NL2021890A

NL2021890A - Composition for tableware, tableware and method for moulding tableware

Info

Publication number: NL2021890A
Application number: NL2021890A
Authority: NL
Inventors: Josephine Van Dillen Amber
Original assignee: Josephine Van Dillen Amber
Priority date: 2018-10-26
Filing date: 2018-10-26
Publication date: 2020-05-13
Also published as: NL2021890B1

Abstract

The present invention relates to a composition, method and use of the composition, for tableware. The composition is biodegradable. The composition for producing tableware comprising seaweed 5 and biodegradable polymer. The present invention also relates to the method for producing tableware. The method for producing tableware, comprising the steps of: — mixing the seaweed and biodegradable polymer; — blow moulding or injection moulding or thermodynamically moulding of the composition according to any one of the preceding clauses.

Description

COMPOSITION FOR TABLEWARE, TABLEWARE AND METHOD FOR MOULDING TABLEWARE

The invention relates to a composition for producing tableware and a method and tableware comprising seaweed and biodegradable polymer.

There is an increasing awareness that fossil-based plastics provides several (severe) disadvantages, such as the so-called ‘plastic soup’, the spreading of nano-particles of plastic and a relatively high emission of carbon dioxide over the lifetime.

Fossil-based plastics, for example for use in disposable tableware, are manufactured from materials such as polyethylene, polypropylene and styrene. These materials are not bio-degradable and often end up in the environment as pollution. Instead of ending up in the environment as pollution such materials can be to burned or recycled. However, burning leads to carbon-dioxide, whereas recycling leads to a degraded quality of plastics that have (very) limited application possibilities.

In order to solve these issues, the commonly used materials are increasingly substituted with biodegradable plastics made of biopolymers. These biodegradable polymers are usually derived from potatoes, sugar beets, corn, wheat and other plants from agriculture. A disadvantage of these biodegradable agriculture-based polymers is that the production thereof requires significant amounts of farmland. It is known that there is not enough farmland available to provide the amount of biodegradable polymers in order to substitute all the plastic by biodegradable plastic. Furthermore, due to the fact that the production of biodegradable polymers requires farmland, the biopolymer production has to compete with the production of food, thus leading to a so-called ‘food production versus resources’-competition.

An objective of the present invention is to provide a composition for producing tableware that obviates or at least reduces the aforementioned problems.

To that end the invention relates to a composition for producing tableware, which often is also referred to as moulded tableware, and more specifically a composition comprising seaweed and biodegradable polymer.

It will be understood that the composition according to the invention is a biodegradable plastic. For the purpose of the invention, a biodegradable plastic is considered to comprise at least a biodegradable polymer, and may additionally comprise other substances. According to the invention one other substance in the biodegradable plastic is seaweed. Furthermore, for the purpose of the invention, seaweed is not limited to weeds or plants grown in seawater (as saline solution), yet also includes plants or weeds grown in fresh water and mixtures of fresh water and seawater.

An advantage of the composition according to the invention is that the production of seaweed does not compete with food production, since it is grown in water. As a result, no assignment of (potential) farmland to bioplastics production is required. Preferably, the seaweed is manufactured in a controlled environment, such as seaweed farms in (preferably) shallow coastal waters of the ocean. However, the seaweed may also be a by-product of other production or harvesting processes or may be harvested from existing locations of seaweed.

Another advantage is that a fully biodegradable composition is achieved that is capable of degradation in a relatively short amount of time. Furthermore, the biodegradability of the composition also provides the advantage that natural creatures, such as fish and/or birds and/or other animals are capable of digesting the composition when they actually consume it. Therewith, the composition according to the invention reduces the mortality rate of birds and/or fish due to the ingesting of plastics. The biodegradability of the composition also reduces the amount of (nano)particles of plastic in the environment, which may be harmful for humans.

