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Special Five PLA pioneers

significant number of companies have launched bev- erages in PLA in recent years. AMAGAZINE spoke to the responsible people at five of the early pioneers in this field about their motivation, their experience and their future plans. Motivation Being asked how they came to the idea of using PLA as a bottle material, David Zutler of BIOTA said, that as early as 1996 he was already looking for a better material. In May of 2002 he read an article in the local Telluride newspaper how plastic bottles were helping to destroy the environment of our planet. Just shortly after Cargill and Dow opened their production plant for PLA in Blair, Nebraska, USA, he and Planet FriendlyTM Products, a bioplastics consultancy firm also founded by him, contacted Cargill Dow (now Na- tureWorks LLC) and with the support of Cargill Dow, Husky and SIG Corpoplast they started the rollout of the World‘s First PLA preforms, bottles, and with the intention of “helping change the world as far as plastics is concerned,“ as David puts it. A similar idea drove Bill Horner of Naturally Iowa, when his company established the guidelines for creating a new all natural or even all organic dairy company. In October of 2005 they saw a major shift in consumer demand for organic products. “We decided to make a shift in our business plan BIOTA Brands of America, Inc. / as well, and with regard to packaging we wanted to set our- Planet Friendly Products selves apart from all the others,“ says Bill, “and the only real Telluride, Colorado, USA breakthrough in plastics packaging that we could see was David M. Zutler, Founder and CEO PLA“. Two years earlier they had contacted Cargill Dow, just Belu Mineral , London, UK an hour and a half down the road, and enjoyed the benefit Reed Paget, Co-founder of earlier experience gained with the help of BIOTA bottles. and Managing Director Naturally Iowa uses Norland blow moulding equipment for Ihr Platz GmbH + Co. KG, Osnabrück, Germany their in-house production of the bottles. Bernd Merzenich, former Consultant London (UK) based Belu is an environmen- now: Managing Director of tal initiative which contributes 100% of its net profits to clean german bioplastics GmbH & Co. KG water projects. Working with the charity WaterAid, every bot- Plus One Water, Inc., Montreal, Canada tle of Belu water purchased in the UK provides someone in Michael Keeffe, CEO India or Africa with clean water for one month. About five years ago Belu contacted the Rocky Mountain Institute, an Naturally Iowa, LLC, Clarinda, Iowa, USA environmental organisation in the USA. “I discussed with William Horner, President them how to make a low impact bottle to create a more sus-

10 bioplastics MAGAZINE [02/07] Vol. 2 Special

tainable product,“ says Reed Paget of Belu, “and they sug- gested we use a sort of biopolymer“. As PLA was not ready for commercial use in those days, Belu started the launch of Belu Mineral Water with bottles. After the successful launch of BIOTA, Belu finally introduced in May 2006 the Belu PLA bottle, using preforms purchased from Planet Friendly Products. The bottles are blown on SIG Corpoplast stretch blow moulding machines and filled at Brecon Mineral Water in a factory located near Llandeilo in South Wales. To set up a socially responsible water company was the idea with which Michael Keeffe of +1Water in Canada ap- proached co-founders Paul and David Smith a few years ago. “We wanted to contribute 20% of our profits towards water development organisations like WaterCan and Ryan‘s Well Foundation in Canada and Operation Hunger in South Africa,“ says Michael. These non profit organisations help provide communities in need with access to safe, clean wa- ter. “Unlike most people living in North America and Europe, there are over one billion people in the world that do not have access to safe drinking water,“ he adds. Within a few months they found out about PLA and decided it would pro- vide the environmentally responsible component to round out the socially responsible dimension of the product. With the technical support of NatureWorks, Krones and Ben Ben- edict at Iroquois Water +1Water was able to launch their PLA +1 bio-bottle last January. +1 bottles natural spring water from a family owned spring called “Bell Falls“ in Quebec. Iroquois Water, use Krones equipment, to blow and fill the bottles for +1Water. Bernd Merzenich (today head of german bioplastics) has acted as a consultant to different companies with regard to the production and marketing of organic food for about 25 years. In recent years he has also been keen to use bio- plastics as a packaging material for organic produce. When working for the German drugstore chain “Ihr Platz“, es- tablishing a new range of organic food products and natu- ral cosmetics, he came across the BIOTA bottles. He found exciting the idea of using PLA as a packaging material for a pilot project of wellness beverages with a strong appeal to health and environment, which Ihr Platz was planning to introduce. When Hycail (today with Tate&Lyle) could not con-

