Pilot Plants & Services

Starting from Biomass

Nanoadditives and Raw Materials

Extraction of raw materials, solvents, monomers and oligomers from biomass
  • Cooking and bleaching of cellulose pulp (CTP)
  • Production of lignin from black liquors (CTP)
  • Development, optimization and scale-up of processes for the production of bio-plastics or bio-based building blocks from carbon-rich industrial side streams (Biotrend)
  • Hydrolysis of any lignocellulosic material and HPLC analysis of hydrolysis products (ACIB)

Obtaining cellulose nanofibers and nanocrystals, nanolignins
  • Production of CNF by mechano-enzymatic homogenization and twin-screw extrusion (CTP)
  • Production of CNF by enzymatic or chemical treatment and mechanical grinding (ITENE)
  • Production of CNC by acid hydrolysis of cellulose (ITENE)
  • Production of nanolignin through the application of mechanical treatment to lignin (ITENE)

Block copolymer production
Synthesis and development of tailor-made block copolymers from biomass (ITENE)

Metallic nanoparticles obtained by plant resources
Functional nanocapsules production
  • Development and production at pilot scale of nanocapsules by nanoemulsion (CENTI)
  • Development of functional (sub)-microcapsules by spray drying (ITENE)

Starting from Nanomaterials

Bionanocomposites

Network 2 is the group for the production of bionanocomposites and the pre-treatment needed to process the bionanomaterials that will be introduced in these bionanocomposites.

Modification and functionalization in liquid and gaseous medium
  • Functionalization of nanoparticles to improve compatibility with the biopolymers (ITENE)
  • Chromatogeny grafting to bring hydrophobic properties to hydrophilic substrates (CTP)
  • Deposition of metallic nanoparticles onto nanoclay or CNF (ITENE)
  • Spray drying of nanoadditives to obtain them in powder form (ITENE)

Nanocomposites compounding, thermoplastics
  • Compounding process of biopolymers with nanoadditives. Gravimetric & volumetric feeding
  • Chemical modification of biopolymers by grafting nanomaterials through reactive extrusion.
    • Packaging
    • Automotive
    • Textile and Agriculture
    • Packaging

Biobased nanodispersion
  • Preparation of stable dispersions of nanoadditives. CNF, CNC, nanoclays in coatings (ITENE)
  • Dispersion of nanoparticles by in-situ polymerization (CIDAUT)
  • Polymer-based dispersions with functional nanocapsules (CENTI)

Starting from Bionanocomposites

Bionanoproducts

Network 3 includes pilot plants to obtain bionanoproducts from the different bionanocomposites of network 2.

Rigid and flexible packaging
  • Production of monolayer films of biopolymers with bioadditives (CIDAUT)
  • Production of multilayer films: coextrusion process up to 5 layers (ITENE)
  • Rigid packaging prototypes obtained by thermoforming (ITENE)

Cellulosic products
  • Production and evaluation of paper containing nanoadditives in mass (ITENE)
  • Wet-lamination of CNF on paper and cardboard (CTP)
  • Production of CNF self-standing films (lab and pilot scale) (CTP)

Textiles and nonwoven fabrics
  • Production of fibre nonwovens and meltblown nonwovens (STFI)
  • Consulting services for fibre and meltblown nonwovens (STFI)

Injection and 3D printing
  • Injection of rigid packaging: injection moulding of test specimens and packaging (ITENE)
  • Manufacturing of 3D-printed moulds by SLA (ITENE)
  • Biopolymer filaments for 3D printing (CIDAUT)
  • 3D printing of prototypes by FDM (CIDAUT)

Foam applications
Coating applications
  • Roll-to-roll slot-die coating and spray-coating (CENTI)
  • Flexo and gravure coating
  • Spray-coating on 2D and 3D-shape substrates (CTP)
  • Paper and board coating by blade, rod and size-press (CTP)

Supporting technical services (Process parametrization)

Quality control and process optimization
  • Energy Dispersive X-ray Fluorescence (EDXRF) techniques applied to inspection and monitoring of new materials or coatings.
  • Process Optimization through simulation: Advanced numerical simulation tools are used to optimize the design step considering the final applications.

