A process of BIO-waste utilization for manufacturing a biodegradable composite

Abstract

The present invention relates to a process for manufacturing a biodegradable composite. The process comprises the following steps: a) providing a bio waste selected from a group comprising a brewery spent grain, food production waste, used ground coffee and composition thereof; b) dewatering of provided bio waste; c) shredding of provided bio waste into pieces; d) drying the shredded pieces until a moisture level into the piece is down to 3-7%; e) grinding of dried pieces into smaller particles so that a size of the particles is less than 350 to 100 micrometres; and f) blending grinded particles with polybutylene succinate in result of which a biomaterial composite is formed, wherein the biomaterial composite comprises 10 to 50 % by weight the grinded particles and 50 to 90 % by weight of polybutylene succinate.

Description

[0001] A PROCESS OF BIO- WASTE UTILIZATION FOR MANUFACTURING A BIODEGRADABLE COMPOSITE

[0002] DESCRIPTION

[0003] Field of the invention

[0004]

[0001] The present invention relates to a process of agro-waste utilization for manufacturing a biodegradable composite.

[0005] Background of the invention

[0006]

[0002] In recent years the environmental impact of any industrial process has become a key aspect in the decision making not only of those involved in the production of goods, but most importantly of those buying goods.

[0007]

[0003] Many manufacturers in a wide array of fields have felt the need to minimize the use of toxic and / or polluting agents and machineries in their production processes. At the same time a huge effort has been put in providing new eco-friendly materials, in particular biodegradable materials, which could be used as substitute for more polluting, usually plastic-based, ones.

[0008]

[0004] However, the biggest problem to face when trying to replace plastic and / or metal based materials with more eco-friendly ones, is that to maintain the mechanical and aesthetic performances, while at the same time obtaining a material that can be easily decomposed.

[0009]

[0005] Various attempts have been taken to produce biodegradable composites. One of those attempts is disclosed in Chinese patent publication No. CN115819937. It discloses a preparation method of biodegradable composite material, and the composite material is prepared from the following components in parts by weight on the basis that the total mass of the composite material is 100 parts: 50-70 parts of poly (butylene adipate-co- ter ephthalate), 15-30 parts of thermoplastic starch and 15-30 parts of modified calcium carbonate. Summary of the invention

[0010]

[0006] The present invention proposes a process for manufacturing a biomaterial composite that comprises essential and certain sequence of steps to obtain biodegradable composite from a bio waste.

[0011]

[0007] The initial step is a step of providing a bio waste selected from a group comprising vegetables, grains, fruits, agricultural processing waste and combination thereof. The bio waste may also be selected from a group comprising a brewery spent grain, food production waste, used ground coffee and composition thereof. Vegetables are selected from a group comprising zucchini, potatoes, tomatoes, Brussels sprouts, marjoram, carrots, pattypan squash, beets, asparagus, cucumbers, tarragon, peppers, cumin, eggplants, onions, and garlic. Grains are selected from a group comprising buckwheat, wheat, corn, quinoa, wheat, daggusa, rye, rice, oats, sorghum, soybeans, lentils, beans and peas. Fruits are selected from a group comprising apples, plum, cherry, currant, bilimbi, gooseberry, edible dacryodes, cherry, plum, fig, strawberry, lemon, raspberry, mabolo, blackberry, pear, quince, orange and kiwi. The agricultural processing waste is selected from a group comprising sunflower, sugar beet, flax, tobacco, hops, cotton, hemp processing waste.

[0012]

[0008] The suitability of the bio-waste for this purpose depends on several factors, including the type of biomaterial composite being produced and the specific characteristics of the bio-waste. Here are some common technical requirements. Bio- waste should have a controlled moisture content to ensure proper processing and mixing with other materials. Excess moisture can lead to mold growth and affect the quality of the composite. The biowaste should have consistent properties to ensure uniformity in the composite material. Inconsistent bio-waste can lead to variations in the final product's quality. The moisture content of the provided bio waste shall be up to 40%. In case, when the moisture content of the provided bio waste is in a range of 40% to 80%, a dewatering step is performed until the moisture content of the provided bio waste is between 30 to 40%. The step of dewatering may be performed by means of mechanical dewatering or thermal dewatering. Mechanical dewatering involves a use of pressing machine, where the moisture content is reduced by pressing the bio- waste, and subsequently, the excess water within the bio-waste is removed. Thermal dewatering involves a use of drying machines, where the moisture content is reduced by heating the bio- waste and subsequently the excess water in a form of steam is removed.

[0013]

[0009] The step of providing the bio-waste is followed by a step of quality control of that bio-waste. Contaminants, such as foreign materials or non-biodegradable components, should be minimized or removed from the bio-waste to maintain the desired purity of the composite. Bio-waste should not contain toxic substances that could pose health or environmental risks when incorporated into the composite material. The bio-waste should meet relevant regulatory and safety standards for use in composite materials, especially if the end product will be used in applications such as food packaging or medical devices. The allowable limit for contaminants in bio-waste may vary depending on specific regulations and standards in different regions or industries. In many cases, the goal is to minimize contaminants as much as possible, and the allowable limit may approach zero presence, especially for certain types of contaminants like mold or pathogens. However, the specific allowable limits can vary, and it's important to refer to local regulations, industry standards, or the requirements of the end product or process for precise guidelines on acceptable levels of contaminants in bio-waste.

[0014]

[0010] After quality control, a step of shredding of provided and quality controlled bio waste into pieces is followed. The bio-waste may need to be shredded or ground to achieve a specific particle size range that is suitable for blending with other components. Particle size affects the material's properties and further processing.

