Advanced Manufacturing for Sustainable Biodegradable Microbeads - BIOBEADS

Lead Research Organisation: University of Bath
Department Name: Chemistry

Abstract

In project BIOBEADS we propose to develop, in combination, new manufacturing routes to new products. Manufacturing will be based on a low-energy process that can be readily scaled up, or down, and the products will be biodegradable microbeads, microscapsules and microsponges, which share the performance characteristics of existing plastic microsphere products, but which will leave no lasting environmental trace. Using bio-based materials such as cellulose (from plants) and chitin (from crab or prawn shells), we will use continuous manufacturing methods to generate microspheres, hollow capsules and porous particles to replace the plastic microbeads currently in use in many applications.

Cellulose and chitin are biodegradable and also part of the diet of many marine organisms, meaning they have straightforward natural breakdown routes and will not accumulate in the environment. BIOBEADS will be produced using membrane emulsification techniques.

The project builds on our joint expertise in membrane emulsification for continuous production of tunable droplet sizes, dissolution of cellulose and chitin in green solvents and in characterization of nanoscale and microscale structures to study all aspects of particle formation from precursors, through formation processes, to degradation routes. Yhe primary focus will be spheres and capsules, for use in cosmetics and personal care formulations, but, by understanding the processes and mechanisms of formation of these spheres, we aim to be able to tailor particle properties to suit larger scale applications from paint stripping, to fillers in biodegradable plastics.

The BIOBEADS research team will work with industrial partners, including very large manufacturers of personal care products, to ensure that the research conducted can be taken up and used, so having a real, positive impact on the manufacturing of new, more sustainble products.

Planned Impact

BIOBEADS has been developed with the imminent exploitation of our outcomes in commercial activities as a major goal. The overarching idea is that development of the underpinning manufacturing processes will occur simultaneously with synthesis of novel biodegradable, tailorable and highly functional materials. We will work with industrial project partners, Unilever, Croda and Micropore Technologies, to ensure that our results are disseminated to relevant stakeholders who have potential to take the results forward for eventual commercialization. With both a UK SME and large multinationals engaged, the potential for impacting real future manufacturing is significant.
ECONOMIC IMPACT & UK COMPETITIVENESS: BIOBEADS' industrial partners will benefit directly from this project, through wider applicability and uptake of their technology (Micropore), or by gaining early access to potential new ingredients and biobased microspheres, capsules and microsponges to underpin development of more sustainable products and thus more sustainable industries (Croda, Unilever). The immediate opportunity in the UK is in the personal care and cosmetic products (PCCP) market where Croda and Unilever are major actors (worth >£16bn in 2015), with wider opportunities in fillers in the growing bioplastics market (while this is currently small, it is growing rapidly and globally demand for bioplastics for packaging are expected to grow to >2m t by 2020, with a value of $5 billion).
SOCIAL & ENVIRONMENTAL IMPACTS: The replacement of plastic microbeads and capsules that are persistent in the environment with biodegradable BIOBEADS will have important environmental impacts by reducing the plastic load in the environment with follow-on effects of preserving marine and riverine environments, and avoiding incorporation of potentially deleterious components into the food chain. Funding has been requested in Pathways to Impact to independently validate the sustainability claims for the technology, using Truecost to providing estimates of potential environmental impact reduction for the processes and products to be developed here.
THE WIDER MANUFACTURING COMMUNITY: The biodegradable capsules and microsponges, to be developed in BIOBEADs have clear opportunities in delivery of active pharmaceutical ingredients, foods, nutriceuticals, flavours and fragrances. As membrane emulsification allows production of narrow particle range materials, formulations containing well defined particle size distributions can provide sustained active ingredient release profiles and/or triggered release (in response to external stimuli). Such profiles can potentially provide greater efficacy than competitor products, e.g. in crop protection applications, which could offer a competitive advantage, increasing market share while decreasing environmental chemical load. Such 'smart' products assist UK based companies in competition with those who rely on low prices (e.g. by producing in low-wage economies). Thus, BIOBEADS has strong potential to add to UK manufacturing capability in biobased, biodegradable functional materials for formulated products. We have discussed the potential for BIOBEADS with Syngenta (agrochemicals) and AzkoNobel (paints and coatings) and these and other companies have expressed an interest. Thus, we plan to run two industry facing workshops, which will be used to disseminate our results beyond the current grant partners (following appropriate protection of any IP arising).
This grant will also provide training and networking opportunities to two PDRAs, an RA and PhD (funded by Bath), enabling them to launch their careers in this exciting, broad and rapidly growing field of manufacturing of sustainable products. The UK will therefore benefit from gaining trained researchers, and potentially licensable new technologies for biodegradable microbead, microsphere and microsponge production.
Finally, BIOBEADS is an excellent vehicle for engaging the public.

