in disposable mask wearing has led to an increase in littering, which can harm wildlife and contribute to the spread of microplastics.

Microplastics, major problem

Wearing masks is incredibly important in helping stop the spread of contagions. However, public health does not have to come at the expense of plastic pollution. The release of microparticles and heavy metals into the environment is one of the greatest risks disposable masks pose.

Disposable medical masks are produced from polymers such as polypropylene and polycarbonate to create three protective layers. The inner layer is made up of soft fibres, the middle layer has a melt-blow filter and the outer layer uses dyed, nonwoven fibres that are water-resistant to create a barrier against droplets.

When these masks begin to degrade, over time or through contact with water, they release microplastic fibres. These fibres are under five millimetres in size and can be ingested by humans and other forms of wildlife. Human consumption of microplastics can lead to issues such as oxidative stress, immunotoxicity and metabolic disturbances. Currently, the full extent of microplastic exposure to humans remains unknown.

The future is bioplastics

19 billion face masks are incinerated in the UK each year. The rest end up in landfills, or are littered across our streets. While some businesses have started reusing plastics to create personal protective equipment (PPE), UK Prime Minister Boris Johnson has stated that recycling materials “is not the answer” as it justifies overproduction and encourages the “industrial addiction” to plastic.

Other solutions include making reusable masks from materials such as cotton. However, there is an argument that these masks do not offer the same level of protection as medical grade options. Priorities need to be devised, handling the pandemic and stopping its spread is the most important thing at the moment. But in the long term, as mask wearing becomes the norm, there needs to be a full investigation into the impact of disposable masks.

The 2019 directive agreed by EU states and Norway to restrict single-use plastics from being produced and sold in the EU came into effect in July 2021. As more anti-plastic legislation is passed around the world, we could see further interest and investment in the bioplastics industry.

Some bioplastic companies, like Teysha Technologies, are going further than developing a single polymer system through investment and working with world leading research scientists.

Teysha’s unique IP is a platform technology that uses sustainable feedstocks in the form of various modified natural-product monomers and co-monomers to generate polycarbonate material. A key feature of this platform is that the material’s physical, chemical and mechanical properties can be tuned. One example of this is developing a system where the main mechanism of polymer degradation is water driven. This allows for the formation of a wide variety of final products with multiple applications.

This technology allows us to remain agile and responsive to unanticipated product demands, such as the sudden need for billions of disposable masks caused by the global pandemic.

Continued use of face-masks is incredibly important to limit the spread of respiratory viruses. However, we must push for further research and development into face-masks if we want to protect the planet as well as public health.

To find out more about Teysha Technologies and its research into customisable, biodegradable biopolymers, visit the Teysha Technologies website.

Raving in the rubbish

Raving in the rubbish 1920 1440 Packaging Scotland

Fields littered with abandoned tents and plastic bags, bottles and containers. These are the images people often see on the TV after a large music festival. An estimated 23,500 tonnes of waste is left by UK festival goers each year according to think-tank Powerful Thinking. That’s more than double the weight of the Eiffel Tower. Here, Duncan Clark, head of operations at biodegradable biopolymer research platform Teysha Technologies, explains some of the best solutions for festival organisers to minimise their plastic problem.

for many, the return of events like Reading Festival will be a blessing after a long period of isolation during the global pandemic. However, many people are waiting in trepidation for the scenes of fields covered with discarded plastic waste that have been a regular occurrence since the iconic Woodstock Music and Art fair in 1969.

However, music festivals don’t have to be synonymous with mass littering and festival organisers are trying to change this stereotype. For example, Glastonbury, which produces around 2,000 tonnes of waste per year, has required attendees to adhere to the Glastonbury Green Pledge since 2019. Single-use plastic bottles were no longer available, and attendees were encouraged to refill their water bottles for free at water taps. While this is a step in the right direction, there is still so much more that music festival can do to limit their plastic waste.

Go a step further

Firstly, it’s not enough to just ban the sale of single-use plastic bottles. This needs to be extended to all areas of packaging supplied by festivals. Sustainable products are increasing and many events are currently utilising them, music festivals must do the same. From food and drink packaging to small plastic trinkets, limiting the amount of traditional plastic allowed will see a direct decrease in plastic waste.

Secondly, music festivals should encourage attendees to make sustainable choices. Every year more than 250,000 tents are abandoned at music festivals in the UK. Though some may be salvaged and given to those in need, this only pushes the plastic problem onto another location when the cheap tents eventually become unusable.

