Films and plastics made in Halle rot down like potato peelings
Frohberg invented synthetic materials which are made from renewable raw materials and which can dissolve in air and water. The films, moulds and coatings from PolyNature were able to prevail against 2,600 competitors because they are ideal for the current times. They are eco, they replace crude oil, they are energy efficient and they are completely biodegradable.
"Nothing remains from our products. We take the raw material from nature and return it to the natural cycle," explains Partner Isabell Stolte, who was also part of the team to establish the company in the winter of 2011. The company came to into being with the name 'Protein2Plastix' as a spin-off project from the Martin-Luther-University Halle-Wittenberg. Their step to independence was achieved with the help of the start-up grant, as supported by the state of Saxony-Anhalt and provided by the university start-up network Univations. They took this step because over many years of research work, Frohberg had succeeded in developing a procedure in which plant and animal proteins are converted into synthetics which are water soluble and one hundred percent biodegradable. Frohberg and Stolte primarily concentrated on short-term applications in the area of agriculture such as seed tapes with or without added fertilisers, on cover films and on disposable items in the catering sector. "Our films rot down like potato peelings," says Bio-Engineer Stolte describing one of the benefits of their products.
They also use the special attributes of plant and animal proteins. "We discovered that proteins are able to develop a three dimensional network," explains Frohberg. This is the condition for a polymerisation reaction such that occurs with conventional plastic on a mineral oil basis. With their procedure the molecular network is loosened up and pressed into a new form using a machine.
Frohberg brought the idea to reality in his dissertation with which the 32 year old became a doctor of engineering (Dr.-Ing.). His work has resulted in two patents. One is for a product, the other for the procedure to manufacture protein-based products. Isabell Stolte is still working on her dissertation, and hopes to complete it in spring 2013. She is researching the modification of protein-based products with additives. This would be of interest to customers because of an additional use which we can give the film or the moulded part, explains Frohberg. As an example he mentions seed tapes to which fertilizers are added that are gradually released over time. This not only strengthens the germination and growth process of the plants, it would enable entire working steps on the field to be omitted in the farming industry.
During the spin-off project, the industrial engineer and the bio engineer planned to create the new products in their own company. After weighing up all of the opportunities and risks of such a project, they buried this idea and founded the services company PolyNature which helps customers through providing engineering advice to help with the introduction and production of protein-based products. "Our customer base is growing," explains Frohberg. "The price has made us well known."
The future also promises increasing levels of turnover. Experts are predicting the production of bio-based synthetics will increase by 15 to 20 percent each year. Stolte and Frohberg are certain that they will be able to share in this upswing. They envisage a wide range of reasons why companies will begin using these synthetics more and more. They not only give companies an ever more important 'green image' they also help with the move away from and the replacement of crude oil. The costs of the 'Green Dot' of the Dual System in Germany are also omitted because the recycling is superfluous.
The costs of converting the plastic processing machines are also limited as a key advantage of the process is that the available plastic processing systems such as extruders can also be used for the processing of the protein based plastics. "Depending on the requirements, we adjust the systems on location. Sometimes the outlay is relatively low, sometimes several weeks are required in order to solve a problem," explains Frohberg, who originates from Halle. The new process provides the customer with advantages under all circumstances: Energy savings are especially important, highlights Frohberg. While conventional synthetic granulate has to be heated to up to 400 degrees Celsius to be able to melt, materials made from plant proteins can be processed at room temperature. "If the quantities are big enough the energy savings can run into the millions," explains Frohberg.
The scientists haven't completely given up on the idea of manufacturing their own products, however. In the laboratory they aren't only tinkering with additional new products, they are also manufacturing highly innovative films for farmers, gardeners and anglers on a small series basis which they sell in their online shop. They primarily view the packaging and food industry as being further areas of application for their non-toxic, biodegradable and compostable films and plastics. The young entrepreneurs' business is going so well that they are thinking of employing staff. And at the moment, PolyNature isn't even taking any orders. Their order books are full.
Contact:
PolyNature GmbH
Dr.-Ing. Patrick Frohberg
Birnenweg 21a
06112 Halle/Saale
ph: +49 345 5528414
E-Mail: patrick.frohberg.ignore@polynature.de
Web: www.polynature.de