INJECTOSE

In Europe, particularly in France, the context is conducive to replacing plastics with bio-based and recyclable materials. European directives (SUPd) and French laws, such as the AGEC law, are gradually banning single-use plastics. PPWR and EPR regulations are pushing companies to think about the end of life of their products.

The LGP2 laboratory, which specialises in bio-based materials, has been working on plant biomass for 30 years. It is renowned for its research on cellulosic and nanocellulosic materials.

The MatBio team, led by Julien Bras, develops bio-based materials to replace fossil-based materials, particularly in the field of packaging, through the Cellulose Valley chair. Over the past decade, it has developed a new technology based on twin-screw extrusion. The laboratory is involved in numerous national and European projects on this subject, notably through a European project on cellulose fibre injection moulding, involving 12 PhD students and several European laboratories.

The core of the technology lies in the adsorption of a specific polymer onto the surface of cellulose fibres. Once the polymer has been adsorbed onto the surface, it creates a thin hydrated layer that acts as a lubricant. This lubrication allows the fibres to rearrange themselves in relation to each other under mechanical stress, enabling them to move without degradation. These adsorption and lubrication phenomena enable the injection of cellulose fibres. In its dry state, the polymer acts as a reinforcing agent for mechanical properties.

Injectose is revolutionising injection moulding by using cellulosic fibre pastes composed of 90-98% fibre after drying, producing fully recyclable packaging with complex shapes. Unlike thermoplastic composites, Injectose avoids conventional polymer matrices (petroleum-based or bioplastics) that cause recyclability and/or biodegradability issues. The process uses existing equipment, adapting it to reduce carbon footprint and costs. The technology aims to match the production rates of plastics while producing a recyclable, low-carbon material.

Several demonstrators have been produced: coffee capsules, caps, closure clips, plugs, tensile and flexural test tubes. This achievement places the project at TRL 4.

A pilot test bench on a 15-tonne injection moulding machine is under construction in collaboration with the Plastics Injection Moulding Technical Centre (CT-IPC) and the Paper Technical Centre (CTP).

• Perfume caps
• Refills for cosmetics, packaging inserts (box)
• Watch packaging
• Protective shells for wines and spirits
• Packaging for electronic devices
• Packaging for fashion accessories and eyewear
• Caps for nutraceutical and pharmaceutical products
• Food: complex trays, measuring spoons, caps
• Medical devices (packaging, replacement of single-use parts)