Inline Monitoring
Monitoring systems based in photonics enabling to upgrade the capabilities of targeted processes in terms of optimization, reliability and quality control. (IRIS)

Modelling and Simulation
  • Optimization of composites formulation and processing parameters (IMT)
  • Methodologies for nanocomposites virtual characterization (IMT)
  • Prediction of the properties of nanocomposites from their constituents (IMT)
  • Modelling of printing materials and simulation of 3D printed parts behaviour (CIDAUT)

Non technical services

Life Cycle Assessment (PARTI)
  • LCA measures and calculates the lifetime environmental impact of the product or service by both the use of resources and the emissions created
  • Life Cycle Cost Assessment: is an economic evaluation of a product, service or an engineering project across its lifetime, which helps decision makers to choose the best investment plan, based on the least cost.
  • Social Life Cycle Assessment (S-LCA): provides information on social and socio-economic aspects for decision-making, in the prospect to improve the social performance of an organisation or a product and ultimately the well-being of associated stakeholders.

Safety evaluation of biomaterial (ITENE)
  • Definition of an Integrated Risk Assessment Approach (IATA) for nanobiomaterials
  • Hazard profiling assessment services
  • Exposure assessment services in workplaces
  • Risk-management services
  • Definition of Safe-by-Design strategies for the specific industrial cases

Compostability and recyclability analysis
  • Compostability: characterization, biodegradation, disintegration & compost quality (ITENE)
  • Recyclability Analysis: Test of recyclability according to EN13430 standard (CTP)

Food safety (ITENE)
  • Assessment on the verification of compliance of any kind of food contact material
  • Legislative vigilance
  • Diagnosis and implementation of GMP standards
  • Legal diagnosis/supplier management
  • Documentation and guidance for the authorisation of new substances for plastic materials
  • Technical support for the authorisation of recycled processes for plastic materials

Techno-economic assessment
  • Regulatory compliance and advisory services (interpretation and implementation of regulatory requirements, legal design of business activities)
  • Legal workshops on regulatory challenges & Regulatory Updates
  • IPR Management & Protection: IP strategy and management & IP advisory services

Business support

Success Stories

UC 1

Cleaning wipes composed of 85% viscose and 15% PLA to apply calendered by needle punch

  • Chemical modification of PLA by reactive extrusion to provide antimicrobial properties; obtention of PLA stable fibers (PP11)
  • Obtention needle punch wipes with different percentages of modified PLA (PP11)

UC 3

Cellulose nanofibers reinforcements for paper-based materials in terms of mechanical and barrier properties

  • CNF production (cooking and bleeching; PP2)
  • Laboratory bulk addition trials in the paper palp (PP10)
  • Wet lamination with CNF
  • Prototypes obtention, bulk trials, characterization

UC 6

Block copolymers as reinforcement of biobased/compostable formulations for film packaging, injection moulded cutlery and coffee capsules, and thermofoamed trays and containers

  • Monomer development (PP1)
  • Synthesis of block copolymer (PP3)
  • Biomaterial formulation with the block-copolymer by melt compounding
  • Film packaging by blow extrusion, trays by thermofoaming
  • Validation of final product

UC 9

Modified nanoclays will reinforce the biodegradable formulations, improving mechanical and barrier properties of 100% compostable packaging

  • Modified nanoclays development (PP5)
  • Masterbatch with modified nanoclays (PP7)
  • Compounding of masterbatch with nanoclays into Novamonts biomaterial formulations
  • Flexible packaging
  • Characterization

UC 10

Cellulose Nanofibers and Nanocrystals for cosmetic applications

Technical services:
  • Obtaining cellulose nanofibres, nanocrystals and nanolignins (PP2)
  • Cosmetic formulation with CNF and CNC for sun cream emulsion
  • Solubility in water, concentration in emulsion, viscosity in water, electrolyzed capacity, hydration properties, texture and mechanical properties
  • Characterization
  • Compatibility test formulation

UC 14

Bottle 100% compostable reinforced with nanoclays

  • Bottle development and definition
  • Development of nanoclays with Novamonts biopolymer (PP6)
  • Compound of nanoad into biopolymeric matrix (PP7)
  • Characterization
UC 17

Biobased polypropylene with nanocellulose; complex shaped foamed parts for the automotive sector

  • Nanocomposites compounding, bioPP with commercial organoclays (PP7)
  • Foam applications; complex shaped parts fort he automotive sector through bead foaming and shaped by steam-chest moulding (PP13)
  • Recyclability tests
  • Mechanical characterization
UC 18

Recyclable solution reinforced with nanocellulose and/or nanoclays to achieve high barrier performance

