Compounding and film extrusion for biocomposites

The pilot‑scale extrusion service supports the development and optimisation of advanced plastics and composites, with a particular focus on bio‑based polymers. The service covers the entire process chain – from compounding to film extrusion and reactive extrusion – enabling rapid testing, evaluation and scale‑up from laboratory to production.

Extrusion is a key method in polymer processing and is used to produce films, coatings and components with defined properties. Our pilot facilities can handle both conventional polymers and more complex, sustainable materials, making it possible to fine‑tune material performance and develop solutions for new applications. Reactive extrusion adds an additional level of capability by allowing chemical reactions to occur directly in the extruder, enabling the production of advanced materials with improved performance in a single processing step.

With broad expertise in material formulation and process design, we work with a wide range of bio‑based materials to create high‑performance and sustainable solutions. This includes optimising material blends, developing stable processing conditions and producing tailored films and coatings for sectors such as 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.