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CORN STARCH BLEND COMPOSTABLE PLASTIC
Dr. ANOMITRA CHAKRAVARTYKPS CONSULTANTS & IMPEX PVT. LTD.
www.kpsimpex.com
Indian Plastics Institute – Delhi, 26th APRIL 2019
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Conventional, Biobased & Biodegradable Plastics
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Biodegradation is a process, not an end resultIS / ISO 17088 (2008) provides the specifications for compostable plastics.
Disintegration during compostingA plastic product is considered to have demonstrated satisfactory disintegration if, after 84 days in a controlled composting test, no more than 10 % of its original dry mass remains after sieving through a 2.0 mm sieve. The tests are carried out in accordance with ISO16929, ISO 20200, ISO 14855-1 or ASTM D 5338 under thermophilic composting conditionswithout CO2 trapping equipment.
Ultimate aerobic biodegradationA plastic product is considered to have demonstrated a satisfactory rate and level ofbiodegradation if when tested in accordance with ISO 14855-1, ISO 14855-2 or ASTM D5338, it achieves the ratio of conversion to carbon dioxide specified (90% of organic carbon in the polymer) within the time period specified (equal or less than 180 days)
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No adverse effects on ability of compost to support plant growthConcentrations of regulated metals and other toxic substances in the plastic product ormaterial should be less than 50 % of those prescribed for sludges, fertilizers and compostsin the country where the final product will be placed on the market.The plastic product or material should contain a minimum of 50 % of volatile solids.The seedling germination rate of the finished compost and the plant biomass in the compostshould be not less than 90 % of that of corresponding blank composts to which test orreference material was added at the start of testing.
Thermoplastic Starch (TPS)Tg of pure, dry starch is above its decomposition point, so it does not softenand flow on heating. However, starch can be plasticized (destructurized) bylow levels organic plasticizers and shear force.
This “thermoplastic starch” (TPS) flows at elevated temperature andpressure and can be extruded to produce pellets, sheets, films and solidmoulded articles.
Unfortunately properties of TPS tend to be disappointing hence it has to beblended with other bio-degradable polymers like PVA, PBAT, PLA, PBS,PCL, PBSA, PHAs etc.
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Composition of Corn Starch
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Polyvinyl AlcoholPolyvinyl alcohol (PVOH or PVA) is a water-soluble synthetic polymer.
PVA has excellent film forming, emulsifying and adhesive properties.
PVA is also resistant to oil, grease and solvents.
PVA has high tensile strength and flexibility, as well as high oxygen and
aroma barrier properties.
However, these properties are dependent on humidity
PVA has a melting point of 230°C and 180 – 190°C for the fully hydrolyzed
and partially hydrolyzed grades respectively and decomposes rapidly above
200°C.
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Typical Compound Composition
Corn Starch Powder (higher amylose content)
Polyvinyl Alcohol (DH 88%, medium MW or Viscosity)
Plasticizers
Nucleating agent
Lubricants
Plasticization aids
Organic Colour Pigment
CORN STARCH – PVA BLEND THERMOPLASTIC
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Manufacturing Process
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High Speed Heating & Cooling Mixer
Parallel Co-rotating Twin Screw Extruder
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Vacuum Degassing System
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Plasticizer Injection
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Hydraulic Screen Changer and Strand Extruder Die
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Air Cooling Conveyor Belt
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Poly (butylene adipate co-terephthalate)
PBAT is a bio-degradable random co-polymer
Co-polyester of adipic acid, 1,4 butanediol and terephthalic acid from dimethyl
terephthalate
Produced by random co-polymerization of 1,4-butanediol, adipic acid, and dimethyl
terephthalate (DMT) monomers.
Main advantage of PBAT is that it is a biodegradable alternative to LDPE, having
similar properties including high flexibility and toughness, allowing it to be used for
various packaging applications.
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Polylactic Acid - PLA
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Lactic acid (2-hydroxypropionic acid) is the most widely occurring hydroxycarboxylic optical
active acid. Polylactide is based on lactic acid monomers obtained from the fermentation of
sugars obtained from renewable sources such as sugar cane or corn starch.
Direct polycondensation - leads to low molecular weight polymers which then can be
converted to higher molecular weight polymers by addition of chain coupling agents.