Yet another advantage is that seaweed is cheaper than a biodegradable polymer obtained from potato, corn, rice and/or wheat. This is due to several reasons. First of all, the cost of the production location of seaweed, such as a stretch of ocean, is lower than the cost of farmland. Secondly, the growth rate of seaweed is relatively high, which allows multiple harvestings per year, thus increasing the yield and, consequently reducing the costs of production. Furthermore, seaweed is a by-product of fishing, which often allows the seaweed to be obtained at a very low cost. As useable by-product, it thus increases the effectiveness of the fishing industry and reduces the environmental impact of the harvesting.

Yet another advantage of the composition is that seaweed can be grown at various locations all around the world. As a result, the production of seaweed can be positioned near a processing plant to allow local production. This reduces the transportation distance and, therewith, the environmental impact of manufacturing the composition.

Yet another advantage is that seaweed provides a filtering effect on the water in which it grows and additionally consumes carbon dioxide from the water in which it grows. Therewith it is an emission neutral resource that has an environmentally positive effect.

Yet another advantage of the composition according to the invention is that the seaweed helps the biodiversity of the water. For example the seaweed acts as shelter for small organisms, provide feed for organisms and/or filter the water from undesired materials.

Yet another advantage of the composition according to the invention is that any seaweed that remains after production of the composition may be used in the feed industry, for example as basis or additive to cattle fodder, yet may also be used as fertilizer for farmland. Furthermore, the composition can even be used after the expiry date for such purposes. It will be understood that the composition is a carbon neutral resource and that it is possible to produce the composition without (carbon dioxide) emissions.

Yet another advantage of the composition is that the composition is stronger compared to a composition made of biodegradable polymer or seaweed.

Furthermore, this composition, when based on edible, food grade seaweed and biopolymers, also allow for disposable tableware which can be consumed by the consumer. For example, the composition can be used to prepare a stock solution for soup, wherein the stock is severely heated, yet may also be used as edible forks and/or spoons and/or knifes and/or plates and/or straws.

In a presently preferred embodiment according to the invention, the amount of seaweed is between at least 10% and at most 60%, preferably between at least 20% and at most 50%, more preferably between at least 30% and at most 50%, most preferably between at least 40% and at most 50% in the composition.

An advantage of an amount of seaweed between at least 10% and at most 60% is that it reduces the amount of biodegradable polymer that is required for the composition, and thus reduces the amount of farmland that is required for the manufacturing of the composition. The amount of seaweed depends on the purpose of the composition, yet may in many cases be as high as 50% or, depending on the specific use of the composition, be even higher. Thus, the amount of seaweed influences the fluidity of the composition and is determined by a melt flow index meter.

Another advantage is that the resource cost for manufacturing the composition will be reduced with an increasing amount of seaweed in the composition. This is mainly due to the fact that the production of seaweed is cheaper than the production of crops from which biodegradable polymers can be obtained. This is for example due to the fact that growing and harvesting seaweed is less labour intensive compared to any type of (land-based) crop and use of (drinking) water is reduced.

In a presently preferred embodiment according to the invention, the seaweed is chosen from the group of Chlorophyta, Rhodophyta, Phaeophyta, or a mixture thereof.

Besides the earlier mentioned advantages, another advantage of seaweed chosen from the group of Chlorophyta, Rhodophyta, Phaeophyta, or a mixture thereof is that the different genera of seaweed provide a composition which is biodegradable and thus can be used as disposable tableware. Additionally, these genera can also advantageously be used as fertilizer.

In a presently preferred embodiment according to the invention, the species seaweed is chosen from the group of Laminaria saccharina, Gracilaria spec., Alaria esculenta, Saccorhiza polyschides, Ulva lactuca, Ascophyllum nodosum or a mixture thereof.

Besides the earlier mentioned advantages, another advantage of seaweed chosen from the group of Laminaria saccharina, Gracilaria spec., Alaria esculenta, Saccorhiza polyschides, Ulva lactuca, Ascophyllum nodosum or a mixture thereof is that these species provide in an even higher degree of biodegradability. The composition thus degrades in an even shorter period of time, thus leading to a reduced processing time after disposal. A further advantage is that these species are readily available. In addition, these species are easy to grow, which allows them to be grown at virtually any location around the world.