If music festivals were to offer attendees eco-friendly alternatives to the main culprits of waste, the problems would lessen. Teysha has developed a unique polycarbonate platform from renewable resources that can be customised for a multitude of applications. These products can even undergo selective degradation into non-harmful substances, a good solution if attendees continue to litter.

Festivals can encourage visitors to purchase products made from these alternative materials through festival branding or endorsement from performing artists on stage and social media. Encouraging a change in attendee behaviour is just as important as providing greener alternatives.

Finally, festivals need to start investing more heavily in sustainability schemes. Eco-friendly materials, like biodegradable biopolymers, are only able to compete with the traditional petroleum-based plastic industry with funding. Contributions will not only fund further developments in how to make products more durable and user friendly, but they also make a statement of solidarity in progressing towards green technology. The more events push towards sustainable products, the more options they will begin to see.

Funding biopolymer research is better than fracking

Funding biopolymer research is better than fracking 638 425 Pollution Solutions Online

For the first time ever, the Plastic Waste Makers Index has reported that 55 per cent of the world’s plastic waste is produced by just 20 companies. While the report stimulates the necessary ‘name and shame’ conversations, it’s now time for the most influential businesses to take responsibility for driving the climate crisis. Here, Duncan Clark, head of operations at biopolycarbonate research platform Teysha Technologies, discusses how investing in biodegradable polymer alternatives could lead to the termination of single-use plastics for good.

National Geographic estimates that the Great Pacific Garbage Patch, spanning from the west coast of North America to Japan, is comprised of 1.8 trillion plastic pieces. If the report by the Plastic Waste Makers Index is to be believed, just 20 companies could be responsible for more than half of this debris.

While oil and gas giants, like ExxonMobil and Sinopec, each produce more than five per cent of single-use plastics, financiers such as Barclays Bank and HSBC are being held accountable for lending more than $3.1 billion each to virgin polymer producers.

If these companies are to take responsibility for their huge plastic waste footprints, they need to start investing in the search for cheaper, durable and truly sustainable alternatives. But how can this be achieved?

Digging for liquid gold

We know that plastic is damaging our environment. So, why do we still produce it? Firstly, it’s durability, malleability and low-cost mean it’s convenient for use in a variety of consumer and industrial products. What’s less considered is its inability to degrade naturally or within a reasonable timeframe without the help of energy-intensive, greenhouse gas-producing industrial catalysts, or without releasing harmful chemical pollutants into the environment.
In fact, every stage in the lifecycle of plastic contributes significantly to the climate crisis. Fracking, for example, leaks thousands of tonnes of harmful gases into the atmosphere every day. National Geographic estimates that 540,000 tonnes of methane per year is produced in the North Texas Barnett Shale region alone, which is the equivalent of 46 million tonnes of carbon dioxide. What’s more, fracking drills often must invasively dig up to 5,000 feet underground using explosive charges to puncture holes in Earth’s shale layer.

Currently, only 14 per cent of oil fracked globally is used to make plastic. But our increased reliance on this material over the next few decades will undeniably increase the need for these destructive activities. Therefore, the solution for these companies is not to dig a little deeper, but rather switch the focus to creating a biodegradable, sustainable polymer with the strength and convenience of traditional plastic.

Financing future research, not fracking

If researchers were given just half of the funding granted by the world’s biggest banks, we’d be a lot further along in the transition to zero-waste plastic.  Despite this, research into developing biodegradable biopolymers is continuing to yield promising results, with companies like Teysha Technologies making landmark breakthroughs in viable plastic substitutes.

Teysha have developed a plug-and-play platform where various modified natural-product monomers, co-monomers and additives can be combined to create versatile, tuneable materials akin to traditional plastic. Because platforms like these use a variety of natural components, everything from strength to thermal stability and degradation rates can be carefully controlled according to the application.

Most petrochemical-derived polycarbonates achieve their versatility through control of molar mass, crystallinity and blending with other potentially toxic petrochemicals. The resulting materials can persist in the environment for more than 450 years, causing irreparable damage to organisms and their ecosystems. By diverting funding away from the production of virgin plastics and towards biodegradable biopolymer production, it may be possible to reverse the climate crisis.

Leading this change should be the companies identified in the Plastic Waste Makers Index report. If each one were to silence their drills and direct their attention to the search for sustainable plastics, a healthier, greener carbon-neutral world may just be possible.

