Röchling Group Launches First Polylactide-Based Bioplastic on the Market

Bilden den Vorstand der Röchling-Gruppe (von links): Franz Lübbers, Prof. Dr. Hanns-Peter Knaebel sowie Evelyn Thome. / The Executive Board of the Röchling Group (from left): Franz Lübbers, Prof. Dr. Hanns-Peter Knaebel, and Evelyn Thome.

Bilden den Vorstand der Röchling-Gruppe (von links): Franz Lübbers, Prof. Dr. Hanns-Peter Knaebel sowie Evelyn Thome. / The Executive Board of the Röchling Group (from left): Franz Lübbers, Prof. Dr. Hanns-Peter Knaebel, and Evelyn Thome.

The Röchling Group is defined by its innovations. Hence, the three divisions also invested time and money in the further development of the product range last year. For example, last year Röchling Automotive introduced Röchling-BioBoom, a plastic that is made of 90 percent renewable raw materials. In May 2021, the new bioplastic was awarded the Sustainability Award in Automotive in the Complete Vehicle category by the management consultancy company Roland Berger and Springer Fachmedien. A first series order has also already been received.

Industrial Division: Smart wear sensor and post-consumer recycling (PCR) material

The Röchling Group is intensively involved in the development of smart products. The use of sensors is particularly suitable for wear parts in machines and systems in order to reduce the maintenance effort. For example, Röchling Industrial has developed a wear sensor for hydraulic hammers. These tools, which weigh several hundred tons, are used to prepare the seabed for offshore plants, wind turbines or bridges. The maintenance of a hydraulic hammer is very time-consuming and takes several days. The sensor provides information about the wear of the hydraulic hammers and thus makes the maintenance process plannable and considerably more efficient and cost-effective.

Leading manufacturers have used the Play-Tec® branded material from Röchling Industrial for many years in the construction of children’s playground equipment. With Play-Tec® PostCon®, Röchling has developed a sustainable variant based on post-consumer recycling (PCR) materials. PCR materials are recycled plastics from household or commercial waste. Careful treatment processes and quality testing are required to obtain high-quality PCR products. Play-Tec® PostCon® is used by customers in the sports and leisure industry, for whom sustainable construction materials are becoming increasingly important.

Automotive Division: Röchling-BioBoom – a PLA made of 90 percent renewable raw materials

It is not possible to imagine modern vehicles without plastics. But with every component made of this material comes some responsibility. Until now, there have been no adequate solutions for the sustainable use of plastics in vehicles. Now manufacturers can act in a more environmentally friendly way. This is because Röchling BioBoom is the first bioplastic to be made of at least 90 percent renewable raw materials. It is also capable of completely replacing conventional plastics.

The new bioplastic from Röchling Automotive impressed the expert jury in the Complete Vehicle category at the Sustainability Award in Automotive ceremony held by management consultancy company Roland Berger and Springer Fachmedien. Röchling-BioBoom received the award primarily because of five properties:

- the high proportion of renewable raw materials,
- its certification and traceability that ensures transparency and control of the supply chain,
- the uniqueness of a tier 1 development material compared with buying off-the-shelf products from
material suppliers,
- its use avoids technical compromises, allowing customers to maintain current quality and
performance standards and
- additional aesthetic benefits.

Röchling-BioBoom is created using polylactides (PLA). These polymers are mainly used as packaging for foodstuffs. PLA is also used in the medical field. Röchling Automotive has further developed this bioplastic and optimized it for use in the automotive industry. Röchling-BioBoom can be used at temperatures in excess of 100 degrees Celsius. On the other hand, standard PLA is only stable up to about 60 degrees.

The production process generates up to 90 percent fewer CO2 emissions than comparable plastics such as PP or PA6. In the case of a mid-range vehicle, the use of bio-PLA can save an average of 480 kilograms of carbon dioxide during production alone.

Fermented sugar serves as the basis for the raw plastic. This is a renewable resource that is available in large quantities. Production is very efficient, as only 1.6 kilograms of fermentable sugar as a raw material is needed for one kilogram of PLA. This process has no influence on food production, as Röchling Automotive uses raw materials that are only suitable for further industrial processing. The division has established its own supply chain for this bioplastic with the components subject to continuous quality control by Röchling – from the raw material production right through to the finished product.

The fact that PLA is initially a raw plastic allows Röchling to flexibly adapt the material to different possible applications for its customers. The division currently offers three variants which enable it to cover almost the entire product range of Röchling Automotive with the same level of quality and, in some cases, with superior material durability. In April 2021, Röchling Automotive received the first series order for Röchling BioBoom for an engine compartment design cover. The purpose of this product is to shield thermally sensitive components and present a high-quality design for the engine compartment area to enhance the perceived quality of the vehicle. Production start is scheduled for September 2021.

Medical Division: NICCI sensor for hemodynamic patient monitoring after surgery

Patient monitoring both during and after surgery is highly important. Continuous monitoring, which is usually performed conventionally by means of arterial access, is not medically indicated in all cases. Non-continuous blood pressure monitoring systems are therefore often used, but this means that fluctuations in blood pressure may go undetected. The medical technology company Pulsion Medical Systems has developed the continuous and non-invasive NICCI sensor for precisely this group of patients.

The device, which is similar in design to a PC mouse, is attached to two fingers. The blood flow is detected by infrared sensors and kept constant by applying counterpressure to the artery. In addition to continuous monitoring, another advantage of this product over conventional blood pressure cuffs is its single-use concept, which prevents contamination, especially in the highly sensitive operating room environment.

Röchling Medical Waldachtal is responsible for the production of the NICCI sensor. Many of the sensor’s components are manufactured by injection molding and further processed in the clean room with purchased parts from certified suppliers, such as sensors or films, to produce the finished product. There are also further finishing steps such as laser printing, laser welding, and the coding of sensors inserted inline.

The product design and the design for manufacturing were optimized in several workshops, considering the complex assembly steps. The product was involved through the early involvement of research and development at Röchling Medical and industrialization. In addition, the entire manufacturing process was optimally planned, resulting in an economical solution. Three different size variants of the sensor are currently manufactured and packaged for sale in Waldachtal.