In search of sustainable material alternatives: What is the potential of bio composites?

What are bio composites? 

Stephan Sell: Bio composites are composite materials with a biogenic component. They offer a sustainable alternative to conventional materials based entirely on petroleum by combining traditional polymers with natural fibers, natural fillers or biopolymers. Another bio composite variant is the combination of natural fibers and biopolymers. These bio-based polymers consist entirely or at least partially of renewable raw materials. Some of them are even biodegradable. For the production of biopolymers, for example, natural products such as wood, corn starch, sugar cane or even vegetable waste from fat or paper production are used.

What are the advantages of this?

Stephan Sell: Thanks to bio composites, fossil raw materials can be replaced by renewable ones in product development. This goes hand in hand with CO2 savings and a lower environmental impact, while also being a possible step toward independence from petroleum. Depending on the materials used, microplastic discharges into the environment can also be reduced or avoided. But there are even more advantages: Bio composites are characterized by very high strength and rigidity. These composites are of particular interest to the automotive industry because, in addition to good mechanical performance, they offer excellent insulating properties at a low density. This means that weight can be saved, and components can be designed to be lightweight and environmentally friendly at the same time. Because of these properties, more research has been carried out in recent years into other areas of application and more and more markets have been opened up for the use of bio composites.
 

What areas of application are there for these composites?

Dominic Tilgner: Natural fiber-reinforced plastics with wood have long been used in decking boards or fences. In addition, bio composites are used primarily in the furniture sector or in packaging. For some years now, the areas of application have become increasingly diverse: The spectrum now ranges from musical instruments to toys and suitcases. And many more are conceivable. We see great potential for technical applications in particular. That's why two years ago we took part in a market study on bio composites by the AZL Institute (Aachen Center for Integrative Lightweight Construction), experts in the field of lightweight construction technology.

What was the purpose of this study?

Stephan Sell: The purpose of the study was to be able to design products that are more environmentally friendly in the future thanks to an accurate assessment of the market potential, possible applications and relevant technologies of biocomposites. For a long time, biocomposites played a subordinate role in technical applications, so further areas of application were to be explored. The study showed that biocomposites can also replace standard fibers in many technical products. One example is the possible production of car door components based on biobased composites, which is currently also being researched further. But there are also already practical examples: BMW and Daimler are working with the start-up Bcomp to replace carbon fiber-reinforced plastic with natural fiber composites. They are used in various vehicle components and help save weight, costs as well as consumables in production and drastically reduce CO2 emissions. In addition, solutions for many other industrial sectors were considered, such as public transport, aircraft, furniture, and construction and infrastructure. We took part because we are always on the lookout for innovative and sustainable solutions and see great potential for reducing CO2 emissions through biocomposites.
 

Where are biocomposites already being used at REHAU?

Dominic Tilgner: By launching RAUKANTEX evo, we have introduced another sustainable product line in the edgeband department alongside RAUKANTEX eco. Non-fossil basic raw materials are utilised in it instead of the crude oil usually used. In the future, this use of sustainable raw materials will be ensured throughout the entire production process by means of external auditing and the renowned ISCC certification. The sustainable polypropylene edgeband is currently undergoing this certification process. In addition to this, we are currently reviewing other possible applications and are working with our subgroups and divisions to achieve this.

You work in a cross-company department that develops solutions for all subgroups and divisions. How does the cooperation with other functions work?

Dominic Tilgner:

We are constantly looking for new possibilities and work on concrete product ideas together with our colleagues from the technical departments. They know the market demands and customer needs, we develop innovative materials and processes. For this purpose, we have built up a broad network of partners and get new inspirations in order to be able to transfer promising concepts to other industrial sectors and products. Together with the specialist departments, we want to find suitable solutions that are tailored to the wishes of our target groups and contribute to our vision of improving life through the use of innovative technologies. The same applies to participation in the biocomposite study with the aim of identifying applications and initiating new developments to bring sustainable materials into more and more products.
 

Vielen Dank für das Interview!