Starch-based foams

Bio-based solutions

There is a need in the market for thick, light bio-based foamed materials with competitive price, which can replace fossil-based foamed materials such as EPS. Ideally, these bio-based solutions also fit within the cardboard recycling scheme and/or are compostable, making them suitable to be discarded together with the surrounding cardboard. Bio-based foamed materials could contribute to reduce greenhouse gas emissions, as well as contribute to the circular economy.

Starch and fibers as feedstocks

Starch is the second most abundant carbohydrate, following cellulose feedstocks. It is a complex polymer stemming from crops such as potato and corn. Depending on the crop, starch molecular structure is different resulting in different processing conditions and product properties. Foams containing starch as the polymeric matrix and small percentage of cellulose fibers were shown to be a very interesting combination in a previous TKI project (AF-17037).

Technology and materials knowledge

Obtaining foamed materials with good mechanical properties and well-defined shapes requires fundamental knowledge of the raw materials, the foaming technologies and the processing parameters. In this project, we research fundamental rheological properties of the raw materials, explore the behaviour of these materials in practical extrusion foaming processes, produce prototypes, characterize them and make simulations to understand the flow and expansion of the raw materials during the processing.

About the project

This project is financed by the Netherlands Enterprise Agency (RVO) and contributes to the long term goals of the Dutch Top sector Energy by closing industrial chains. The goal of the project is to industrially research and experimentally develop a prototype of a biobased and innovative alternative for EPS-based packaging materials and the process to manufacture it. WFBR, Naples University and PaperFoam b.v. work together to achieve this goal.