Polystyrene alternative wins prize

A sustainable alternative to polystyrene, developed by the Biopolymer Network, is the commercialisation collaboration winner at the annual KiwiNet research commercialisation awards.

Rotorua-based research company BPN, set up in 2005, is jointly owned by three of the government's Crown Research Institutes, Scion, Plant & Food, and AgResearch.

BPN is focused on developing a portfolio of intellectual property in products based on materials from trees and plants.

Its first commercial hit is expected to be Zealafoam, an environmentally-friendly polylactic acid foam that is a sustainable alternative to petroleum-based polystyrene. Under development for the past nine years, Zealafoam is being tested by a large US global company for an, as yet, undisclosed product.

BPN chief executive Sarah Heine says the focus is on proving the technology works in large-scale volumes in partnership with Auckland plastics maker Barnes Plastics and the US company.

The judges say Zealafoam addresses a huge world environmental issue and BPN is actively engaging business partners to capture the value of the intellectual property.

The bio-based plastic used in Zealafoam is derived from corn starch and the novel patented process involves introducing CO2 as a blowing agent which expands the small bioplastic beads so they can be moulded into different shapes and products. One of its main benefits is that Zealafoam can be produced on the same machinery used to make polystyrene.

Ms Heine is hopeful Zealafoam can be released commercially by the end of this year, with production staying in New Zealand if the US deal pans out. The technology will also be licensed to other manufacturers when used for packaging.

BPN has retained full ownership of the IP, which Ms Heine says isn't always easy when doing international collaboration to take a product to market.

"The world polystyrene market is worth about $US38 billion," she says. "A bio-based alternative is not going to replace the whole market but even a thin slice of that is still a big number. There's big potential for it if we can get it right. We're the global leaders in this, but a lot of people are trying to get this one out of the door because it's a real prize."

Ms Heine says BPN has a narrow focus for its overall research, with emphasis on four key areas: bio-based foams and resins; aqueous extracted proteins and starches; tannin extracts and derivatives; and liquid CO2 processing.

It dropped work last year on harakeke fibre after failing to find commercial partners despite nearly a decade of research and producing a composite product that could replace fibreglass in a number of applications.

"One of the bases for forming the company was that we could access scientific capability in the three organisations and bring it together to exploit research niches," she said.

One example is taking Plant & Food's plant-based research into starches and proteins and adapting those extracts for use in natural personal care products.

One of its other technologies close to being commercialised is a protein extract derived from the ancient grain amaranth. It is being tested at commercial scale levels by NZ Extracts in Blenheim.

Known to the Aztecs as the "grain of the gods", amaranth is a protein source rich in bioactive peptides and Ms Heine says the extract's properties enhance personal care products such as shampoos and face creams.

BPN, which receives $3.4 million annually in government funding for targeted research, has about 10 technologies it is working on.

The Supreme award winner was Professor Andy Buchanan from the University of Canterbury, whose research lifted engineered timber buildings into serious contention against concrete and steel for large span and multi-storey buildings for the post-earthquake Christchurch rebuild.

His patented products allow architects to design structures not previously possible with traditional materials. He is commercialising them globally with industry partners. Buchanan also won the People's Choice award and the researcher entrepreneur award.

BusinessDesk receives funding to help cover the commercialisation of innovation from Callaghan Innovation.

(BusinessDesk)