The solution to plastic pollution

The solution to plastic pollution 1536 727 Engineering Update

~ Looking at the impact of each stage in the plastic lifecycle ~

“People and the planet are only as healthy as the ecosystems we depend on.” This is a statement to encourage ecosystem restoration published by the United Nations Environment Programme (UNEP). But ecosystem restoration is more than a pathway to achieving climate goals. Here Duncan Clark, head of operations at biopolymer researcher Teysha Technologies, explains how we can take steps in restoring ecosystems by terminating the use of Earth’s biggest polluter, plastic.

The WWF describes plastic pollution as one of the most visible symptoms of the environmental crisis, damaging natural habitats and threatening wildlife. In fact, the Geneva Environment Network estimates that the cumulative production of plastic surpassed eight billion metric tons worldwide in 2020 and is expected to increase in the coming decades.

The images we see in the media of litter-strewn beaches and marine life tangled up in single-use plastic bags are powerful conversation starters, but they don’t represent the entire problem. Plastic is harmful from the point of manufacture and even with more robust recycling policies, the plastic crisis will persist into the future if we can’t source a sustainable alternative.

To understand the extent of this issue, we must dig deeper into how plastic is produced.

Plastic’s ugly truths

Most plastic production requires a core ingredient: crude oil dug deep from the Earth’s crust. The seismic vibrations caused by oil extraction is enough to disrupt some habitats. But when you factor in the threat of oil spills and the infrastructure needed to transport resources in-land, thousands of species have been displaced to accommodate demand for crude oil.

It may not seem much, but five per cent of all global crude oil extracted is used for the manufacturing of plastics. This actually equates to approximately 35m barrels per year.

Plastic production is also extremely energy intensive, consuming 2000 times the amount of energy it takes to treat and distribute tap water. It also generates harmful pollutants that damage the Earth’s atmosphere and leach into our land and water systems.

The carbon emissions from producing plastic are threatening thousands of species who are struggling to adapt to rapidly changing environmental temperatures. National Public Radio (NPR) estimates that carbon emissions from plastic production could amount to 56 gigatons between now and 2050.

Finally, the products made from plastic pose an even bigger threat to our ecosystems. One single-use plastic bottle, whose contents may take minutes to consume, will persist in the environment anywhere from 450 years to several thousand years.

The result is that there are now some 80,000 tonnes of plastic — the equivalent weight of 500 jumbo jets — in the Great Pacific Garbage Patch alone, according to The Ocean Clean Up. Once broken down into microplastic particles, these are consumed by marine life, only to work their way back through the food chain and end up on our plates.

The evidence is clear that plastic is a cause for concern, but it’s convenience cannot be understated. The good news is that there is now a viable alternative that means we can feasibly outlaw traditional plastic for good.

Solving the polymer puzzle

Teysha Technologies has developed a polymer platform using sustainable feedstocks to generate Earth-friendly polycarbonate materials. This plug-and-play system incorporates natural monomers and co-monomers, rather than hydrocarbons from crude oil, formulated from starches or agricultural waste.

A major benefit of this is that the resulting material’s physical, mechanical and chemical properties can be tuned to fit specific applications. Even the polycarbonate’s degradation rates are tuneable. Food packaging, for example, is often disposed of after a single use, so it could be tuned to break down quicker in an environment with sufficient moisture.

A common problem with traditional bioplastics, despite being composed of ‘greener’ materials, is that they still need industrial catalysts and the right microbial conditions to degrade. Most countries simply don’t have the infrastructure to facilitate this.

By considering the impact of each stage in the lifecycle of plastic on ecosystems, we can start to transition from petrochemical-based plastics towards truly natural, harmless materials. To find out more, visit Teysha Technologies’ website.

Biopolymer specialist Teysha Technologies urges cosmetic companies to move to green polymers

Biopolymer specialist Teysha Technologies urges cosmetic companies to move to green polymers 767 776 Renewable Carbon News

Teysha Technologies to discuss the use of its biodegradable biopolymers as an additive to reduce environmentally damaging microplastics

A specialist in the development of biodegradable polymers from natural sources is calling on the cosmetics industry to reduce its use of conventional polymers, which contribute towards global plastic pollution. The company, Teysha Technologies, is in talks with several global cosmetic brands to discuss the use of its biodegradable biopolymers as an additive to reduce environmentally damaging microplastics — and is now urging other companies to follow suit.

