Innovative fully biodegradable mulching films & fruit ... · A. Montanari Multibiosol Workshop,...

Multibiosol Workshop, Pisa, 23rd November 2017

Innovative fully biodegradable mulching films & fruit protection bags for sustainable agricultural practices LIFE14 ENV/ES/00048

LIFE MULTIBIOSOL

Life BiocopaPlus: sustainable bio-lacquer for food cansfrom tomato peels

Angela Montanari, Angelica Ciffarelli e Serena Chierici, SSICA

[email protected]

Laboratori ARCHA Srl

Via di Tegulaia 10/A

56121, Ospedaletto

Pisa, Italy

A. Montanari Multibiosol Workshop, Pisa, 23rd November 2017

SSICA, Experimental Station for the Food

Preserving Industry, is a Research Institute,

established in Parma in 1922.

SSICA activities focus on applied research

regarding the production chain in the agro-food

sector and food processing industry.

SSICA has about 80 employees in 2 locations,

Parma and Angri (SA).

The Packaging department focuses

its activity on the hygienic-sanitary

properties as well as on the correct

functioning of the containers and of

the materials involved in relation

with their construction

characteristics and operating

conditions for use: metal, glass,

plastic, bioplastic and rubber


The metal substrate is protected with a thin organic coating both on the internal and external

surface, which is essential to prevent corrosion

The coating: most of the coatings for internals are made starting from epoxy resins, because of

their exceptional mechanical and chemical resistance. (BPA migration limit: 0.6 mg/kg)

Metal packaging is made of tinplate, TFS and Aluminum.


THE KEY-IDEA starting from tomato industrial residues to

formulate a bio-based lacquer to protect metal

cans and closures.

from renewable resources to metal packagingbio-lacquer

The global metal packaging market is expected to grow by 4.5% annually to

a total value of $132.1 billion in 2021. Strong growth of end-use

industries in emerging coutries, India, China and Brazil.


World Tomato Production: 170 mln tonnes

World Tomato Processed: 38 mln tonnes

46

130

2.700 4.914

6.300

130

13.247

810

100

260

1.400

WPTC World production estimate of tomatoes for processing (in 1000 metric tonnes)

Country Tonnes

Brazil 4.302.777

Chile 909.025

China 52.722.967

India 18.735.910

Italy 5.624.245

Morocco 1.230.953

Senegal 180.513

South Africa 513.376

Spain 4.888.880

Thailand 119.049

USA 14.516.060

World Tomato Production


• The tomato cutin is a natural polymer of polyester type

• The main component of tomato cutin is the 10,16

dihydroxyhexadecanoic acid (70-80%), starting substance

for the polymerization

Each year in the world more than

1 mln ton of solid tomato

residues (peels and seeds) are produced.

The initial substance is cutin, a component of the

cuticle of the tomato peels.


BiocopacPlus Life project is based on the positive results

obtained in any step of the experimental work developed at

laboratory level in the FP7 Biocopac project.


Objectives

• To prove on semi-industrial scale the

technical feasibility of the

production process of the bio-lacquer

• To realize a pilot plant

• To evaluate yields and costs

Total cost: € 2.056.045

(LIFE+ contribution: 50%)

BiocopacPlus (June 2014- December 2017)


Methodology of cutin extraction developed at pilot scale (Italian Patent n. 0001419412)

EXTRACTION BY THERMAL TREATMENT

FILTRATION

CUTIN

ACIDIFICATION + PRECIPITATION

EXHAUSTEDPEELS AND

SEEDS

POLYMERIZATION

BIOGAS

TOMATOES BY-PRODUCTS

Liquid

phase

Production site: Azienda

Agricola Virginio Chiesa,

Canneto sull’Oglio (MN)


Test performed Skins processed Cutin extracted

35 5050 Kg 245-250 Kg

• Pilot plant capacity: 100kg/h, equal to

10-20% of a future industrial line

• Yield of extraction: 10-15%


FTIR spectrum All cutin samples presented the characteristic peaks of

an aliphatic fatty acid at 1702 cm-1

GC-MS analysis Principal unit of tomato cutin was identified as the 10,16

– bishydroxyhexadecanoic acid (70-80%)

