Bioplastic

PLASTICS

Two main reasons why they are so widespread.

• An enormous range of possible structures, giving a huge variety of properties.

• Easy to process and shape, leading to simple manufacture.

Snag…

Bioplastics

Biodegradable plastics

Recycled plastics

BIOPLASTICS

Bioplastics are a form of plastics derived from renewable biomass sources, such as vegetable oil, corn starch, pea starch, or micro biota, rather than fossil-fuel plastics (which are derived from petroleum).Bio-plastics are based on the principle of the natural cycle i.e. organic material is generated by photo-synthesis and is broken down by microbial degradation into the initial products of CO2 and water.

Types of Bioplastics

• Starch and Starch Blends

• PLA/ Poly Lactic acid

• PHB Poly-3-hydroxybutyrates

Starch based plastics - from plants

Amylopectin

Non branched Amylose

Cont…

• Partially crystalline

• Higher density

• low resistance to oil and solvents

• Easy to process but vulnerable to degradation

• Sensitive to moisture and high water vapour permeability

Thermoplastic starch

Diagram of the inlet zone of an extruder

The raw materials are mixed, heated and converted into a homogenous substance

Thermoplastic starch

Diagram of the inlet zone of an extruder

A cooling water systemensures stable temperature conditions.

Thermoplastic starch

Diagram of the inlet zone of an extruder

At the end of the extruder, the moltenthermoplastic starch discharges as a strand through a nozzle plate

POLY LACTIC ACID

• Monomer

• Depending on the links between these isomers, 3 different lactides can be produced:

• mesolactide, D-lactide and L lactide.

PLA production

Properties

•PLA from L and D degrades within weeks•High stability•Transparency•Softening point around 60 degree•Normal processing

Poly-3-hydroxybutyrates

Poly-3-hydroxybutyrates

R. Eutropha

Properties

• Good thermoplastic material

• Wide temperature range

• Lower crystallinity

• Tendency to creep and shrinkage 1.3%

• Higher melt viscosity

• UV resistance

Applications Packaging

• Food packaging --

- PLA foil and paper has turned out to be a great match for the packaging of cheese.

- Carrots in starch based packaging.

- Biodegradable trays for milk tray chocolates.

Cont…

- Water vapour transmission of the crystal clear PLA film can provide fresh products with a longer shelf life (9 days).

- Polylacticacid can replace PET in certain applications.

- Single use cold drink cups, plates, containers and cutlery, which are all based on renewable raw materials and are compostable after use.

Cont…• Electrical packaging -- An optical media made from cornstarch, “bio-disk” is 1.2mm thick, has a capacity of maximum 25 gb and is biodegradable.

- Sticky tape made from cellulose

- The cover comes with an embedded sunflower seed, which grows a sunflower once it is composted. According to experts 10% of the plastic in electricals will be able to be replaced by bioplastics.

• Pharmaceuticals packaging -

- Thermoplastic starch in the form of capsule material, for instance, can substitute conventional gelatin capsules.

- These materials are breathable and allow water vapor to permeate, but at the same time they are waterproof.

• Sanitary Products -

Cont…

Advantages

Lower fossil fuel consumption

Lower fossil fuel consumption

If all plastics in the world were replaced by bioplastics and the energy used in the process came from renewable sources the fossil fuel savings would be approx 3.49 million barrels a day. That is 4% of the world’s fossil fuel usage

If all plastics in the world were replaced by bioplastics and the energy used in the process came from renewable sources the fossil fuel savings would be approx 3.49 million barrels a day. That is 4% of the world’s fossil fuel usage

CO2 emission with Typical Plastic

Polymer LDPE PP HDPE PHB PLA TPS

CO2 emissions (Kg CO2/ Kg polymer)

3.0 3.4 2.5 2.6 2.16 1.14

CO2 emission with Bioplastic

Carbon foot printCarbon foot print

Energy Requirements

LDPE PP HDPE PHB PLA TPS

Energy requirements (MJ/Kg-polymer

81.8 85.9 73.7 44.7 54.1 25.4

Green House Gas Emission

How to Reduce Exposure

• Need to look at all stages of production

• Low fossil CO2

• More efficient / smarter technologies

• Capture / re use / sequestration

Total water consumption

DISADVANTAGE

• Bioplastics don't always readily decompose. Some need relatively high temperatures and can still take many years to break down. Even then, they may leave behind toxic residues.

• Bioplastics are made from plants such as corn and maize, so land that could be used to grow food for the world is being used to "grow plastic" instead.

• Some bioplastics, such as PLA, are made from genetically modified corn.

• Bioplastics cannot be easily recycled. To most people, PLA looks very similar to PET but, if the two are mixed up in a recycling bin, the whole collection becomes impossible to recycle.

Market growth•Bioplastics fast market growth of more than 8-10% per year• Bioplastics cover approximately 10-15% of the total plastics•market and will increase its market share to 25-30% by 2015

•Bioplastics fast market growth of more than 8-10% per year• Bioplastics cover approximately 10-15% of the total plastics•market and will increase its market share to 25-30% by 2015

Market summary

The current global production capacity for bioplastics in 2009 amounts to over 400,000 tones.

The current global production capacity for bioplastics in 2009 amounts to over 400,000 tones.

PRODUCTION CAPACITY

By 2020……Over 500 bioplastics processing companies are alreadyavailable, more than 5000 is expected by 2020

CONCLUSION

– Bioplastics is a reality and is a practical truth. Our willingness and improvement in technologies will give it a wider success.

Special thanks to…..

• CIPET-Central Institute of Plastics Engineering and Technology Chennai.

• Dr.B.Naazar SulthanDepartment of Polymer Science,AC Tech, Anna University, Chennai

• Dr. SSM. Abdul MajeedDepartment of Polymer ScienceCrescent College Chennai.

References

• http://www.hkc22.com/bioplastics.html

• http://www.bccresearch.com/index.htm

• www.fnr.de

• www.natureworksllc.com

• www.bioplastics24.com

• www.bpf.co.uk

• www.nnfcc.com

Thank you