Bioplastic Created From Eggshells and Nutshells

Interview with Rania Elkalla

Shell Homage

 

Shell Homage Hangers by Rania Elkalla

 

In our current society, industrial and household waste are abundantly available, so designers and researchers have recognized the potential of using this waste to innovate new materials. With our current linear model of "take-make-dispose," we can witness the negative impacts of this economic system on the environment and society. We can no longer consider design as an activity that simply focuses on aesthetics and functionality. Still, with an urgent need for an efficient and cyclical approach, designers are hastily changing their relationship with materials and creative processes.

As argued by Seetal Solanki in Why Materials Matter, we are on the edge of a material revolution where designers could improve our relationship with the planet and change society for the better. Everyday materials have the incredible potential to provide solutions to some of the most urgent environmental and socio-economic issues facing our world today.

We spoke to product designer Rania Elkalla about her innovative and green award-winning project (2018/2019), Shell Homage. 

Tell us about yourself. How did you become a material designer?

I’m an integrated designer with an educational background in product and graphic design, as well as experience in material science and production. I had an interest in materials from a very young age. I love feeling and touching tangible objects; for example, I would rather buy a magazine than read it online because I love the texture of the paper, the embossed elements on the cover, and the smell of the fresh print. From when I was a design student, I began to understand the integral role of materials in design and began collecting various materials for inspiration, like the net from cheese packaging or the mesh metal sheet used in filters. 

I believe that good design is long-lasting and that every product should have a purpose and a function. I strive to challenge myself and the materials I use to create products that are eclectically designed but visually simplistic. When it comes to any design, function, and quality should be as important as ethical sourcing and production. I believe that all types of design are linked with one another, and a designer must be a flexible risk-taker who is able to merge different techniques. 

I’m skilled in visual communication, branding, illustrating, designing 2D and 3D products, experimenting with materials, and merging different disciplines. I would describe my work as rich, vibrant, eclectic, and derived from various cultures and styles. My main aim is to keep on improving my skills and to present the best, most authentic version of myself through my work. Designers should always remember the word “FUN” that exists in Function. I tend to design things with humor and interaction with users.

What is the meaning of sustainability to you?

To me, sustainability means using non-toxic, sustainably produced, or recycled materials that have a lower environmental impact than synthetic materials. This should be paired with the use of energy-efficient manufacturing processes, and we should strive to build longer-lasting, better functioning products that need to be replaced less frequently. The product’s life cycle should be considered carefully; sustainable goods should be designed with recycling in mind, making it easy to disassemble so that its parts can be used to create new products. If this isn’t possible, the materials should come from renewable sources that can be composted when the product’s use has been exhausted. 

What is the role of designers and researchers in sustainable initiatives?

“Sustainable development is the pathway to the future we want for all. It offers a framework to generate economic growth, achieve social justice, exercise environmental stewardship, and strengthen governance.”
— Ban Ki-moon

When designing sustainably, we must consider the product’s entire life cycle. A designer needs to decide which material they are going to use and what the material source is. They have a multitude of options to choose between these days, but there are also countless environmental consequences to consider when designing a product. 

A primary example of a sustainable project is Smart Energy, a means to provide people with digitally-enabled solutions that help to maintain the stability of our planet. Another great example of a sustainable project is the Dutch initiative Fitzroy: ‘From Waste to Wasted’, where they transform waste from the North Sea into liquor packaging. 

How and why did you create the biomaterial out of eggshells and nutshells?

The idea of using different nutshells came from my father; he was my inspiration. I grew up in a family that cared a lot about eating healthy, organic food, and we ate a lot of nuts. My father always used to buy fresh nuts sealed in their natural shells and crack them just before eating because of their rich oils. When he would crack them at home, they used to scatter everywhere, and as I helped him to collect the shells, I began to realize how wonderful and strong the material was and its resemblance to wood. Afterward, a similar idea came to me with eggshells. Eggs are one of the main ingredients in the kitchen, but their versatility is often overlooked. In 2010, I started to work my investigation into eggshells and nutshells into my bachelor thesis. I collaborated with material engineers, but my main concern was finding the right recipe for creating a completely sustainable and biodegradable material that did not rot or break down easily. Initially, I reprocessed the shells by combining them with synthetic resin. The resulting material looked great and was mechanically hard, but I felt guilty for using an artificial resin and not allowing the material to decay ecologically. 

