Injection moulding of bio-based components with controlled composting time
The launch of the LEAF research project marks the start of an innovative approach to the development of sustainable plastic components. The aim of the project is to develop bio-based materials that can not only be efficiently processed using injection moulding, but whose composting time can also be specifically controlled.
Technology in harmony with nature: a moulded plastic component made from bio-based material embedded in autumn leaves – symbolising the sustainable cycle of the LEAF research project. (AI-generated with Copilot)
The LEAF research project aims to enable the production of plastic components with controllable compostability
Biodegradable plastics offer a sustainable alternative to conventional plastics such as polyethylene (PE) and polypropylene (PP), which are associated with significant environmental problems as they take hundreds to thousands of years to decompose. Their long decomposition time leads to the formation of microparticles that accumulate in water, soil and the food chain. These microparticles can bioaccumulate and have toxic effects. Biodegradable plastics such as polylactic acid (PLA), polybutylene succinate (PBS) and polyhydroxyalkanoates (PHA) are considered promising alternatives to conventional plastics. However, in many cases, they can only be broken down under industrial conditions. This is precisely where the LEAF project, led by the Plastics Centre in cooperation with partners Dressel GmbH and Boßler Werkzeug & Formenbau GmbH, comes in: by integrating granular leaf materials into biopolymer compounds, the aim is to create new materials that are both environmentally friendly and industrially viable.
‘Our innovative approach is to use granular leaf materials that are processed in bioreactors. These materials are suitable as a reinforcing phase, for improving flowability and for precisely controlling the composting time,’ explains Christian Schlör, scientist at SKZ.
The project, which started in January 2025, addresses key challenges such as thermal stability and phase separation. The aim is to develop a leaf-based biopolymer that can be processed using injection moulding and has a defined decomposition time. The results could be of great importance, particularly for companies in the packaging, automotive, textile and agricultural industries.
LEAF thus represents a new generation of sustainable materials that combine ecological responsibility with industrial efficiency.