Publications

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Coombs OBrien J (2017) Continuous Production of Cellulose Microbeads via Membrane Emulsification in ACS Sustainable Chemistry & Engineering

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Wilson A (2021) Keratin-Chitosan Microcapsules via Membrane Emulsification and Interfacial Complexation. in ACS sustainable chemistry & engineering

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Callaghan C (2022) Continuous production of cellulose microbeads by rotary jet atomization. in Journal of colloid and interface science

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Ekanem E (2022) Production of sub-10 micrometre cellulose microbeads using isoporous membranes in Journal of Membrane Science Letters

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Shi H (2022) Stable Cellulose Nanofibril Microcapsules from Pickering Emulsion Templates. in Langmuir : the ACS journal of surfaces and colloids

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Gomes M (2022) Cellulose Microbeads: Toward the Controlled Release of Nutrients to Plants in ACS Agricultural Science & Technology

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Callaghan C (2023) Cellulose Acetate Microbeads for Controlled Delivery of Essential Micronutrients. in ACS sustainable chemistry & engineering

 
Description We have developed a process for continuous production of cellulose microbeads across a range of sizes as replacements for persistent plastic microbeads now banned in many countries (or soon to be banned) as a source of microplastic pollution. We have designed and commissioned two novel rigs for particle production resulting in higher productivity and greater control over particle sizes compared to traditional crossflow and rotational membrane emulsification processes. We have positive outcomes in hand w.r.t. developing similar biopolymer based microcapsules, which demonstrate stability and dye encapsulation for more than 6 months.
Exploitation Route We have links to established commercial partners who were advisors on the grant and who had first refusal on the outcomes which we communicated to them. At present these partners have not elected to take up our outcomes, so we are pursuing IP protection and licensing of one of our novel methods of particle production through the IAA grant listed in follow on funding.
Sectors Manufacturing

including Industrial Biotechology

Other

 
Description There has been extensive publicity around our findings w.r.t. cellulose microbeads including many interviews on radio and tv and print (and online) media coverage. This has also led to a large number of invitations to speak at public events. The paper "Continuous Production of Cellulose Microbeads by Cross Flow Membrane Emulsification-Precipitation, ACS Sustainable Chem. & Eng., 2017, 5, 5931-5939" was covered in a University of Bath press release on 8 June 2017 (World Oceans Day) which resulted in wide coverage in the press and a number of radio and television interviews (readership/estimated viewers in parentheses) - a summary from the University of Bath Press Office includes: a. Radio: BBC Radio 4 Today (2.9 million reach); BBC Radio 1 Newsbeat, BBC Wales, BBC Pointswest; BBC World Service NewsHour & Newsday (421,000) b. TV: Sky News (1 million), c. Media (254 articles across online, broadcast and print outlets): The Times (451,000), iNews (266,000), Daily Mail (1.5 million), MailOnline (2 million) Daily Telegraph (472,000), The Chemical Engineer, Metro (890,000), Record (149,000) d. Estimated at 46 million total news reach e. £493,000 worth of Advertising Value Equivalent Coverage (growing) f. A number of video clips were published online, including: Reuters video: http://www.reuters.com/video/2017/07/04/eco-microbeads-producible-on-industrial?videoId=372018027; EurekaAlert (American Association for the Advancement of Science) video: https://www.eurekalert.org/pub_releases/2017-06/uob-smb060617.php and others
First Year Of Impact 2018
Sector Manufacturing, including Industrial Biotechology,Other
Impact Types Economic

 
Description Chair ISIS Triennial Review
Geographic Reach National 
Policy Influence Type Participation in a guidance/advisory committee
 
Description Deputy Chair of STFC Science Board
Geographic Reach National 
Policy Influence Type Participation in a guidance/advisory committee
 
Description COVID-19 - Enzyme immobilization on natural and biodegradable cellulose beads for biocatalysis applications
Amount £47,000 (GBP)
Funding ID 105285 
Organisation Small Business Research Initiative (SBRI) 
Sector Public
Country United Kingdom
Start 09/2020 
End 12/2020
 