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tinue their initial support Bernd started to cooperate with NatureWorks, “from whom we received considerable sup- port towards sourcing and processing the material.“ The Luxembourg based company Plastipak supplied the pre- forms, made on Husky equipment, to the German mineral water company Quellenhof who blow-moulded and filled the bottles for Ihr Platz . Summing up the first part of our conversation, we can say that all of the parties interviewed consider their decision re- garding the use of PLA as a material for their bottles as the right one. David Zutler: “Absolutely the right decision. Pe- troleum based plastics are one of the world‘s biggest prob- lems. Just look at some of the developing countries where no is in place for PET bottles and where they openly burn their overloaded .“ Bill Horner: “100 percent the right decision. We are planning further products to be packaged in PLA.“ Reed Paget: “Almost any analysis shows that PLA is the most sustainable option.“ Michael Keeffe: “At this point in time we are convinced it was the right deci- sion. We have outlets across three of the Canadian provinces here, and we are about to expand to the west coast of Cana- da.“ And even though Ihr Platz recently discontinued selling the Vitamore wellness , Bernd Merzenich considers the use of PLA as the right decision. Bernd: “It was good to make a statement in favour of bioplastics and to be the first on the German market. However, a drugstore chain is not a food store and beverages in bottles with, at the moment, limited barrier properties need a faster turnover.“ Labels and caps How important are labels and caps from renewable re- sources for the companies that sell PLA bottled products? While the Vitamore and +1Water labels are made of and therefore made from a renewable - and biodegradable - source, BIOTA, Belu and Naturally Iowa are already using PLA labels. +1Water is eventually planning to switch to PLA labels. When it comes to caps, it‘s the other way round. Ihr Platz introduced the world‘s first compostable cap, made of MaterBi which is partly sourced from renewable raw materi- als. BIOTA is planning to roll out what David calls a planet- friendly cap, made of 100% renewables and 100% composta- ble. The composition is mainly based on PLA. This cap will be available to other bottlers too, as David points out. Reed says that “Belu will use a bioplastics cap as soon as we can find one that will work with our product“. Naturally Iowa is also interested in caps and “we‘ve been working with a company in Japan who‘s developing a PLA-blend that will work on closures,“ says Bill. He is confident of having one next year. +1Water will move to biobased caps, as soon as Planet friendly cap they are there,“ Michael points out.

12 bioplastics MAGAZINE [02/07] Vol. 2 12 - 13 September 2007 1st PLA-Bottle-Conference possibilities | limitations | prospects

PLA (Polylactide), a compostable plastic made from renewable resources such as corn, is a highly topical subject right now, especially in the light of increasing crude oil prices. The stretch blow moulded PLA bottles used by Biota or Natural Iowa (USA), Belu (UK), Vitamore (Germany) and +1water (Canada), as well as reports in the trade press, have aroused signifi cant interest from the PET and beverage industry. Would you like to fi nd out more about the possibilities, limitations and future prospects of PLA for bottle applications? That‘s exactly why bioplastics MAGAZINE is organising the 1st PLA Bottle Conference on the 12th and 13th of September 2007 in the Grand powered by powered Elysee Hotel in Hamburg, Germany. This 1½ day conference offers a comprehensive overview of today‘s opportunities and challenges.

Experts from companies such as Purac, Uhde Inventa-Fischer, Natureworks, Netstal, SIG Corpoplast, Wiedmer, Treofan, Sidaplax, SIG Plasmax, Doehler, Polyone, Ihr Platz, Coca-Cola, Interseroh, and € 850.00 more, will share their knowledge and … …on the afternoon of Thursday September 13th delegates will visit SIG Corpoplast, the manufacturer of the stretch blow moulding equipment that is used to produce for example the Biota and the Belu bottles.

