MATERIALS | BIOPLASTICS
Right: The BreadCell project produced several foam prototypes including a skateboard
data for these simulations, the material was characterised through a series of tests. Based on the results, foams with different densities and mechanical properties were produced and applied in various demonstrators including a skateboard, bicycle helmet and shoe insoles. Florian Feist of the Institute of Vehicle Safety at
TU Graz said: “It was a challenge to keep density homogeneous over the thickness of the foam, but this proved advantageous in one specific application: bicycle helmets.” Here, a softer centre layer enables a kind of
shearing between the outer and inner layers – reducing rotational load on the brain when there is an impact. The project has given rise to a spin-off company,
Foamo, which makes lightweight cushioning insoles based on the developed foams.
Lighter PLA Similarly, Nexam Chemical has expanded its Lightweight product range with a new bio-based foam.
In collaboration with Verdofoam, it has used its additive technology to expand PLA into a foam, which can be used to replace conventional polystyrene in applications such as packaging and insulation materials. “PLA foam opens up an entirely new market for
Below: Navico is using Aquapak’s Hydropol bags to protect its marine electronics during shipping
us,” said Ronnie Törnqvist, CEO of Nexam. “We are demonstrating how our technology can help reduce the climate footprint of plastics without compromising performance or functionality.” Packaging foam is typically used to protect
products during transport. The global volume of expanded polystyrene (EPS) used in packaging is estimated at around 5.8 million tonnes/year. This corresponds to 18-30 million tonnes/year of CO₂e, says Nexam. “With the help of Nexam additives, we have produced a completely bio-based foam with the
right structure and properties,” said Hans-Erik Ouwehand, CEO of Verdofoam.
Electronic protection Navico is using Hydropol bags from Aquapak to protect its marine electronics during shipping. Hydropol is water soluble and non-toxic to marine life. It can be processed on existing packaging machinery at scale to produce a barrier film layer that can be combined with paper and other bioplastics or simply turned into strong, durable, puncture-resistant, anti-static bags. Thanks to these properties, Navico used Hydropol bags as part of its commitment to protecting the natural environment and ensuring its supply chain is as sustainable as possible. “Hydropol is perfect for a business like Navico, which operates in the highly sensitive marine environment,” said Mark Lapping, CEO of Aquapak. “It can be used as an alternative to conventional plastic as it provides the same functionality and performance but without harming the environment.”
Compostable barrier Sukano, Brueckner and NatureWorks have teamed up to develop a masterbatch and a biobased material that enables the creation of compostable packaging with barrier properties. “By combining our Ingeo biopolymer with
Brückner’s biax technology and Sukano’s S/AB surface additive, we’ve opened the door to a new generation of ultra-thin, cost-effective barrier films,” said Roger Tambay, chief growth officer at NatureWorks. “This makes it possible to reduce thickness while still delivering the sealability, barrier performance, and lamination strength
brand owners need.” Sukano’s new Antiblock masterbatch – which
14 FILM & SHEET EXTRUSION | January/February 2026
www.filmandsheet.com
IMAGE: AQUAPAK IMAGE: WOLF/TU GRAZ
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