(Translated with ChatGPT without further editing)

The Fraunhofer IGB in Straubing combines application-oriented research with hands-on industrial expertise – particularly in the field of bio-based plastics. In conversation with Ms. Falcke, we take a closer look at the institute’s capabilities in supporting companies with the processing of biopolymers and discuss challenges and perspectives surrounding additives, successful product developments, and the future of bioplastics.

Ms. Falcke, Fraunhofer IGB in Straubing has been a long-standing partner of the Chemistry Cluster Bavaria. In addition to the research areas of electrosynthesis and bioinspired chemistry, you contribute your extensive industrial expertise in plastics technology to work with customers and partners on processing polymers into bio-based plastics. What opportunities do you have to support the processing of biopolymers?

In the “Bioinspired Chemistry” department, headed by Dr. Michael Richter, we were able to establish the “Laboratory for Technical Biopolymers (LTBP)” thanks to funding from the Free State of Bavaria. This enables us, in particular SMEs, to support the development of bio-based and biodegradable plastic products. With appropriate processing and testing equipment, we can apply interdisciplinary approaches at the interface of polymer chemistry and biology, or more generally, determine processing properties and material characteristics.

A particular focus is on cooperation with regional and now also supraregional SMEs and start-ups. But large companies are also welcome. We have expertise in screening polymerization methods, functionalization, and compounding. We have facilities for small-scale extrusion and injection molding for R&D purposes, and from autumn 2025 also a planetary roller extruder for pre-series sample production on a multi-kg scale. In addition, we use a conventional injection molding machine to produce directly for and with our customers as part of service projects. Beyond processing, we offer standardized mechanical material testing (tensile and impact tests), thermal material testing (DSC and TGA), and rheological testing (MFI). From autumn 2025, we will also offer thermo-mechanical material testing (rheology and DMA).

Whether PLA or bio-based polyamide, novel bioplastics can only be successfully implemented if they can be processed on available machines. You are also developing and testing bio-based additives for this purpose. What approaches are there for new additives, and where do the challenges lie?

Additive development (especially bio-based additives) is one of our central topics (e.g., plasticizers, nucleating agents). In Straubing, we are a relatively small team and therefore cannot compete with large R&D institutions in terms of equipment and manpower. However, we are in the advantageous position of being able to think holistically about topics such as additive development for bio-based polymeric materials. We have excellent chemical-synthetic and bio-synthetic expertise and can combine this directly with our plastics processing and testing methods in an iterative way. This leads to high “agility and flexibility” and few barriers to truly exploring new ground. Our customers very much appreciate this.

Can you give us an example of a successful product development?

T2G is a 100% bio-based and biodegradable grafting tape for fruit tree grafting, characterized by its bioactive additives. The development reflects the strength of our activities in Straubing:
The idea came from my colleague Manuela Kaiser. Technologically, we were able to cover all chemo-synthetic and biological aspects in Straubing, and for the development work, a very creative team with industry-experienced colleagues was available. Formulations as well as processing and material testing also took place in Straubing. Pre-series production of the semi-finished product can hopefully take place this autumn on our new planetary roller extruder. Subsequent processing will then be carried out by an industrial project partner.

What do you think the future of bioplastics will look like? What is needed for plastics based on renewable raw materials to succeed on the market?

In addition to ideas for innovative bio-based base materials (polymers), there is a strong need for well-designed additive concepts that give the materials application-driven properties and make them accessible to highly efficient processing. A great deal of creativity, perseverance, and even stronger collaboration between industrial research & development and application is required. This is precisely where Fraunhofer IGB in Straubing serves as a reliable and experienced development partner.

Claudia Falcke has been head of the Plastics Technology division within the Department of Bioinspired Chemistry at the Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB in Straubing since 2019, where she has been working since 2013. After studying chemistry, she began her professional career in 1999 in pharmaceutical research at Bayer HealthCare, where she worked as a laboratory engineer in the chemical-scientific laboratories until 2007. After moving to Polymer-Chemie GmbH in 2008, she took on the role of deputy head of the central laboratory and, from 2010, worked in the management staff unit “Strategic Development Projects – Materials and Technologies.” She deepened her knowledge of plastics through a degree in Applied Plastics Engineering at Schmalkalden University of Applied Sciences. Her scientific research results on terpenes, polyamides, and other bio-based chemicals and materials have been published in renowned scientific journals.