Library Reference

Biopolymers in Packaging

BY: Kavita Singh 0817 2nd sem 24th batch, IIP

Biopolymer

Biopolymers are polymers that are generated from renewable natural sources and biodegradable

Need Of Biopolymer

Conventional resources are exhausting Biopolymers are abundantly available Renewable polymers, Biodegradable and Compostable Biopolymers are sustainable, and Carbon neutral Biopolymers have unique functionality Can contribute to healthier rural economies

Applications

Biopolymer Types
Biopolymers are categorized on the following basis:

Category 1: Polymers directly extracted/removed from biomass. Examples are: 1) starch 2) cellulose 3) proteins like casein and gluten etc 4) chitin/Chitosan 5) lignin

Category 2: Polymers produced by classical chemical synthesis using renewable biobased monomers. Examples are: 1) poly lactic acid, a biopolyester polymerized from lactic acid monomers. 2) biobased monomers Category 3: Polymers produced by microorganisms or genetically modified bacteria: 1) poly hydroxy alkanoates 2) poly hydroxybutyrate 3) bacterial celluloses

Manufacturing of packaging material from biopolymer

1) Two main strategies may be followed in synthesizing a polymer. One is to build up the polymer structure from a monomer by a process of chemical polymerization. The alternative is to take a naturally occurring polymer and chemically modify it to give it the desired properties 2) Biopolymers

Modifications Thermoplastic Modification (physical/chemical) Product properties Product

The major processing routes to potential biopolymer based products

Processing route (Co-) Extruded film Cast film Extrusion coating Blown films Injection (blow-) molding Fibers and non-woven Thermoformed sheets Product examples Packaging film Packaging film Laminated paper or films Packaging film Salad pots, cutlery, drinking Agricultural products, diapers Trays, cups

Market

Biopolymer - an environmentally friendly and harmless polymeric material continues to show good growth potential.

A recent survey conducted shows that global demand would grow from 180 million tons to 258 million tons by 2010 - definitely growing faster than the commonly used plastics such as polyolefin.
Several factors such as soaring oil prices, worldwide interest in renewable resources, growing concern regarding greenhouse gas emissions and a new emphasis on waste management have created renewed interest in biopolymers and the efficiency with which they can be produced. New technologies in plant breeding and processing are narrowing the biopolymers-synthetic plastics cost differential, as well as improving material properties. Implementation of the Kyoto Protocol will also bring into sharper focus the relative performance of biopolymers and synthetics in terms of their respective energy use and CO 2 emissions

Current stage of development (2007) of thermoplastic biopolymers

Production Data

There are four major biopolymer groups in the market : PHA or PHB Polylactic acid (PLA) Starch-based polymers Cellulose

PHAs Poly hydroxy alkanoates

PHAs are linear polyesters produced in nature by bacterial fermentation of sugar or lipids. More than 100 different monomers can be combined within this family to give materials with extremely different properties. They can be either thermoplastic or elastomeric materials, with melting-points ranging from 40 to 180C. The most common type of PHAs is PHB (poly-beta-hydroxybutyrate). PHB has properties similar to those of PP, however it is stiffer and more brittle. A PHB copolymer called PHBV (polyhydroxybutyrate-valerate) is less stiff and tougher, and it is used as packaging material.

Contd

Products: Coating of paper and foils, Household goods, Bone plate, Razor, biodegradable (PHA) Shampoo bottle, biodegradable (PHBV) Surgical sutures References: NODAX, BIOPOL, BIOMER Processes: Blow moulding, Injection moulding, Extrusion Creation: Made from renewable natural sources like sugar.. Disposal: It biodegrades in microbially active environments in 5-6 weeks. The action of some enzymes produced by microbes solubilises PHB which is then absorbed through the cell wall and metabolized. PHB is normally broken down to carbon dioxide and water when degraded in aerobic conditions. In absence of oxygen the degradation is faster, and methane is also produced. PHB is not degraded in biologically inactive systems such as sanitary landfills

PLA Polylactic acid

PLA is a biodegradable thermoplastic derived from lactic acid. It resembles clear polystyrene, provides good aesthetics (gloss and clarity), but it is stiff and brittle and needs modifications for most practical applications (i.e. plasticizers increase its flexibility). It can be processed like most thermoplastics into fibers, films, thermoformed or injection moulded. Used for: compost bags, plant pots, diapers, loose fill packaging, table ware, bottles, medically used products etc

Cont

Most conventional plastic processes like: Blow moulding, Injection moulding, Extrusion, Vacuum forming, Fiber spinning References : Cargill Dow Polymers LLC-Natures Way PURAC Creation: Lactic acid can be obtained on the basis of renewable starch containing resources (e.g. corn, wheat or sugar beat) by fermentation, or by chemical synthesis of non-renewable resources Disposal: If composted properly it takes 3-4 weeks for complete degradation. The first stage of degradation (two weeks) is a hydrolysis to water soluble oligomers and lactic acid. The latter, as a naturally occurring substance, is a rapid metabolisation into CO2, water and biomass by a variety of micro-organisms.

