­3DCell

3DCell - Packaging made from three-dimensionally shaped cellulose composites

Aim

The aim of the "3D-Cell" project is to develop and produce environmentally friendly, recyclable packaging solutions based on cellulose composites. The aim is to create packaging that both meets the ecological requirements of current legislation and is economically attractive for industry - especially SMEs.

Specifically, the aim is to enable the reliable production of packaging materials with optimized properties. This will be achieved through the development of suitable materials and material combinations as well as through the application and further development of joining techniques, mechanical thermoforming and coating processes. The project pursues a holistic approach that covers the entire value chain: from the selection and preparation of fiber raw materials to material development and testing to the design of load-bearing packaging solutions. A particular focus is on the use of natural fibers and their processing in the extruder.

Another goal is the development of demonstrators for thermoformed 3D packaging, which show the feasibility of the concepts in practice. The targeted innovations will also increase design freedom, opening up new possibilities for sustainable packaging designs. The project results are intended to make existing plant technology largely usable, which is expected to result in economic implementation with a high probability of success.

In the project, the Chair of Solids Process Engineering is primarily concerned with the evaluation and selection of suitable fiber raw materials with regard to their availability, cost-effectiveness, processing and environmental compatibility. It develops and optimizes analytical methods for characterizing fibre properties and investigates the correlation of these properties with material and product formation. One focus is on continuous fiber disintegration in the extruder in order to achieve reproducible material properties. The chair also evaluates energy and material process intensification as well as the economic efficiency of the developed processes. It contributes significantly to the recyclability assessment and to project coordination, documentation and the structured processing of research results.

The Chair of Wood Technology and Fiber Materials Technology, Paper Technology working group, is responsible for market research and evaluation of fiber sources with a focus on chemical composition and quantity availability. It compares and synchronizes analytical methods with other project partners and characterizes fibre properties such as fibre length distribution, water retention capacity and dewatering behaviour. The Paper Technology working group prepares fiber suspensions using conventional laboratory methods and evaluates the influence of the extruder parameters on the relevant suspension, fiber and strength properties based on the analysis results and material testing on the laboratory sheets formed. It also investigates recyclability using standardized methods and documents the results in publications and trade fair presentations.

The Fraunhofer IVV is responsible for extensive analyses of material processing properties, including thermomechanical behavior, tribology and forming behavior under various temperature and humidity conditions. The IVV develops process strategies for deep-drawing forming, designs suitable tools and integrates steam technologies to activate bonding mechanisms. Furthermore, the IVV is significantly involved in the implementation and evaluation of packaging demonstrators, tests their behavior under climatic and logistical loads and analyzes their scalability for industrial applications. Its tasks also include economic evaluation and the preparation of research results for publication.

The Department of Machine Elements deals with the development and combination of different material layers and joining processes for drawable natural materials. It tests mechanical and climatic loads, validates property models and develops concepts for stable, stackable packaging demonstrators. The group analyses recyclability through delamination tests and ageing tests, develops interface concepts for series production and coordinates the results in the form of project reports, formulas, visualizations and by organizing conferences and meetings.

Partner

• TU Dortmund - FG Maschinenelemente
• TU Dortmund - Lehrstuhl Feststoffverfahrenstechnik
• Fraunhofer-Institut für Verfahrenstechnik u. Verpackung

Funding reference

© Bundesministerium für Wirtschaft und Klimaschutz