GPC spectra Relative molecular weight 650 g/mol (GPC based on

calibration with polystirene standard

Cutin caracterization

4000.0 3000 2000 1500 1000 650.0

10.0

20

30

40

50

60

70

80

90

100.0

cm-1

%T

3248.96

2851.66

1703.10

1514.79

1461.86

1168.40

1105.99

1045.73

834.37

723.65

676.47

1630.00

1403.33

11

100 200 300 400 500 600m/zR.Match: 865, F.Match: 830

0%

25%

50%

75%

100%

Search

S SS S S S S

57.2 2.989e+8

59.1 5.336e+8

73.2 1.598e+9

81.2 9.880e+8

107.2 2.357e+8

109.2 4.423e+8

113.2 6.837e+8

129.2 1.288e+9

151.2 2.600e+8

159.2 5.180e+8

169.2 9.195e+8

217.3 9.334e+7

273.4 1.335e+9

274.4 4.707e+8

275.4 7.414e+8

276.4 1.614e+8

Spectrum 1A22.452 min, Scan: 2143, 50.0:600.0>, RIC: 3.605e+10BP: 73.2 (1.598e+9=100%), cutina.xms

0%

25%

50%

75%

100%

Match

41.0 130

73.0 999

75.0 500

81.0 210

83.0 100

95.0 400 103.0 300

123.0 60

159.0 80

169.0 170

244.0 70

273.0 770

274.0 150

275.0 430

OSi

OSi

OO

Hexadecanoic acid, 10,16-bis[(trimethylsilyl)oxy]-, methyl esterCAS No. 21987-16-6, C23H50O4Si2, MW 446BP 73.0 (999=100%) 34559 in MAINLIB


The extraction method is reproducible independently from

• the geographical origin of the peels

• the kind of peels: any type, also homogenized

• the peels from which lycopene has been previously extracted

Better performances of the exhausted peels for the biogas production

•Heavy metal <10ppb

•Sugars and fibers <0,5%

•No pesticides residues

•No microbiological charge

Cutin contamoination

Sample Yield of biogas

( dm3 / Kg of v.s.)

Volatile substances

(%)

Tomato peels as they are 43 dm3 / Kg of v.s. 70%

Exhausted tomato peels 100 dm3 / Kg of v.s. 65 %


Formulation and production of the new

bio-lacquer (50kg)

Industrial application on aluminium, tin

free steel and tinplate

Industrial production of 2 and 3 pieces

cans and open top ends

Compliance with the Italian and European

legislations. The lacquer does not modify the

products’ organoleptic characteristics.


Filling of the cans; LCA

The results of the pack-test (in progress) are very interesting and

promising. LCA results are really impressive

The cans (4000) were

filled with tomato,

legumes and fish

products and stored at 20,

37 and 50°C

In comparison with a standard lacquer of fossil origin lower

emissions of CO2, equal to 130.7 mg in the CO2

produced (or avoided) for each can.14


Optimization plant components

Reduction environmental impact of the

process

Evaluation pack test

Evaluation cost

implementation of

BiocopacPlus pilot plantto treat several vegetable by-products,

tomato cull, wheat. olive, potato


The bio-based lacquer we

are developing meets the

demand for sustainable

production and for the

safeguarding of consumer

health, it doesn’t contain BPA,

it improves the recyclability

of the can

Conclusion


17

Simple and well-known technologies

No organic solvent in the process

No environmental permission required

High performance and yield

At a relatively low costs

easy to

replicate even

in a tomato

industry

Locally sourced

lacquer

Total cost of the prototype € 800.000,00

Conclusion


Thanks for your attention

www.ssica.it

www.biocopac.eu

www.biocopacplus.eu

Biocopac BiocopacPlus

Tomatoes with a can do attitude29/09/2014

[email protected]

http://www.ssica.it/

http://www.biocopac.eu/

http://www.biocopacplus.eu/

Innovative fully biodegradable mulching films & fruit ... · A. Montanari Multibiosol Workshop,...

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