Now, our process is different. Before disposal, the shells are collected, sterilized, dried, and then ground down. This material is then bonded with organic and biodegradable substances, creating a mixture that can be handled through different production techniques. It is a similar texture to stone or ceramic and can be drilled, sanded, or laser cut. 

Some of the material is mixed with colors extracted from food ingredients. The created composite material can be pressed, extruded, 3D printed, or formed by injection molding. The resulting material is lightweight and aesthetically appealing, resembling marble or natural stones. The material is versatile and can be used in a product or interior design to make consumable goods in the fashion industry or jewelry design. Each piece produced by Shell Homage is handcrafted, unique, and 100% compostable. 

 

Could you explain a little more about the importance of using food waste to create new material?

One of the biggest industries in the world is the food industry. Generally, eggs and nuts are overlooked, but there is more to these foods than meets the eye. Consider that there are more than 1 trillion eggs produced per year, then imagine how much waste results from this production. Eggshells are made up of about 95% calcium carbonate, one of nature’s most absorbent materials. Eggshells also contain collagen, and their membranes can absorb up to 78% of the carbon dioxide in the air. There are millions of tons of nuts that are unused every year. Nuts are heat and water-resistant, as strong as wood and very durable. Most of the weight in a nut comes from its outer shell; for example, a walnut shell is typically 67% of the total weight of the fruit. Nutshells have been studied scientifically, and it is proven that they enhance the biopolymer properties of a product. Those shells are a wonderful natural resource, and there is no need to throw them away. We do that far too often these days. 

What were the main challenges in Shell Homage project?

Throughout the project, there were many questions that I needed to discover the answers to get the best possible results. What was the right binder or biopolymer to combine with the shells? What were the best production techniques to use? How could I balance design with material engineering to develop the best material from these natural products?

At the beginning of my research, I had a lack of manufacturing facilities and experience. It was vitally important to create a material that could withstand different mechanical strengths, so I needed to understand the properties of the biopolymers that I was considering to use. To do this, I required the expertise of somebody with a background in biomaterial science. One big challenge for me was to balance my spontaneous side as a designer with the practical guidelines of material science and production methods. 

What are the advantages and disadvantages of using your biomaterial? 

Most plastic products currently available in the market are oil-based, and there are very few that are made from plants and are biodegradable. There is a lack of biocomposites in the market that can maintain various mechanical strengths, loads, and can be optimized for different applications. Shell Homage is a great solution for phasing out oil-based plastics, that are made with toxic materials and don’t decay and replacing them with a compostable material made from natural products that are often disregarded. The end material’s properties can be controlled by the production method, creating end-results that range from hard, translucent, or opaque surfaces to malleable, elastic sheets. 

As with any project, there are a few cons to the material produced. It is most long-lasting when used in dry environments and kept away from UV light. The material preparation can be time-consuming and have high production costs if made on a small scale. However, the production can be easily scaled up and used in several industries. 

One of the main pros is how the material contributes to a circular economy. When you no longer have use for it, it can be disposed of in your garden and will decompose naturally, providing your soil with minerals. It is a closed-loop. 

How do you see the future of design and the conscious use of materials in product creation?

I stated in the early days that we were only at the beginning of our exploration into this area: 10 years later, this still remains true. One significant development is that material innovations are now not only deriving from scientists but often from the designers themselves. My research project that developed into a startup demonstrates how well-known natural materials can be innovated to create new material from scratch.  

Design is often intended to create an experience that is both useful and delightful to the product user, rather than singularly to provide a basic function. Materials play a central role in this as they are an integral part of the innovation. Our basic human need for certain products remains unchanged, but these products develop substantially over time with the discovery of new technologies that can enhance their design. The materials used are as critical as the product’s function. They must be well-chosen and fulfil the technical performance that is required. The people who have the most success in creating a product that is contemporary and useful are designers who can manipulate materials and their manufacturing possibilities, to give birth to something tangible and innovative. 

 

Interview

Nina Zulian

Editor

Gemma Osei

Material Research, InterviewNina ZulianMaterial Research, Bioplastics