In a presently preferred embodiment according to the invention, the amount of biodegradable polymer is between at least 40% and at most 90%, preferably between at least 50% and at most 80%, more preferably between at least 50% and at most 70% and most preferably between at least 50% and at most 60%.

An advantage of an amount of biodegradable polymer between at least 40% and at most 90% is that less biodegradable polymer is used, and thus more farmland is available for food production. The amount of biodegradable polymer depends on the purpose and will influence the fluidity of the composition.

Another advantage is that the resource cost for manufacturing the composition will be reduced with an increasing amount of seaweed in the composition. This is mainly due to the fact that the production of seaweed is cheaper than the production of crops from which biodegradable polymers can be harvested. This is amongst others due to the fact that growing and harvesting seaweed is less labour intensive compared to any type of (land-based) crop.

Another advantage is that the biodegradable polymer is efficient as binding material.

In a presently preferred embodiment according to the invention, the biodegradable polymer is chosen from the group of polyhydroxyalkanoate, poly(lactic acid), poly(glycolic acid), poly(lactide-co-glycolide), poly(butylene succinate), starch, polyurethane, polyurea, polyamide, and/or a mixture thereof.

An advantage of these biodegradable polymers is that these species lead to reduced degradation time and consequently a reduced processing time after disposal.

Another advantage is that these species provide efficient binding of the composition.

In a presently preferred embodiment according to the invention, the biodegradable polymer is starch, in particular corn starch, wheat starch, potato starch, rice starch and/or root starch.

An advantage wherein the starch is corn starch, wheat starch, potato starch, rice starch and/or root starch is that these types of starch are readily available as well as are effective and efficient as binder. Although other types of biodegradable polymer (binder), for example nonbiodegradable polymers, can also be used, the abovementioned starch provides the advantage that, due to the binding efficiency, they can be applied in relatively low amounts, thus allowing an increased amount of seaweed. Consequently, the manufacturing costs of the composition are reduced.

In a further preferred embodiment the biodegradable polymer comprises 30% to 50% starch, preferably 35% to 45% starch, more preferably 40% starch.

An advantage of starch is the efficient binder and is cheaper than alternative binders and/or biodegradable polymers.

hi another presently preferred embodiment according to the invention, the biodegradable polymer is Solanyl® Cl 201 and/or Solanyl® C2201 and/or Optinyl.

An advantage of Solanyl® C1201 and/or Solanyl® C2201 and/or Optinyl as biodegradable polymer is that this biodegradable polymer is readily available and efficient as binder. Although different types of binder can be used, the abovementioned biodegradable polymer provides the advantage that, due to its binding efficiency, can be applied in relatively low amounts, thus allowing an increased amount of seaweed. Consequently, the manufacturing costs of the composition are reduced.

It will be understood the composition is not limited to any of the before mentioned biodegradable polymers. The binding properties as well as the Heat Distortion Temperature (HDT) are leading when the composition is applied in disposable tableware.

Other important parameters are the elongation and strength of the composition. The amylose content of starch influences the elongation and strength. An increase in amylose content results in an increase of the elongation and strength too. Therefore, when starch is used as the biodegradable polymer the composition can be tailored for its needs.

In a presently preferred embodiment according to the invention, the biodegradable polymer comprises poly(lactic acid) as the biodegradable polymer, in particular 50% to 70% poly(lactic acid), preferably 55% to 65% polydactic acid), more preferably 60% poly(lactic acid).

In another embodiment mixtures of two or more biodegradable polymers are used. An advantage of a mixture of biodegradable polymers is that the composition will bind even better and provides a biodegradable polymer which is readily available. An example of a preferred mixture is 60% poly(lactic acid) and 40% starch. This mixture provides efficient binding properties.

The composition is characterised by the Heat Distortion Temperature (HDT). This is the temperature at which a (bio)plastic sample deforms under a specified load. In a presently preferred embodiment according to the invention, the HDT of the composition is at least 55 °C, preferably at least 65 °C, more preferably at least 75 °C, even more preferably at least 85 °C, most preferably at least 95 °C.

