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
t
Mean EPS
Internal Wall
Temp
Mean ZealaFoam™
nternal Wall
emp
Export Simulation Res
Mean Air Temp at
Surface of Boxes
sults
t
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