Researchers from Fraunhofer Institute for Microstructure of Materials and Systems (IMWS) and DEUREX AG have successfully developed and scaled bio-based wax additives that could replace conventional petrochemical property modifiers used in biodegradable plastics and packaging applications.

Developed through the BioZ project within Germany’s TransBIB industrial bioeconomy network, the innovation demonstrates how renewable raw materials can be integrated into existing plastics manufacturing processes while supporting the transition toward more sustainable packaging materials.

Renewable Waxes Replace Petrochemical Additives

The project focused on developing bio-based wax-based property modifiers, known as biomers, as an alternative to petroleum-derived additives commonly used to modify polymer performance.

Unlike conventional petrochemical waxes or graft copolymers, the newly developed biomers are biodegradable, produced from renewable raw materials, and designed to integrate directly into existing industrial processing equipment.

The project aimed to partially or completely replace conventional property modifiers while maintaining the performance required for commercial plastic products.

Improving Bioplastics for Packaging Applications

Researchers also developed new bioplastic formulations for fruit and vegetable packaging nets, targeting the replacement of conventional polymer materials with engineering biopolymers.

The technology focuses on polybutylene succinate (PBS), a biodegradable polymer increasingly used in sustainable packaging applications.

According to the research team, the bio-based wax additives allow manufacturers to adjust the processing characteristics of PBS by controlling melt viscosity while also improving the dispersion of fillers such as color pigments.

Importantly, these performance improvements are achieved without reducing the biodegradability of the finished material.

From Sugarcane Waste to Industrial Production

The biomers were produced by modifying bio-based feedstocks derived from sugarcane bagasse, an agricultural by-product.

Researchers adjusted the molecular weight of the waxes through oxidative degradation before introducing reactive chemical groups to improve compatibility with the PBS polymer matrix.

The additives were then incorporated into the biopolymer using both batch processing and continuous melt-mixing techniques before the resulting material structure and performance were evaluated.

Successfully Scaled from Laboratory to Industrial Production

One of the project’s key achievements was demonstrating that the material could move beyond laboratory research into commercial-scale manufacturing.

Production was successfully scaled from approximately 1 kg per hour in laboratory trials to 10 kg per hour using a pilot-scale twin-screw extruder.

The material formulation was subsequently processed into blown film and converted into strips for manufacturing commercial packaging nets, confirming its compatibility with industrial production processes.

Small Additive, Significant Material Performance

Testing showed that adding as little as 1.5% bio-based wax produced measurable improvements in the rheological and mechanical performance of PBS.

Researchers observed changes in:

• Melt flow behavior
• Material stiffness
• Mechanical strength
• Processing characteristics

These improvements could help manufacturers optimize biodegradable packaging materials without requiring major modifications to existing production equipment.

Supporting the Industrial Bioeconomy

The project also highlights the role of TransBIB, Germany’s industrial bioeconomy network, in accelerating the commercialization of bio-based technologies.

By connecting research organizations, manufacturers and innovation hubs, the network supports technology transfer, production scale-up and industrial implementation of renewable material solutions.

For the sustainable packaging industry, the project demonstrates that bio-based functional additives are moving beyond laboratory development toward commercial manufacturing. As demand grows for biodegradable and renewable packaging materials, technologies that can improve material performance while fitting into existing production lines may help accelerate the wider adoption of bio-based plastics across packaging applications.

Last Updated on 29/07/2026 by Jota Machinery