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Reducing Carbon Footprint: The Role of Bio-Based and Renewable Raw Materials in Adhesive Production

Posted 06 Dec 2024 by Elizabeth Staab, Marketing Manager, Packaging Solutions EIMEA

According to the National Oceanic and Atmospheric Administration (NOAA), the global average atmospheric carbon dioxide concentration reached a new record high in 2023. The record, 419.3 parts per million (ppm), is on par with the rapid growth over the last twelve years. Experts estimate that atmospheric carbon dioxide could reach 800 ppm by the end of the century if humanity continues to use fossil fuels to meet energy demands—resulting in a drastically different environment for future generations.

Reducing carbon dioxide and other greenhouse gas (GHG) emissions can slow their environmental impact and limit the consequences of atmospheric change, such as more frequent and intense storms. Companies can limit GHG emissions, otherwise known as their carbon footprint, through various approaches, including innovative technology.

One emerging solution for manufacturers to lower their carbon footprint is replacing adhesives made with fossil-based materials with adhesives containing material derived from recycled or virgin biomass (e.g., switchgrass, sugar cane, wood). Although adhesives containing renewable raw materials are currently not widely used, they are increasingly available. Here, we’ll cover how adhesive manufacturers use renewable raw materials to develop bio-based adhesives without compromising product quality or efficiency. 

What is Biomaterial?

Biomaterials come from natural resources capable of replenishing over time, such as sugar cane and cornstarch. Companies process biomaterials into resins or oils for use in formulating adhesives. Certified “bio-based” adhesives must contain a certain percentage of biomaterial. The percentage differs per certification. Table 1 provides an overview of three widely used certifications: EN 16785-1, ASTM D6866, and EN 16640.

Table 1. Examples of Bio-Based Content Certifications.
Certification Standards Table

EN 16785-1 ASTM D6866 EN 16640
Certifier TÜV Austria and TÜV Germany USDA and TÜV Germany TÜV Austria
Definition Amount of biomass in a product Amount of organic bio-based carbon content in a product Amount of bio-based carbon content out of total carbon content
Label Percentage of bio-based content Certification + percentage of bio-based content Certification + star system based on percentage of bio-based content

 

Why Increasing Biomaterial Content in Adhesives Matters?

Although adhesives are typically a small, often unseen part of a product, they play an important role. For example, adhesives hold the different layers of a disposable diaper together, affix labels to beverage bottles, and manage thermal activity in electric vehicle batteries. Bio-based adhesives help companies moving toward decarbonization reduce Scope 3 GHG emissions—the emissions generated from their product’s value chain.

“Having the right adhesive is the most important part of a product,” says Nora Behrens, Personal Care Marketing Manager at H.B. Fuller, “If you don’t have the right adhesive, the article doesn’t come together. Our main goal with bio-based adhesives is to help our customers achieve their sustainability goals and reduce our own environmental impact. The adhesive must support the customer's journey, and we are part of the journey.”

Hygiene Applications for Bio-Based Adhesives

Incorporating biomaterial in adhesives has its challenges. Fossil-based materials are cost-effective and generally have a consistent, uniform chemical structure derived from precise synthetic processes. In contrast, the chemical structures of renewable raw materials can vary because they are derived from natural sources whose composition is influenced by biological and environmental factors. Biomaterials require controlled processing for consistent quality. 

Research and development teams have made enormous headway in developing high-performance bio-based adhesive lines. Manufacturers can use H.B. Fuller’s bio-based hot melt adhesives for hygiene product construction (how the material is held together) and positioning (keeping the product in place). H.B. Fuller works with customers to customize the formulation to meet their product’s requirements, work with their production equipment, and ensure products comply with regulatory guidelines.

Overcoming Challenges in Creating Bio-Based Adhesives 

When developing bio-based adhesives, H.B. Fuller experts first work closely with customers to know their needs. This includes the percentage of renewable raw materials for the final product, the application method, and the substrate material they expect to use. For example, disposable diapers made from natural substrates, such as cotton, require an adhesive that holds its bond even when the material swells upon contact with moisture. 

“You cannot invent adhesives without knowing the application,” says Karsten Voss, Technical Manager for Research and Development, EMEA Region, at H.B. Fuller, “We work closely with customers to develop adhesives for different applications. We are not just throwing an adhesive over the fence—we are testing adhesives on customer articles and customer substrates. The adhesives and substrates must work together." 

Once H.B. Fuller teams understand the needs of their customers, they study biomaterial candidates for the formulation. They review each material's properties, behavior, and application effects to see if it can be used in a standard hygiene product line. Most formulations require similar components, such as resins, polymers, plasticizers, and additives. Experts use Design of Experiments (DOE) methods to optimize adhesive formulations, aiming to identify the ideal bio-based alternatives that match or improve upon the performance of traditional fossil-based materials.

Partnerships Key to Developing Bio-Based Adhesives

Transitioning from fossil-based adhesives to bio-based adhesives requires a close partnership between adhesive manufacturers, raw material suppliers, and customers. Meeting the customer’s requirements for production and application is just one piece of the puzzle. H.B. Fuller teams often find educating customers on what constitutes a bio-based adhesive is just as essential. These conversations kickstart the process and help ensure its success.

“There’s still some confusion about the different terms out there,” says Behrens, “We educate our customers and provide direction. ‘Relationship’ is one of our key values. You don't only need a supplier—you need a partner.”

Packaging Applications for Adhesives Made with Renewable Raw Materials

In addition to bio-based hot melt adhesives for hygiene applications, H.B. Fuller creates a near-carbon-neutral adhesive for more sustainable packaging. The Advantra® Earthic™ 9370 hot melt adhesive, used to seal cartons and packages, includes a high percentage of bio-circular and circular materials. H.B. Fuller’s manufacturing facility in Lüneberg, Germany, has the ISCC PLUS certification to track the use of circular and bio-circular materials through the manufacturing process. Carefully documenting circular and bio-circular materials through the ISCC PLUS mass balance approach ensures customers can claim sustainable benefits under the ISCC PLUS certification.

The mass balance approach provides companies with a pathway to increase the amounts of circular and bio-circular materials in production replacing fossil-based raw materials. However, it comes with its challenges. Not only are renewable raw materials currently more expensive than fossil-based materials, but they are also not as readily available in the quantities necessary for manufacturing. Overcoming costs will move bio-based adhesives from an alternative to a standard product.

Technology Bridges Standard of Life and a Sustainable Future

Replacing fossil-based materials with biomaterials in adhesives is possible and can reduce companies’ scope of 3 emissions. Bio-based adhesives are one example of how scientific innovation enables more sustainable products without sacrificing function and performance. Voss sums it up well:

“We are responsible for keeping the standard of living we have today with different approaches—with the invention of technology. We want to provide the same quality of products but in a more sustainable way.”

Developing bio-based adhesives is one of many steps H.B. Fuller is taking to help customers reduce their Scope 3 emissions. Find more information on H.B. Fuller’s commitment to sustainability in our 2023 Sustainability Report.

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