Description Cellulose microbeads for biocatalysis applications
Amount £164,820 (GBP)
Funding ID 10004526 
Organisation Small Business Research Initiative (SBRI) 
Sector Public
Country United Kingdom
Start 03/2021 
End 03/2022
 
Description IAA AirBeads
Amount £52,129 (GBP)
Funding ID IAA401 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2021 
End 06/2022
 
Title Dataset for "Keratin-Chitosan Microcapsules via Membrane Emulsification and Interfacial Complexation" 
Description Primary data relevant to Figures 2, 3, 6 and 7 in the article "Keratin-chitosan microcapsules via membrane emulsification and interfacial complexation". The data for Figures 2 and 6 consist of zeta potential measurement results of keratin and droplets respectively; the data for Figure 3 consists of turbidity measurement results; and the data for Figure 7 is data on the release of Nile red from microcapsules, specifically the absorbance at 520nm, and the calculated concentration of Nile red and % release. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
Impact na 
 
Title Dataset for "Production of sub-10 micrometre cellulose microbeads using isoporous membranes" 
Description Dataset for "Production of sub-10 micrometre cellulose microbeads using isoporous membranes" 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
Impact na 
 
Title Dataset for ''Stable cellulose nanofibril microcapsules from Pickering emulsion templates'' 
Description We used cationized cellulose nanofibrils (CCNF)-stabilized Pickering emulsions (PE) as templates, and the electrostatic interactions were induced by adding the oxidized cellulose nanofibrils (OCNF) at the oil/water interface to form sustainable microcapsules (MCs). The oppositely charged cellulose nanofibrils enhanced the solidity of interfaces allowing the encapsulation of Nile red (NR) dye in sunflower oil droplets. This dataset provides the raw data of the dye release study from these MCs under different conditions, such as through diffusion, centrifugation and mechanical stirring at various pH environments. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
Impact none so far 
URL https://doi.org/10.15125/BATH-01110.
 
Title Dataset for Continuous Production of Cellulose Microbeads by Rotary Jet Atomization 
Description Continuous Production of Cellulose Microbeads by Rotary Jet Atomization. Data which concerns the production of cellulose microbeads using ionic liquids, co-solvents and jet breakup. This data reports on the continuous fabrication of cellulose microbeads in the size range 20-500 µm with narrow size distribution, via rotary jet atomization. Utilizing Rayleigh breakup as a method of droplet generation, jets of cellulose dissolved in solutions of [EMIm][OAc] and DMSO are expelled from rotating nozzle systems, generating droplets which, when captured in a suitable anti-solvent bath, initiate phase-inversion allowing regeneration of the cellulose into beads. The dataset includes calculations of dimensionless parameters as well as droplet sizes and distributions. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
Impact none so far 
URL https://doi.org/10.15125/BATH-01067
 
Description Wide media engagement following a University of Bath press release 
Form Of Engagement Activity A press release, press conference or response to a media enquiry/interview
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact 71. The paper "Continuous Production of Cellulose Microbeads by Cross Flow Membrane Emulsification-Precipitation, ACS Sustainable Chem. & Eng., 2017, 5, 5931-5939" was covered in a University of Bath press release on 8 June 2017 (World Oceans Day) which resulted in wide coverage in the press and a number of radio and television interviews (readership/estimated viewers in parentheses) - a summary from the University of Bath Press Office includes:
a. Radio: BBC Radio 4 Today (2.9 million reach); BBC Radio 1 Newsbeat, BBC Wales, BBC Pointswest; BBC World Service NewsHour & Newsday (421,000)
b. TV: Sky News (1 million),
c. Media (254 articles across online, broadcast and print outlets): The Times (451,000), iNews (266,000), Daily Mail (1.5 million), MailOnline (2 million) Daily Telegraph (472,000), The Chemical Engineer, Metro (890,000), Record (149,000)
d. Estimated at 46 million total news reach
e. £493,000 worth of Advertising Value Equivalent Coverage (growing)
f. A number of video clips were published online, including: Reuters video: http://www.reuters.com/video/2017/07/04/eco-microbeads-producible-on-industrial?videoId=372018027; EurekaAlert (American Association for the Advancement of Science) video: https://www.eurekalert.org/pub_releases/2017-06/uob-smb060617.php and others
Year(s) Of Engagement Activity 2018
URL http://www.bath.ac.uk/news/2017/06/16/biodegradable-microbeads-hit-the-headlines/