For disposable tableware it is important that the bioplastic has a HDT of at least 55 °C, preferably at least 65 °C, more preferably at least 75 °C, even more preferably at least 85 °C, most preferably at least 95 °C. An advantage of plastics with a HDT of at least 75 °C is that the plastics are suitable for disposable tableware used to serve beverages with a temperature lower then 75 °C. It is less likely that beverages will be served at temperatures higher than 75 °C due to the fact consumers will be subject to the risk of getting severely burned.

The composition according to the invention can also be used for producing disposable tableware. The composition according to the invention is not limited to producing tableware. Other examples are packaging material, plastic bins, seats, transport material. Examples of packaging material are hotties, wrappers, cling film, bags, crates, boxes.

The invention further relates to a method for producing tableware, comprising the steps of: mixing the seaweed and biodegradable polymer;

blow moulding or injection moulding or thermodynamically moulding of the composition according to the invention.

The method provides similar effects and advantages as described for the composition. For the purpose of the invention, the step of mixing the seaweed refers to mixing dried seaweed. It is preferred that the seaweed, prior to delivery to the manufacturing site at which the method is performed, is dried. Drying of the seaweed is preferably performed such that the dried seaweed contains a water content of less then 2% by weight, preferably less then 1.5% by weight and more preferably is in the range of 1% to 1.5% by weight. Furthermore, the dried seaweed is grinded to obtain fibres of preferably less then 10 mm, more preferably less then 5 mm, even more preferably less then 1 mm.

Alternatively, when the seaweed that is provided to the manufacturing site at which the method is performed, is harvested seaweed without prior treatment. The method according to the invention may comprise drying the seaweed, wherein the step of drying preferably comprises drying the seaweed to obtain seaweed having a water content of less then 5% by weight and preferably less then 2% by weight, and/or grinding the seaweed to obtain seaweed fibres. The size of the fibres is preferably less then 10 mm, more preferably less then 5 mm, even more preferably less then 1 nun.

In an embodiment according to the method of the invention, the method additionally comprises the step of drying the mixture after mixing the seaweed with biodegradable polymer. The mixture is dried to a water content of less then 5% by weight, more preferably less then 2% by weight, more preferably less then 1.5% by weight.

In a further preferred embodiment according to the invention, the method comprises the step of providing a food grade coating to the tableware.

An advantage of a food grade coating, which often is also referred to as a food safe coating or non-harmful coating for use in food utensils, is that this allows for tableware which has an extended expiry or ‘use before’ date. This allows for tableware which can be stored for longer periods of time, before being used as disposable tableware.

Another advantage of a food grade coating is that it stimulates the compostability of the composition. This allows a composition with a short life-time after being disposed.

Another advantage of a food grade coating is that the design of the tableware can be modified using the food grade coating. This allows for custom designed tableware. For example, colouring of the tableware.

In a further preferred embodiment according to the invention, the seaweed is nonconsumable and/or consumable for humans.

An advantage of using non-human consumable seaweed is that a wide variety of seaweed species is available to be used in tableware.

Another advantage of consumable seaweed is that a wide variety of seaweed species is available to be used in tableware.

The invention is not limited to producing tableware. The method can be applied to produce any object with the mixture of seaweed and biodegradable polymer which initially is made of plastic.

The invention further relates to tableware products produced from the composition according to the invention.

The tableware products provides similar effects and advantages as described for the composition and method. It will be understood that tableware products are for example forks, knifes, spoons, rods, plates, bowls, cups, dishes, drinkware, straws.

The invention further relates to the use of the composition according to the invention for production of tableware.

The use of the composition according to the invention tor production of tableware provides similar effects and advantages as described for the composition, method and tableware products.

The invention further relates to tableware comprising the moulded composition according to the invention.

The tableware comprising the moulded composition according to the invention provides similar effects and advantages as described for the composition, method, plant based tableware and use of the composition according to the invention.