Ring opening polymerization - PLA is produced by formation of lactide monomer first and
formed lactide is then put through ROP using metal alkoxides as catalysts resulting in high
molecular weight polyester
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Commercial L-PLA products are semi crystalline polymers with a high melting point
180°C and having their Tg in the range of 55 – 60°C
PLA is a high strength and high modulus thermoplastic with good appearance
Has high stiffness and strength at room temperature
However, there are some disadvantages associated with the polymer
Its glass transition temperature is low (Tg ~ 55°C)
Its poor ductility, low impact strength and brittleness limits its use
It has low crystallization rate and processing results in amorphous products
It is thermally unstable and has poor gas barrier performance
It has low flexibility and has a slow degradation rate
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Typical Compound Compositions
Corn Starch Powder
PBAT and / or PLA
Plasticizer
Nucleating agent
Lubricants
Compatibilizer
Peroxide initiator
Chain Extender and Branching enabler
Organic Colour Pigment
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Different Compounds
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Property Unit Test Method TPS + PVA PBAT + TPS PBAT + PLA
+ TPS
Density g / cm3 ISO 1183 1.30 1.26 - 1.3 1.26 - 1.3
Hardness D ASTM D2240 ---- 50 - 60 50 - 60
Melt Flow Rate g / 10 min ISO 1133 (190°C, 2.16 kg) 2 - 4 2 - 4 3 - 5
Melting Range °C ASTM D3418 95 - 150 95 - 150 95 - 155
Thermal
Decomposition Temp°C ASTM D6370 200 260 260
Blown Film Unit Test Method
Thickness 30 - 40 µ
Tensile strength MPa ASTM D882 25 ≥ 25 ≥ 35
Elongation at break % ASTM D882 300 ≥ 250 ≥ 200
Tear strength N / mm ASTM D1004 ≥ 100 ≥ 100 ≥ 100
Indicative Properties
Market Potential
No reliable statistics for the production or consumption of plastic bags in India.
Proxy to estimate total consumption of plastic bags in India
Plastic bags are mainly based on LDPE or low density polyethylene.
Domestic LDPE consumption in 2016 - 17 was around 700,000 metric tons.
Assuming 60% of total LDPE consumption was for the manufacture of plastic bags, the
LDPE polymer consumption was be around 420,000 metric tons.
Based on this figure, the consumption of LDPE compound for plastic bags will be around
600,000 metric tons.
Even a 5% market share for bio-degradable material plastic bags represents a
consumption figure of 30,000 metric tons per year growing at 20 to 25% year on year.
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Global Scenario
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Biopolymer films market value to surpass $6.7 billion by 2025
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Global TPS blend compound manufacturers
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Biograde Limited - Biograde® Biop - Biopar® Biotec - Bioplast® Cardia Bioplastics - Biohybrid® Cerestech - Cereloy® ENSO Plastics - ENSO Renew® Franplast - Chemiton® Grabio - Grabio® Green Dot - Terratek® Japan Corn Starch - Cornpole® Kingfa - Ecopond Flex® Nexus Resin - Nexus Bio® Resirene - Biorene® Showa Denko - Bionelle® Teknor Apex - Terraloy® Novamont - Mater-Bio® FKuR - Bio-Flex®, Bio-Grade®
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THANK YOU
THE FUTURE BELONGS TO THOSE WHO SEE
POSSIBILITIES BEFORE THEY BECOME OBVIOUS
Dr. Anomitra Chakravarty
KPS CONSULTANTS & IMPEX. PVT. LTD. 812, Devika Tower, 6 Nehru Place, New Delhi 110019
+ 91 98993 59661, 011 26213885, [email protected] / www.kpsimpex.com
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Disclaimer
This presentation is for the sole use of the intended recipient(s) and may contain information that is
confidential, legally privileged or exempt from disclosure under applicable law. KPS Consultants &
Impex Pvt. Ltd. makes no warranties as to the accuracy or completeness of information’s provided
and accepts no liability for any damages, including without limitation, direct, indirect, incidental,
consequential or punitive damages, arising out of or due to use of the information given in this
presentation
Please note it is not the intention of the speaker to promote any product or trade name in this presentation
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