There will be sessions covering: Sponsors  Raw materials, from corn to PLA  PLA preform manufacture  Stretch blow moulding of PLA  Caps, labels, shrink-sleeves made from biodegradable plastics  Barrier solutions for PLA bottles  Temperature stability of PLA  Additives, from processing agents to colorants  Reports „from the market“  End of life options, recycling, energy Supported by recovery, composting

More information and registration: www.pla-bottle-conference.com Special

Planet FriendlyTM bottle

The cost issue None of them is currently packaging products that need a with elevated temperature resistance. However, “The higher price of PLA is acceptable to us and should be all confirm that for certain applications such as hot-filled acceptable to everyone because the planet is worth it,“ says juices etc. enhanced thermal properties will be needed. David Zutler. And he thinks that the majority of consumers “who care“ think so too. Eventually, David is convinced, when When it comes to barrier, the picture looks different. Reed the economy of scale kicks in, the price of PLA will drop. Paget thinks that, as for other plastic materials, PLA also needs an enhanced barrier. Michael Keeffe confirms this Reed Paget too believes that in the long run, the price of thought, for their current product, flat water, improved bar- PLA will come down while petrochemical plastics will be- rier properties will provide greater production and distribu- come more expensive. The environmental sustainability is tion options. “For the long term viability of PLA for other the starting point for Belu and Reed too thinks that some products, such as carbonated beverages or fruit juice, we consumers would accept a slightly higher price. “However, will also need a barrier against CO and Oxygen“. we try to be cost effective as much as we can,“ he says. 2 Bernd Merzenich: “PLA definitely needs to be improved “I really think the price is dominant and I would like to say regarding its barrier properties and heat stability. For still the environmental advantages would outweigh the price“, water the presently available level of material and technol- says Bill Horner. On the other hand he considers that the ogy is OK, on the premise that the turnover at the point of price of PLA today already is almost competitive with PET. sale is sufficiently fast. But for more sophisticated uses in “The price for PET is going higher and higher, and although the beverage and food industry we need material improve- we had a fight on the corn prices that was just temporary. ments by developing new compounds on the basis On a long term view the prices for starch are much more of PLA, as well as by using additives, or the like, stable“, he adds. such as, for instance, the SIG Plasmax plasma proc- Michael Keeffe doesn‘t feel that the price is a super-criti- ess or a bioplastic barrier resin for multilayer applications, cal factor for the consumer. “As soon as it becomes clear which has been announced by Plantic.“ that it is an environmentally friendly bottle, that seals the Naturally Iowa, cold filling their products, are very satisfied decision for most people,“ Michael explains. „We hope that with the quality of the PLA they get from NatureWorks today. the increasing demand for sugar, for example for making Their milk is a short shelflife product and is sold through the bio-ethanol, does not push the price of PLA up through the cold chain, so that up to now better barrier or temperature roof, but as of now the price for us is workable“. properties have not been needed. “We are talking about environmentally and health con- David Zutler however, is already active in this field. To- scious consumers who are willing to accept a premium price gether with strategic partners Danimer, and the Australian for corresponding items,“ says Bernd Merzenich. “But you packaging and recycling group Visy, BIOTA is developing a really need a very clear communication strategy with these Planet Friendly bottle, that is made of PLA plus an additive products,“ he adds. “You need to be transparent and critical, which enhances the elasticity properties, and will help pro- and clearly explain what is bio with these materials.“ vide some additional properties as well. “Our goal is to have Barrier properties and heat resistance such a bottle within the next six months, and in addition to As how important do our interview partners consider en- that, to have a bottle material with barrier properties even for hanced barrier properties and the heat resistance of PLA? use with CSD (carbonated soft drinks) and resistant to water

vapour, heat, and O2 ingress within a year,“ says David.