The invention further relates to tableware obtained by the method according to the invention.

The tableware according to the invention provides similar effects and advantages as described for the composition, method, plant based tableware, use of the composition and tableware comprising the moulded composition.

Further advantages, features and details of the invention tire elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

Figure 1 schematically shows examples of tableware comprising the composition according to the invention;

Figure 2 schematically shows an example of a cross section of tableware comprising the composition according to the invention; and

Figure 3 shows a schematic overview of the method according to the present invention.

Tableware 10 (Figure 1) includes (mixing) rod 12 and fork 14. Tableware 10 comprises biopolymer 15 and seaweed fibre 16. The density of seaweed fibres 16 depends on the ratio seaweed to biodegradable polymer. Tableware 10 comprises edge 18 and foodgrade-coating 20.

Cross section (Figure 2) of tableware 10 comprises biopolymer 15 and seaweed fibre 16. Tableware 10 comprises food grade coating 20.

Method 30 (Figure 3) for the production of tableware follows a sequence of different steps. In the illustrated embodiment this starts with collecting/harvesting 32 of the seaweed.

Optionally a selecting step 34 can be performed. The collected/harvested seaweed is grinded in grinding step 36 and followed by mixing/adding step 38. In mixing/adding step 38 the seaweed and biodegradable polymer are combined. Mixing/adding step 38 is followed by moulding step 40, wherein the moulding can be blow moulding or injection moulding or thermodynamically moulding. Moulding step 40 is followed by drying step 42 and the dried product is optionally coated/laminated in coating/laminating step 44.

The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.

Claims

A composition for the manufacture of tableware, comprising seaweed and biodegradable polymer.

The composition of claim 1, wherein the amount of seaweed is in the range of 10% - 60%.

A composition according to any preceding claim, wherein the seaweed is selected from a group of Chlorophyta, Rhodophyta, Phaeophyta, or a mixture thereof.

The composition of any preceding claim, wherein the seaweed species is selected from the group consisting of Laminaria saccharina, Gracilaria spec., Alaria esculenta, Saccorhiza polyschides, Ulva lactuca, Ascophyllum nodosum or a mixture thereof.

The composition of any preceding claim, wherein the amount of biodegradable polymer is in the range of 40% -90%.

The composition of any preceding claim, wherein the biodegradable polymer is selected from a group of polyhydroxyalkanoates, poly (lactic acid), poly (glycolic acid), poly (lactic acid co-glycolide), poly (butylene succinate), starch, polyurethane , polyurea, polyamide, and / or a mixture thereof.

A composition according to any preceding claim, wherein the starch is corn starch, wheat starch, potato starch, rice starch and / or carrot starch.

A composition according to any preceding claim comprising 30% -50% starch, preferably 35% -45% starch and more preferably 40% starch.

A composition according to any one of the preceding claims, wherein the biodegradable polymer is Solanyl® C1201 and / or Solanyl® C2201 and / or Optinyl.

The composition of any preceding claim, wherein the biodegradable polymer comprises 50% -70% poly (lactic acid), preferably 55% -65% poly (lactic acid), more preferably 60% poly (lactic acid).

The composition of any one of the preceding claims, wherein the deformation temperature of the composition is at least 55 ° C, preferably at least 65 ° C, more preferably at least 75 ° C, and even more preferably at least 85 ° C and at most preferred is at least 95 ° C.

A method of manufacturing tableware, comprising the steps of: mixing the seaweed and the biodegradable polymer;

blowing, injecting or thermodynamic spraying the composition according to any one of the preceding claims.

The method of claim 12, further comprising the step of providing a food-grade coating on the tableware.

A method according to claim 12 or 13, wherein the seaweed is non-human consumable seaweed and / or human consumable seaweed.

Tableware product comprising the composition of any one of claims 1-11.

Use of the composition according to any one of claims 1-11 for the manufacture of tableware.

Tableware obtainable by the method according to any one of claims 12-14.