Despite legislation around the use of plastics in cosmetic products tightening in recent years, the industry still relies heavily on their use as additives. In products such as moisturising lotions, microplastics — polymer fragments that measure less than five millimetres in size — are commonly used as emulsifiers and viscosity regulators.

When such products are washed away, the microplastic fragments are introduced into the environment where they can remain for hundreds of years or be consumed by animals and enter the food chain. According to numbers presented by the UK Government in 2018, a single shower using a shower gel containing microplastics can lead to as many as 100,000 microbeads entering the ocean. Although exfoliating plastic microbeads have been banned in cosmetic products in the UK since 2018, microplastics from other sources are still present.

Teysha Technologies argues that there is little reason for cosmetic manufacturers to still be using environmentally harmful polymers, because greener alternatives are now available.

“Polymers play an important role in most cosmetic products, from stabilising formulations to helping products remain on the skin for longer,” explained Matthew Stone, managing director of Teysha Technologies. “However, there is no reason why many of those polymers need to be unsustainable or environmentally damaging.

“Teysha has been leading research into the development of biopolymers that are completely biodegradable, while still having all the properties needed to suit a range of uses. This led us to develop a tuneable biopolymer that we can tailor to specific applications. Cosmetics is one of these areas and we are working with a global cosmetic manufacturer looking into the use of our polymer platform to support the move away from environmentally damaging products.

“In the coming years, legislation will only continue to tighten around plastic use. The European cosmetics industry is already facing the issues this can present due to the imminent rollout of the European Chemicals Agency’s (ECHA’s) proposed microplastic restrictions in early 2022. Making the swap to biodegradable, environmentally benign alternatives now will save the regulatory cost and complications of product reformulation.”

In 2019, the ECHA proposed new restrictions on the use of ‘intentionally added microplastics’. Although there are some exemptions to the proposed restrictions, the proposal would mean significant reformulation costs for cosmetic manufacturers. Industry association Cosmetics Europe has been critical of the impact the restrictions would impose on the industry, claiming the proposal would be “extremely disproportionate in its effects” on cosmetics manufacturers.

Teysha Technologies developed a natural polycarbonate platform that can create fully biodegradable substitutes for existing petroleum-based plastics. The bioplastic, AggiePol, is derived from sustainable feedstocks and can be physically, mechanically and chemically tuned to suit the needs of its intended application, with degradation time also being tuneable. This means it can be made suitable for use not only in cosmetic products as a functional plastic, but also in cosmetic packaging.

Source

Bioplastics MAGAZINE, 2020-12-03.

Supplier

Cosmetics Europe
European Chemicals Agency (ECHA)
Teysha Technologies

Source: Renewable Carbon News

The next steps in single-use plastics

The next steps in single-use plastics 870 580 Industry Asia

Exploring alternatives to single-use plastic straws, stirrers and cotton buds.

On October 1, 2020, the ban on the sale of single-use plastic straws, cotton buds and stirrers came into effect in England. It forms a key part of Parliament’s strategy to eliminate plastic waste as part of its 25 Year Environment Plan. Here, Duncan Clark, head of business operations at natural biopolymer specialist Teysha Technologies, explores the available alternatives and the future role of earth-friendly plastics.

In England, approximately 4.7 billion plastic straws, 316 million stirrers and 1.8 billion plastic-stemmed cotton buds are used every year. Many of these find their way into water systems, and eventually our oceans. To reduce plastic pollution, and prevent harm to marine life and the environment, England joined Scotland in banning the sale of these products.

In recent years, measures have been taken to reduce plastic usage, like banning the use of microbeads in cosmetics. The nationwide introduction of charges on single use shopping bags led to a 95 per cent reduction in plastic bag usage in supermarkets. However, more action is needed to meet global targets for reducing plastic pollution.

The latest ban leaves consumers seeking alternatives to traditional single-use plastic products. These include 100 per cent cotton swabs, wooden stirrers and metal or paper straws. These products reduce visible plastic pollution, but they have other costly impacts on the environment.

Manufacturers are attracted to plastic because it is cheap to produce. A study conducted by Denmark’s Ministry of Environment and Food found that production of metal, paper and cotton alternatives to plastic are pricier, but also create more harmful emissions. It concluded that paper bags must be used at least 43 times to have a more positive impact on the environment than single use plastic bags.