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End-of-life options looking at the present hype regarding biofuels, the aspect of eco-friendly energy recovery from bioplastics should be There has to be a way for consumers, and recyclers to stressed: Bioplastics create a much higher added value easily tell the difference between biobased products and from agricultural raw materials than biofuels and can gen- based products. “All our bottles say Planet erate a similar output of CO neutral energy when inciner- Friendly™. When the consumer, and recycler, see those 2 ated at their end of life.“ As soon as barrier properties and words, they know what they are,“ says David. “My number heat resistance are improved, biodegradability as an option one end-of-life option is what I would call reclaiming,“ he will anyway become much less an issue, Bernd adds. “Per- adds. „ or recycle to bottles or into other products sonally I don‘t believe in biodegradability unless it has prac- such as garden pots etc. And my second favourite is energy tical reasons,“ he says. “For instance when you pack fruit recovery. PLA burns cleanly and can help augment the use and vegetables you can compost the waste together with the of fossil fuels (petroleum, coal, etc.) in power plants, help- packaging, or when bioplastic shopping are available ing to generate greenhouse neutral energy and alleviate the they can be used to collect and compost organic waste.“ devastating problem of burning plastics in landfills.“ Future prospects Reuse and recycle are also the preferred end-of-life op- tions for Reed Paget, making up the top four together with BIOTA will remain a company, but Planet composting/energy recovery, and with as the last op- Friendly is going to work with different manufacturers to tion. Belu is currently working on life cycle assessments and promote PLA and other bio-based packaging. “I would even home composting seems to be a viable option instead rather help other manufacturers with the different additives of shipping the waste across town to a waste facility. “I did it and different material properties that are being developed,“ myself in my backyard,“ says Reed, “and if you know how to David says. do it, it works.“ Belu as well as +1Water have further projects on the draw- “Our +1 bio-bottle is clearly stamped both with the number ing board. However, “they are not too far down the road as of seven recycling logo as well as the word ‚compostable‘ in- yet“, Reed Paget points out. forming consumers that they have disposal options, says “So far we just produce the 0.5 gallon milk bottles,“ says Michael Keeffe. +1Water is working (with a number of recy- Bill Horner, “but starting in June we are going to be bottling clers) on a pilot project with a company called “Turtle Island milk in 10 and 12 oz. and possibly even 8 oz ‚grab-and-go‘ Recycling“ in Ontario focused on both bioplastics recycling , and in the fall we start with a probiotic - and composting. And when, after reuse or recycling, PLA able yoghurt with an extended life that we are really excited ends up in an incineration plant, because it‘s not petrochem- about,“ he proudly adds. All of the products will be packaged ical based it is also more environmentally friendly as well. in PLA, the single serve units with a PLA shrink sleeve. Today, Naturally Iowa‘s percentage of the market is rath- Bernd Merzenich thinks that for many companies in Ger- er small, so that the bottles end up in a landfill where they many it is a drawback to start using PLA as long as there is degrade. But Bill Horner says that first attempts are being only one supplier. First of all, if a company wants to intro- made to set up industrial composting facilities. duce PLA, they can‘t get the material, and secondly, no one Bernd Merzenich says: “To be pragmatic, just now I only wants to rely on a single source. And David Zutler says that see incineration with energy recovery as meaningful. From governments should support companies that want to build an LCA point of view I would favour thermal disposal, be- up production capacities. cause it generates CO2 neutral energy. Last but not least,

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Final remarks David Zutlers says: “The big beverage companies in the world will not convert to PLA bottles unless they are required to do so.“ They may be pushed to do so because of economic advantages, or by law. “And govern- ments should consider, when the barrier and heat deflection problems that we are working on have been solved, making the use of PLA or other bio- based packaging a requirement.“ Reed Paget wants to stress that all the companies involved today are re- ally pioneers that have taken a significant financial risk and that deserve to be acknowledged and thanked. “Waste in our modern lifestyle is a growing and significant issue, as is energy consumption,“ he says, “and biopolymers are offering a way to maintain a fairly modern lifestyle with the prospect of not leaving a legacy of pollution which the planet cannot sustain.“ Michael Keeffe is very excited about the potential for PLA particularly given growing consumer demands for more environmentally sustainable and socially responsible products. Our PLA water bottle is both of these, a healthier choice for the environment and a healthier choice for the con- sumer while helping others get clean water too: Bill Horner is very happy “that we made the decision early on and have stuck with it through all the research and development rollercoaster that we‘ve been through. But it‘s been worth it all.“ Not only is Bill very pleased with what they have achieved so far, they are also willing to share the les- sons they have learned with other dairy companies around the world. Bernd Merzenich, with a very focused view on the German beverage packaging situation, thinks it essential that government accepts PLA as an ecologically favourable packaging material so that PLA bottles are ex- empted from the mandatory deposit fee laid down in the German Packaging Ordinance. “If this can be achieved, it will really be a breakthrough for PLA because we then enter into a new environmental quality. That will make PLA attractive for a mass market,“ he says. The very final words in this talk with major bioplastics users are from our cover-girl Janina (11). She says: “In school we learned that crude oil is a limited resource and that alternative energies such as wind or solar power can save oil. I didn‘t know that plastics were made from oil and I like the idea that plastics can be made from plants.“ And her little sister Lena www.biotaspringwater.com (6) adds: “Michael Thielen said, microorganisms that live in the compost www.ihrplatz.de www.belu.org heap eat the bioplastics. But I can‘t even imagine what microorganisms www.plusonewater.ca look like!“ www.naturallyiowa.com

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