Starch-based polymers

Usually referred to as thermoplastic starch. They are stable in oils and fats, however, depending on the type, they can vary from stable to unstable in hot/cold water. They can be processed by traditional techniques for plastics. These materials consist mainly (>90%) of starch obtained from renewable natural sources. Coloring and flame retardant additives are possible.

Products : Starch-based tube Degradable compost bags Agricultural mulch film Thermoformed trays

Most conventional plastic processes like: Blow moulding, Injection moulding, Extrusion, Thermoforming

References: Biotec GmbH (Bioplast) NOVON International (NOVON)

Disposal: Depending on the grade, thermoplastic starch can degrade completely within five days in aqueous aerobic testing and in 45 days in a controlled compost, or can even decompose in water

Cellulose

Cellulose is a cheap raw material, but difficult to use because of its hydrophilic nature, insolubility and crystalline structure. Because of its regular structure and array of hydroxyl groups, it tends to form strongly hydrogen bonded crystalline micro fibrils fibers and is most familiar in the form of paper or cardboard in the packaging context. Derivatives: Carboxy methyl cellulose, Carboxy ethyl cellulose, cellulose acetate, cellophane Products: Toys packaging, Tapes, Food packaging, Paper, Membrane

Most conventional processes like Injection moulding, Blow moulding References: Bioceta, Nature flex, Cellophane

Cellulose Acetate

Cellulose acetate (CA) is used for transparent, translucent and opaque objects Furthermore, it is especially suitable for coatings applications requiring high melting-point, toughness, clarity, and good resistance to ultraviolet light, chemicals, oils, and greases. Cellulose acetate is an amorphous thermoplastic material belonging to the cellulosic resin family t is obtained by introducing the acetyl radical of acetic acid into cellulose (as cotton or wood fibers) to produce a tough plastic material

Creation: Made from chemical modification of cellulose, which is one of the most diffuse organic substances in nature. Use: Cellulose acetate is inflammable and burns with a yellowish flame producing a smelling smoke. Additive are often used to decrease its inflammability and to give the material self-extinguishing properties

Biopolymer packaging materials currently available in the market.

Material Suppliers Trade Name Polymer

PHB/PHV (Poly hydroxy alkanoates)

WasMonsanto Biomer

Biopol Biomer

Ester Ester Acetal

Cellulose acetate

Courtaulds Mazucheli Bioceta

Acetal/Es ter Ester Ester Ester Ester Ester Ester

Polylactic acid/PLA

Cargill Dow Polymers Nature Works PLA Mitsui Hycail Galactic National Starch Avebe

LACEA
Galactic Eco-FOAM Paragon

Starch

Issues Associated with Biopolymer use

i. Cost

ii. Energy iii. Renewable iv. Natural Resources v. GM crops vi. Labeling vii. Compost disposal viii. Communication ix. Plastic recycling x. Shelf life and transportation

End-of-life waste management modeling

Several different waste management treatment technologies were modeled to understand how biopolymer degrade in aerobic and anaerobic environments.
Comparative Study-Heres how long it takes for some commonly used products to biodegrade, when they are scattered about as litter:

Cotton rags : 1-5 months Paper : 5-24 months Rope : 3-14 months Orange peels : 6 months Wool socks : 1-5 years Plastic coated paper 5 years Nylon fabric : 30 years Plastic bags : 450 to 5000 years Glass Bottles : 1 million years

Life Cycle of a Biopolymer

Biodegradation of Biopolymer

Treatment technologies Landfill (anaerobic environment); Source separated green and food composting; Municipal solid waste composting; and Municipal solid waste anaerobic digestion.

Challenges ahead
Acceptance of biodegradable polymers is likely to depend on five unknowns: Customer response to costs that today is generally 2 to 4 times higher than for conventional polymers; Possible legislation; The achievement of total biodegradability; and The development of an infrastructure to collect, accepts, and process biodegradable polymers as a generally available option for waste disposal. The belief that the components of biopolymer need to be used for feeding people, by both direct consumption and to aide in growing plants as compost.

Thank You!

Questions?