Alternatives to plastic straws, cotton buds and stirrers help to tackle plastic in our water systems, but they need to have better carbon footprints to facilitate the comprehensive change the world needs. Furthermore, most plant-based bioplastics need industrial catalysts to break them down, but current recycling infrastructure does not accommodate this. Many are also manufactured using petrochemicals, albeit in smaller quantities, just like regular plastic.

While the ban is commendable, more action is needed to deliver sustainable change. A key problem is the cultural attachment we have built to plastic over decades. If plastic were invented today, it’s unlikely it would be approved as a product for single or short-term use. Therefore, we must consider biodegradable plastic alternatives to fill this need.

Following years of research, Teysha Technologies has achieved a landmark breakthrough second generation biopolymers creating a viable substitute for existing petroleum-based polycarbonates, or plastics.

Its technology uses a plug-and-play system that takes monomers and co-monomers, the natural building blocks that make up plastic, to create a polymer that works and functions in a very similar way to the plastic we’re used to. The difference is that the monomer feedstocks are derived from natural sources like starches and agricultural waste products, rather than hydrocarbon-based petrochemicals sourced from fossil fuels.

Teysha’s technology platform allows biopolymers to be physically, mechanically and chemically tuned to the needs of the product. This gives it a variety of uses in packaging, cosmetics and electrical appliances.

Source: Industry Asia

Wrapping up the packaging debate

Wrapping up the packaging debate 899 603 Process and Control Today

Around 350 tonnes of plastic are produced every year, and more than half of this ends up in the ocean or in the landfill, according to the World Economic Forum (WEF). As well as plastic from bottles, packaging or bags, microparticles found in cosmetics, detergents and clothes also end up in the waterways. In the EU alone, 17 tonnes of microparticles are produced annually, the majority of which find their way into the ocean.

To find durable solutions to this imposing issue, many companies globally have committed to replacing plastic, in packaging, and sourcing alternative materials, such as paper. Efforts are being made worldwide to ban such prolific use of plastic, in particular single use plastics, or reduce it. To illustrate, Tesco, the UK’s biggest supermarket chain, has vowed to remove all plastic used in ready-meals trays, lids, straws and loose fruit bags for its own label products. This move alone aims to remove 1 billion pieces of plastic from its supply chain by the end of 2020 as the supermarket will switch to paper alternatives instead.

Paper is often lauded as a more sustainable alternative to plastic. Nevertheless, it’s not entirely sustainable. It is commonly believed that paper is more biodegradable and easily recycled. However, when it reaches landfill its degradation rate slows. Furthermore, paper pulp is often treated with chlorine, which adds pollution to the environment. Lastly, an increase in demand for paper packaging impacts further on deforestation, which in turn causes further damage to our ecosystems and lowers the quality of the air we breathe.

Plastic on the other hand benefits from being significantly lighter, a property which makes it more efficient for containing and packaging food and other non-perishable products. However, not all types of plastic are recyclable. When it reaches landfill, it remains for hundreds of years until it degrades. Experts at Teysha Technologies have developed a bioplastic alternative, which uses plants and other biological materials instead of petroleum as its base.

Teysha Technologies has developed a unique, sustainable and cost-efficient bio-polymer that can provide a cost effective and sustainable alternative to conventional plastics or paper packaging. Its manufacturing process is unique in the field of renewables, offering a fully degradable bioplastic, that is proven to degrade faster and more completely than other bioplastics. Teysha’s bioplastic simultaneously avoids the formation of microparticles too. Instead on using a single polymer system, Teysha’s ground-breaking technology incorporates a polycarbonate platform that enables the company to create a variety of polymers with differing tensile strength and protective properties. This opens up significant potential for Teysha’s material to be specifically tuned to create a variety of end products. The pellet can also be used in existing production lines so doesn’t require big capital investment in new infrastructure.

While reducing and recycling packaging is essential, we should also rethink our understanding of plastic and its potential. Teysha Technologies might have just the right answer when it comes to the plastic dilemma. Their innovative materials provide fully biodegradable alternatives to conventional plastic packaging or alternative materials such as paper. It is clear that the environmental disaster caused by plastic pollution cannot be reversed overnight. However, its consequences can be mitigated, and wiser strategies advanced to fully resolve the wrapping debate.

To find out more about Teysha’s  efforts to produce fully degradable and sustainable bioplastic, check out their website here.

Source: Process and Control Today