An applied research project by Saskatchewan Polytechnic and EnviroWay Detergent Manufacturing aspires to convert fibre from flax and hemp crops into biodegradable, bottle-grade plastic pellets, which will then be used in blow-moulded containers for cleaning products.
Apparently, ‘most’ biodegradable plastics currently available on the market are suitable for food containers, thin films, and compostable cutlery; but cannot meet the requirements detergents, degreasers, or disinfectants. Their bottles are manufactured through high-speed blow moulding and must withstand strong chemicals and rough use during their lifespan.
At Saskatchewan Polytechnic’s Biomaterials Testing and Prototyping (B-TAP) facility, specialized tools are helping researchers process biomass from flax and hemp – which would otherwise be discarded or incinerated – into manufacturing materials.
Locally grown flax and hemp fibres will be evaluated to gauge their suitability for biodegradable plastics, considering factors such as quality, availability, cost, and sustainability metrics. Using these prairie fibres in packaging is anticipated to create new demand for ‘underutilized’ materials, establish a new stream of income for Saskatchewan farmers, and drive investment in rural fibre-processing infrastructure.
With the right blend of fibre and biodegradable resin, Saskatchewan Polytechnic plans to produce biocomposite pellets.
“Getting these pellets to work in blow moulding machines is a major technical hurdle, because fibre‑reinforced plastics often behave unpredictably when melted and shaped,” explains Dr. Satyanarayan Panigrahi, research chair at the B-TAP facility and leader of the project. “The goal is to develop a plastic that flows smoothly and produces bottles that are as durable as traditional plastic ones.”
Once the pellet formulations have been refined, the researchers plan to produce prototype bottles and fill them with real cleaning products, including alkaline degreasers, detergents and acidic solutions. These prototypes will be subjected to real-world conditions, from warehouse storage to shipping processes, to observe any issues with leaching, material degradations, and impacts on product quality.
A production line at EnviroWay’s Saskatoon facility will be used to test the bioplastic bottles on existing moulds and filling systems. The researchers hope that direct collaboration with industry will underline any necessary changes for large-scale manufacturing and smoothen the transition from polymer-based to bioplastic packaging.
In turn, industry-embedded validation is anticipated to shorten the time needed to bring the new format to market and develop a circular economy that benefits farmers and manufacturers alike.
The project is also set to support the processing of crops within the province and establish biobased manufacturing markets. EnviroWay will retain the intellectual property of the project – a move expected to help commercialize home-grown innovation.
“The B-TAP team is tackling a major challenge in sustainable packaging using local resources and manufacturing facilities,” adds Dr. Robin Smith from Saskatchewan Polytechnic’s Sustainability-Led Integrated Centres of Excellence (SLICE).
The project has received $250,000 in funding from the Agriculture Development Fund (ADF) through the Sustainable Canadian Agricultural Partnership, and $7,000 from the National Research Council of Canada Industrial Research Assistance Program. Work is scheduled to begin this year.
In a similar collaboration, Amazon and the Indian Institute of Technology Roorkee are working together to convert wheat, straw, and bagasse waste into recyclable, home-compostable packaging. This is thought to reduce plastic consumption, cut carbon emissions, and help farmers profit from side streams.
One.Five has also helped Foodie & Friends package its organic spices in recyclable barrier packaging made from agricultural residues – a transition set to generate 30% less CO2 than petroleum-based polypropylene films.
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