The ReBioFoam project (renewable bio-polymer foams), a four-year research project launched in February 2009, has presented the results of its work in targeting the development of a new bio-based and biodegradable biopolymer foam. Coordinated by Novamont (Novara / Italy; www.novamont.com), the project involved a 10-strong consortium made up of partners from eight countries – Italy, Poland, Spain, the Czech Republic, Ireland, Germany, The Netherlands and the United Kingdom. Research and development activities have been carried out by a core group of industrial partners – Novamont, C-Tech Innovation, FEN and Chemtex Italia – in cooperation with a number of research centres – Fraunhofer Institut, Czech Technical University and ITENE – packaging producing companies Complas Pack and Recticel and household appliances manufacturer Electrolux.

The expansion of the biopolymers has been achieved using microwave technology, which takes advantage of the water content of the material as the expanding agent. A two-step process has been developed for the production of the bio-foams. First, formulation and processing through the extrusion of the base materials with small quantities of bio-based or renewable additives and subsequent conditioning to produce pellets for the expansion phase. The second step involves microwave-assisted expansion and moulding, where pellets are transferred into a microwave-transparent mould and processed at a controlled temperature to produce a three-dimensional foamed product.

The feasibility of the process has been demonstrated on a semi-industrial scale through the development of an automated pilot line producing a porthole spacer for a washing machine at a density of 40 to 45 kg/m³. In parallel, a new packaging element with a corner shape has been designed, characterised by different bearing surfaces, which may be assembled in a number of ways to obtain elements with different shapes that can function as a foam corner or edge protector for items such as household appliances and consumer electronics.