ABOUT THE PROJECT

Welcome to Bread4pla

BREAD4PLA is a LIFE demonstrative European project. It will demonstrate to the European countries the feasibility of an innovative, user friendly and sustainable environmental solution which promotes the waste recovery in the specific agro-food sector of the bakery industry.

The project´s consortium is expert in five key points for a new way for bakery waste treatment, dealing to new packages for bakery products and closing the life cycle: the organic waste of the bakery industry, production of lactic acid at pilot plant scale by enzymatic processes, production of PLA, PLA modification by compounding and processing to obtain films and finally packaging validation for bakery products.

Objectives and innovations

The main objective of BREAD4PLA is to demonstrate, in a pre-productive continuous pilot plant process, the viability of polylactic acid (PLA) synthesis from waste products of the bakery industry and its use in the fabrication of a 100% biodegradable film to be used in the packaging of bakery products, closing the life cycle.

Other specific objectives are:

» To increase the value of bakery waste by its recovery for acid lactic production.

» Show the technical viability of the pre-industrial process of lactic acid from bakery waste.

» To scale-up the polymerization process of PLA using lactic acid obtained from bakery waste fermentation.

» To obtain a 100% biodegradable thermoplastic film of PLA from the bakery waste 95% from renewable resources.

» To replace the current human food raw material to produce PLA by a residual one, avoiding the problems related to fluctuations in food prices.

BREAD4PLA main innovations are:

» To obtain a high purity lactic acid from bakery waste, at pilot plant level and in a full continuous process.

» The use of non-food resources to produce lactic acid.

» To promote the use of biopolymers (PLA) from natural sources.

BREAD4PLA Project actions

» ACTION 1: DEFINITION OF REQUIREMENTS; SELECTION AND MODIFICATION OF BAKERY WASTE.
This action has as main objective to develop an in-depth assessment of the quantity type and quality of food waste emitted by the food and bakery industries in the different European Union countries. A large number of publications and databases will be reviewed in order to know what the real situation and main search techniques for the recovery and reuse of waste are used today.

» ACTION 2: OPTIMIZATION OF LACTIC ACID PRODUCTION FROM SELECTED WASTE BY FERMENTATION PROCESS AT PILOT PLANT LEVEL.
In this Action, lactic acid fermentation will be scaled-up based on bread/bakery residuals in an already existing pilot plant facility (ATB pilot scale, 450 L fermentation capacity/gross volume). It will be carried out in 3 steps: up-stream processing (pre-treatment & hydrolysis of biogenic raw material/waste), lactic acid fermentation and down-stream processing (separation & purification of products).

» ACTION 3: OPTIMIZATION AT PILOT PLANT LEVEL OF POLYLACTIC ACID POLYMERIZATION PROCESS BY NON-CHEMICAL PROCESS.
In this Action, PLA would be synthesized in 3 subsequent steps: Oligomerisation of lactic acid (produced in Action 2), Cyclisation of lactic oligomer to lactide and Polymerisation of lactide to obtain PolyLactic acid.

» ACTION 4: MODIFICATION AND MANUFACTURE OF PLA PACKAGING IN ACCORDANCE WITH SPECIFICATIONS
The main objective of this action is the optimization and production of flexible, transparent and biodegradable film or sheet for bakery products packaging, based on polylactic acid (PLA) in combination with other additives (plasticizers, antioxidants, UV protection, …) from renewable resources, which can provide an environmentally sustainable alternative to thermoplastics materials (mainly polyolefins) used for this applications.

» ACTION 5: PACKAGING VALIDATION AND SELF LIFE OBTAINED
Intensive update of plastic packaging for bakery used in Europe and definition of packaging requirements and analysis of the thermoplastic packaging developed

» ACTION 6: MONITORING: ENVIRONMENTAL, LOGISTIC AND REGULATORY
In this action every demonstrative actions and the project’s demonstrative product (PLA packaging) will be controlled and validated, from three main aspects/profiles: environmental, logistic/economic, and regulatory/legislative. It will be established the possible scale of the demonstrative results and how the packaging will be affected by these aspects.

» ACTION 7: INTERNATIONAL COMMUNICATION AND DISSEMINATION & EXPLOITATION MANAGEMENT
International Communication and Dissemination, national Communication and Dissemination and exploitation Management

» ACTION 8: PROJECT MANAGEMENT
The objective of this action is to define the project management structure and procedures foreseen to ensure that the project activities are developed as scheduled, that the resources allocated are optimally used and properly justified and that the reporting is done in manner and time.