Utilization of Bio-Energy Waste in Bioplastic Formulations to Manufacture Biodegradable Packaging and Recyclable Electrical devices

Project Leaders:

Carlos Alberto Correa / Plasmacro Ind & Com Ltda (FAPESP/Brazil)
André Leclerc / Casco Inc (ISTP/Canada)

Summary of the project:

The proposed innovation was to find new ways of reprocessing bio-energy waste, such as crude glycerol and DDG/DDGS (Distillers Dried Grains/DDG with solubles) from biodiesel (and ethanol) manufacturing, into new products under a full sustainable concept. This initiative is a partnership between Brazilian SME Company Plasmacro and Canadian Casco Inc. aiming to develop and market green PVC formulations using PVC scrap from pipe industry compounded with controlled amounts of modified starches.

The starches are thermally processed with crude glycerol and further compounded into G-PVC formulations. The initial application prototyped by Plasmacro was injection molding of electrical components and the main challenge to making G-PVC suitable for such application was to find a correct formulation balance and processing protocols that matched product specifications.

Besides G-PVC, another grade destined for packaging thermoforming has been produced using modified starches with Polyhydroxybutyrate (PHB) and Dried Distillers Grains with solubles (DDGS). The high viscosity of plasticized starch with varying levels of DDGS has also posed some challenges to making sheets with required properties for thermoforming. Even though, tray prototypes with acceptable properties were produced after adjustments of the original formulation, while keeping the claims of its biodegradability and 100% renewably sourced. In both cases, further R&D is still required before end products are ready for market.

Carlos Alberto Correa – Project leader

Education
PhD in Advanced Materials - Cranfield University, United Kingdom (1994)
Pos-doc in Polymer Processing at McMaster University, Ontario/Canada (2005)
Pos-doc in Plastics Engineering – University of Texas at Austin, USA (1999)
Master Degree in Materials Science & Engineering - Univ. Federal de São Carlos ((1988)
Graduated in Materials Engineering – Univ. Federal de São Carlos (1983)

Summary of work experience
Over twenty-five years work experience in plastic processing, product design and performance evaluation. Dean of the Graduate Program in Materials Engineering and Science and Associate Professor at Universidade São Francisco, in Itatiba/Brazil. Active international cooperations in plastics processing and biocomposites with McMaster University and University of Toronto. Laboratory supervisor for electron microscopy at CCDM/UFSCar and Research Associate at Faber-Castell S/A. Coordination of numerous cooperation programs in R&D with large companies such as Corn Products International, BASF, Sabic Plastics, Innova Petroquímica, Nitriflex, OPP Petroquímica/Braskem and CENPES/Petrobrás. Supervisor of master and doctorate thesis, many academic papers published in scientific journals, speaker in technical conferences, one patent application in USA and three in Brazil. Current acting as self-employed consultant and responsible for coordination of FAPESP/ISTP program at Plasmacro in São Carlos/SP.

André Leclerc - Project leader

Education
2000 - M.Sc in P&P at Université du Québec à Trois-Rivières (UQTR), Trois-Rivières, Québec, Canada. Master thesis entitled: Impact of the Cationic degree of a corn starch on Fine Paper & Board.
1986 - B.Sc in Chemistry from Université Laval, Québec, Canada

Summary of work experience
Has 25 years of experience in various industrial sectors, of which the last twelve were spent with CASCO in managing major P&P accounts and developing new applications and new markets. Designated ‘’Project leader’’ for this ISTP/FAPESP joint project due to its high interest in biotechnologies and dedication to provide applied technologies to company’s research endeavors.

2000 - … Casco Inc. - Senior Account Manager, Green Solutions
1995-2000 Quadra Chemicals Ltd - Technical Support Leader, Pulp & Paper Group
1987-1995 NALCO Canada Inc - Sales Area Director – Industrial Water Treatment
& Primary Metals