  • CNF and nanoclays development (PP2)
  • Compounding with bioPA with nanoclay (PP7)
  • Obtention of the packaging by blown-film extrusion process
  • Thermoformed for vacuum packed applications
  • Mechanical characterization
  • Barrier characterization, recyclability and food safety

Supported startups

ALGAESYS is a Portuguese company with subsidiaries in UK and Western Australia, dedicated to making affordable, decarbonised water reuse accessible for all. Our innovative technology transforms wastewater into valuable resources, providing high-quality water while extracting materials from biomass. With low energy consumption and lifecycle costs, our system is net energy positive and has a negative carbon footprint. Recognised as a World Economic Forum Uplink Top Innovator and winner of the Circular Water Cities Challenge, we aim to revolutionise the water sector and promote a circular economy. Our patented, solar-powered technology utilises photosynthetic organisms to address the needs of water-stressed communities globally. ALGAESYS has demonstrated rapid installation and can reduce lifecycle costs by up to 80% compared to conventional methods. Proven over eight years at full scale, our system excels in eliminating persistent organic chemicals and providing high-level disinfection. We are currently focusing on markets in the Mediterranean Basin, UK, and Australia, and are exploring opportunities in the Middle East and Southeast Asia.

Ecorbio produces biopolyols from waste biomass to replace unsustainable polyols in the production of polyurethane (PU) products, reducing the industry’s reliance on fossil fuels. However, the industry has been hesitant to embrace bio- materials due to high prices and low compatibility. Ecorbio aims to overcome these concerns by incorporating low- value waste biomass and developing nano-enabled biopolyols. Their goal is to showcase the technology at full scale and enter the polyol market. The support from Bionanopolys would help them facilitate state-of-the-art technology integrate multidisciplinary knowledge and improve the sustainability of the industry’s supply chains – all by overcoming the industry’s reluctance to pilot, experiment and take risks.

Encapsulae S.L. and Airnatech are developing FFP2 masks with a higher filtering capacity under a project called BioEPI. We are conducting tests, and it seems that we have achieved improvements in filtering by several orders of magnitude. However, we do not have the capacity to create a demonstrator of the final product. The objective of our participation in Bionanopolys OITB would be to produce masks with our additive-laden fabric and verify their filtering efficiency. We would be interested in working with biopolymers as the base of our mask and with PP as a control.

Futurechromes has developed a very promising low-cost photochromic technology, self-responding to sunlight intensity variations, based on liquid-core nanocapsules embedded in polymeric matrices, containing a photochromic solution of organic dyes. This structure yields high transparency, fast photochromic response and enhanced fatigue resistance compared to competitive photochromic materials. However, to industrialise and consolidate our technology in the market, some limitations must be mitigated. These involve: (i) Films mechanical properties: Futurechromes films exhibit outstanding photochromic functionality, but lack of other physical mechanical properties (e.g. antiscratch, humidity resistances, etc.), and (ii) the current method of the film preparation does not match with well-established industrial manufacturing processes based on polymerisations or extrusion. Therefore, the main challenge is to achieve nanocapsule-based photochromic materials with good mechanical performance through an industrialisable process. To this end, we are looking at Bionanopolys OITB for the opportunity to develop, test and scale-up (if applicable) the integration of nanocapsule-based photochromic films in different matrices (e.g., polylactic acid, PLA) and through different industrialisable manufacturing methods (extrusion). In addition, good photostability and transparency, which are the currently characteristic of Futurechromes films, will have to be preserved in the new nanobiocomposite.

Kalichem is a manufacturer of active ingredients for beauty industry, with innovative and cosmeceutical products. It produces and distributes personal care specialties, mostly of natural origin and vegetal derivation. It offers a wide range of products for different applications, fields and certifications, such as sun protection, anti-bacterial, anti-ageing, skin, hair and body care, based on natural, biotech and patented technologies.

Magnostics is an Irish company bringing to market technology to improve the effectiveness of personalized cancer therapies and care. Many cancer patients today benefit from liquid biopsies, based on a blood sample, with the aim of detecting cancer earlier and optimizing their treatment. Currently, existing technologies recover only about 50% of the tumour DNA in blood, leading to high liquid biopsy failure rates and high costs in terms of non-optimized treatment. We can recover +90% of the tumour DNA, resulting in significantly improved outcomes.

Management structure

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