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The ZealaFoam™ Process • Use commercial polylactic acid (PLA) beads • Particle foam approach • Drop‐in technology for polystyrene moulders

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Published by , 2017-06-29 08:10:03

ZealaFoam™ A Functional Alternative Polystyrene Foam

The ZealaFoam™ Process • Use commercial polylactic acid (PLA) beads • Particle foam approach • Drop‐in technology for polystyrene moulders

ZealaFoa
Alternative t

am™ A Functional 
to Polystyrene Foam

Outline

• Biopolymer Network Lt
• The ZealaFoam™ proce
• Fish box production an
• Scale up and current re

Ltd
ess
nd testing
esearch

Biopolymer Ne

etwork Limited

Biopolymer Network 

• New Zealand research co
• Established 2004
• Research & Technology F

– NZ Natural Extracts & the
• plastics‐coatings‐cosm
• ultrafine starches and
• tannin 

– Non‐wood Natural Fibres
– Thermoset Biobased Res
– Biofoam Technologies

 Limited

ompany

Focus

eir Biopolymer Products
metics
d  functional proteins

s & Biocomposites
sins

The ZealaFoa

am™ Process

The ZealaFoam™ Proc

• Use commercial polyla
• Particle foam approach
• Drop‐in technology for
• CO2 as a "green" blowi
• Patented US 8283389, 

Australia, China and Ja
Europe.

cess

actic acid (PLA) beads
h
r polystyrene moulders
ing agent
 also granted NZ, 
apan. Pending Canada, 

ZealaFoam™ Process

Impregnat

Fused

ted with CO2
Pre‐foamed with heat

d with heat

ZealaFoam™  Technol

Commercial PLA bea

• Liquid CO2 as a "gr
• Low pressures / am
• Short impregnation

logy: Impregnation

ads

reen" blowing agent 
mbient temperatures
n time 

ZealaFoam™  Technol

Impregnated PLA bead

• heat (steam, water, a
• do not instantaneous
• short foaming time (

dependant)
• do not need a second

pre‐foamed

logy: Pre‐foaming

ds

air)
sly foam
(size / density / temp 
d impregnation after being 

ZealaFoam™ Technolo

Pre‐foamed PLA be

• Rapid moulding
• Current density >2
• No additional che

ogy: Moulding

eads

24 g/L
emicals/materials required

Our ZealaFoam™  tech

• Fine cell structure

hnology: Final foam

ZealaFoam™ : Molecular

• Molecular weight of PL
during prefoaming or m

r weight distribution

LA not compromised 
moulding

PLA original
PLA extruded
PLA pre-foamed
PLA moulded

Lab Scale

Impregnated w

Fus

with CO2
Pre‐foamed with heat

sed with heat

Pilot Plant CO2 Impreg

1 tonne pallet of beads

Colour

gnation

Easy to use
r for difference

Pilot Plant Impregnat

• Recycling of CO2 critica
• Adapted existing equip
• Easy installation and op
• Small footprint – actua

tion

al for cost
pment to process
peration
al and environmental

Pilot Plant Pre‐foamin

Impregnated beads

Pre‐foamer

ng

Density determined by 
pre‐foaming

Pre‐foamed beads

Pilot Plant Moulding

Approx 43
750 x  330
(L x W x H

3 L Fish Box
0 x 240  mm 
H)

Fish Box Product

tion and Testing 





Export Simulation Tria

• Use current export pac

– Fresh fish packed direc

• Simulate temperature 
38 hours)

• Record temperatures b
internal box wall temp

• Compare ZealaFoam™ 

als

cking methods

ctly on ice

 profile (NZ – Singapore 

both inside fish and 
p
 and EPS performance

Export Simulation Res

Mean Air Temp at
Surface of Boxes

M
In
Te

sults



Mean EPS 
Internal Wall 
Temp

Mean ZealaFoam™
nternal Wall 
emp

Export Simulation Res

Mean Air Temp at
Surface of Boxes

sults



Mean EPS 
Fish Temp

Mean 
ZealaFoam™ Fish 
Temp

Mechanical Testing Tr

• Industry driven proper
• Lab testing based on in
• Densities of EPS / Zeala

rials

rty testing
ndustry standards
aFoam™ boxes differed

ZealaFoam™ Mechan

At 25 g/L
Shear modulus (MPa)
Shear strength (MPa)
Shear stress, maximum (MPa)
Cross-breaking strength (kPa)

EPS Density Therm
ZealaFoamTM (g/L) conduc

~30 (W/m
~30
0.03

0.03

nical Properties

EPS ZealaFoamTM
3.2 3.0
0.12 0.11
0.17 0.18

327 418

mal
ctivity
m.k)

32

32

Stack Test

• 18 kg of PLA inside
• Compression tested at 10 

mm/min
• Buckling at maximum load
• Max load at ~12 kN –

GOOD

• AS 2582.3


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