DELIVERING SUSTAINABLE PACKAGING AT SCALE: INDUSTRIAL INTEGRATION OF BIO-POLYESTERS THROUGH ASSET OPTIMISATION
José Canga, Licensing Manager | Zimmer® Polymer Technologies
T.EN Zimmer GmbH

Abstract

As Latin America advances towards a circular economy, the packaging value chain is being reshaped by tighter regulation, sustainability commitments, investment in recycling and packaging innovation, and the need to translate circularity targets into commercially viable production systems.

In this context, the transition from laboratory-scale innovation to industrial deployment remains a critical challenge for bio-based and biodegradable polymers. This contribution presents an integrated scale-up approach combining material development, process engineering and implementation into existing production assets, enabling efficient translation from early-stage research (TRL 3) to commercial application. The focus is not only on new materials, but on how they can be deployed pragmatically within established industrial infrastructure to support circular packaging objectives.

A key differentiator is the provision of engineering know-how to adapt and revamp existing polymer production infrastructure for novel bio-polyesters. Key technical challenges include process adaptation, equipment compatibility, operational stability and consistent product quality at scale. By enabling the use of existing assets, this approach can reduce capital intensity, shorten time-to-market and accelerate the practical adoption of more sustainable packaging materials—an essential step in turning circular packaging commitments into commercial reality. This also connects closely with current market needs around infrastructure readiness, investment efficiency and scalable implementation pathways.

Selected industrial case studies illustrate this approach. First, flexible “swing” plant configurations for polybutylene succinate (PBS) and polybutylene adipate terephthalate (PBAT), both compliant with EN 13432, demonstrate how shared polymerisation and downstream equipment can enable switching between products, improve asset utilisation and increase market responsiveness. Second, polyethylene furanoate (PEF) is presented as an emerging polyester, with emphasis on aligning material properties with process design and integrating production into existing PET lines through targeted process adaptation, equipment optimisation and operational strategies.

These examples show how innovation in materials must be paired with practical process integration if next-generation packaging solutions are to achieve industrial impact.

Finally, the paper discusses the application of online, in situ process analytics, which enhances process control, enables faster deviation detection and improves product consistency. In line with the conference focus on digital innovation and traceability, such tools can play an important role in de-risking new production routes and supporting reliable scale-up.

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