Compounding and film extrusion for biocomposites

This pilot-scale extruder service supports the development and optimisation of advanced plastics and composites, with a focus on bio-based polymers. It offers solutions from compounding to film and reactive extrusion.

Extrusion is a key method for processing plastics, allowing the production of films, coatings, and components with specific shapes and properties. The pilot-scale facilities can handle both conventional polymers and more complex, sustainable materials, supporting the optimisation of material properties for innovative applications. Reactive extrusion further extends these capabilities by enabling chemical reactions during the extrusion process, allowing the development of advanced materials with enhanced performance in a single step.

Extensive expertise in material formulation and process design allows work with a wide range of bio-based materials to develop high-performance solutions. Capabilities include optimisation of material blends, design of processing conditions, and production of customised films and coatings for various industries, including packaging and automotive.

The testbed consists of:

• Minilab-extruder (Haake)
• Medium-sized laboratory extruder (LabTech Technologies) with modular screws, gravimetric feeding, liquid injection, degassing, air or water cooling of extrudates, and pelletizing
• Injection molding machine (BOY) for producing test samples for impact and tensile testing

Through our expertise in compounding, extrusion, and biobased material processing, we help companies innovate sustainable solutions that contribute to a circular economy.

Projects

GoneShells

GoneShells is a biodegradable material that can replace paper, plastic, and glass in food packaging. It consists of a starch-based core with a bio-based barrier against liquid, oil, and oxygen. The material can break down without industrial composting, can even be eaten, and opens new opportunities for sustainability and design. By replacing plastics, it may also help reduce microplastic emissions.

ProMultiFilms – Processing of bio-based multilayer barrier films for packaging

Through extensive assessments of technical, economic, and environmental feasibility, the project will develop highly innovative solutions to replace hard-to-recycle and unsustainable packaging materials, accelerating the transition to a circular bioeconomy.

LIGNOMAT – Bio-based materials from Kraft lignins

The development of LignoBoost XS provided valuable knowledge for compact lignin extraction plants and led to an improved demonstration facility for smaller industries. Modifications increased compatibility with other polymers, and the resulting thermoplastic blends demonstrated lignin’s industrial potential.

NoVOC – Eliminating VOCs from battery manufacturing through dry or wet processing

Manufacturing batteries for clean energy storage has traditionally been a dirty process. However, a consortium of 17 European partners is now developing new technology for next-generation lithium-ion batteries that can eliminate volatile organic compounds from production through dry or water-based cell manufacturing.

BioPitch

The BioPitch project has aimed to develop an environmentally sustainable material for artificial turf pitches that can replace plastic and rubber granules, with the goal of reducing CO₂ emissions and fossil content.

BioScale – Scaling up natural alternatives to plastics for a sustainable industry

Objective: Scale up and validate the production of dry microcellulose powder in a cost-effective and resource-efficient process.
Achievement: The three main process steps – chemical reaction, quenching, and solvent recovery have been evaluated at pilot scale at RISE in Stockholm, Södertälje, and Örnsköldsvik.