[0015] [Oi l] For shredding a disintegrator is used. A disintegrator is a mechanical device designed to break down solid materials into smaller, more manageable particles or pieces. It typically consists of a rotor with rotating blades or hammers that impact the material, causing it to fragment or disintegrate. The disintegrator can be considered more efficient compared to other shredding methods for bio-waste. The disintegrator is capable of producing relatively uniform particle sizes, which is important for consistent processing of bio-waste. This uniformity ensures that subsequent processing steps, such as blending with biopolymers, can be carried out efficiently. The disintegrator often comes with adjustable settings that allow operator to control a size of output particles. This flexibility is crucial when dealing with different types of bio- waste or when specific particle sizes are required for downstream processes. The disintegrator can handle a significant volume of material within a relatively short time, making them suitable for industrial-scale bio-waste processing. Moreover, the disintegrator can process a wide range of materials, including wet or damp bio-waste, which can be challenging for some other shredding methods.

[0016]

[0012] After the step of shredding, a step of drying the shredded pieces is performed until a moisture level into the piece is down to 3-7%. This step is essential for achieving the desired properties of the biomaterials, including improved thermal and mechanical properties and reduced water absorption. Effective drying method is critical to conserving energy and ensuring product quality. A rotary drum dryer is used for drying. Rotary drum dryers provide consistent and uniform drying, ensuring that all particles of bio- waste are exposed to the drying process equally. This results in even moisture removal throughout the dried material.

[0017]

[0013] Previous step of dewatering of provided bio waste to less than 40%, shredding into pieces and subsequent dewatering or drying down to 3-7% of moisture content allows faster drying of the bio waste for further steps, which are grinding and blending. Drying of the biowaste till 3-7% or less without intermediate step of shredding would require longer processing time, which results in higher energy consumption of bio waste utilization rather than the present invention.

[0018]

[0014] The step of shredding is continued by a step of grinding, wherein dried pieces are grinded into smaller particles so that a size of the particles is less than 100 to 350 micrometres, preferably less than 200 to 300 micrometres. The grinded particles are sorted by a mesh that allows downpour of particles with certain size - particles with the size of 350 micrometres and less, or particles with the size of 100 micrometres and less. A Hammer mill is used for grinding. The Hammer mill operates by rapidly rotating hammers that strike the biomass material with high-speed impact. This impact action effectively breaks down the material into smaller particles. Hammer mill can produce a relatively uniform particle size distribution, which is important for consistent processing and blending with other components. Hammer mill can handle a wide range of bio-waste materials, including those with varying hardness, moisture content, and particle sizes. Moreover, Hammer mill is easy to maintain and clean, which helps ensure consistent grinding performance.

[0015] Subsequently, the grinded particles are blended with biodegradable biopolyester, in result of which a biomaterial composite is formed. The biomaterial composite comprises 10 to 50 % by weight the grinded particles and 50 to 90 % by weight of biodegradable biopolyester. The biodegradable biopolyester is polybutylene succinate.

[0019]

[0016] After the step of blending, a step of granulation is performed by forming granules or pellets from the biomaterial composite. Those granules or pellets later can be used for extrusion or forming of various products, such as plates, cups, forks, spoons, and to biodegrade under compost conditions within a maximum of 90 days.

[0020]

[0017] While the invention may be susceptible to various modifications and alternative forms, specific embodiments of which have been described and have been described in detail herein, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention includes all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the following claims.

Claims

CLAIMS1. A process of bio- waste utilization for manufacturing a biomaterial composite, wherein the process comprises the following steps: a) providing a bio waste selected from a group comprising vegetables, grains, fruits, agricultural processing waste and combination thereof; b) dewatering of provided bio waste by means of mechanical dewatering or thermal dewatering until a moisture content of the provided bio waste is less than 40%; c) shredding of provided bio waste into pieces; d) drying the shredded pieces until a moisture level into the piece is down to 3- 7%; e) grinding of dried pieces into smaller particles so that a size of the particles is in a range of 100 to 350 micrometres, preferably 200 to 300 micrometres; and f) blending grinded particles with polybutylene succinate in result of which a biomaterial composite is formed, wherein the biomaterial composite comprises 10 to 50 % by weight the grinded particles and 50 to 90 % by weight of polybutylene succinate.

2. The process according to claim 1 , wherein after the step f) a granulation is performed by forming granules or pellets from the biomaterial composite.

3. The process according to claims 1 or 2, wherein the dewatering in step b) is performed until the moisture content of the provided bio waste is between 30 to 40%.

4. The process according to any of claims 1 to 3, wherein the vegetables are selected from a group comprising zucchini, potatoes, tomatoes, Brussels sprouts, marjoram, carrots, pattypan squash, beets, asparagus, cucumbers, tarragon, peppers, cumin, eggplants, onions, and garlic.

5. The process according to any of claims 1 to 4, wherein the grains are selected from a group comprising buckwheat, wheat, corn, quinoa, wheat, daggusa, rye, rice, oats, sorghum, soybeans, lentils, beans and peas.

6. The process according to any of claims 1 to 5, wherein the fruits are selected from a group comprising apples, plum, cherry, currant, bilimbi, gooseberry, edible dacryodes, fig, strawberry, lemon, raspberry, mabolo, blackberry, pear, quince, orange and kiwi.

7. The process according to any of claims 1 to 6, wherein the agricultural processing waste is selected from a group comprising sunflower, sugar beet, flax, tobacco, hops, cotton, hemp processing waste.