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BY:Kavita Singh
0817
2nd sem24th batch, IIP
Library Reference
Biopolymers in Packaging
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Biopolymer
Biopolymers are polymers that are generated from renewable natural
sources and biodegradable
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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
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Applications
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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 usingrenewable biobased monomers. Examples are:
1) poly lactic acid, a biopolyester polymerized from lactic acidmonomers.
2) biobased monomers
Category 3: Polymers produced by microorganisms or genetically modifiedbacteria: 1) poly hydroxy alkanoates
2) poly hydroxybutyrate
3) bacterial celluloses
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Manufacturing of packaging material from
biopolymer
Biopolymers
Modifications
Thermoplastic
Product properties
Product
Modification (physical/chemical)
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)
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The major processing routes to potential
biopolymer based products
Processing route Product examples
(Co-) Extruded film Packaging film
Cast film Packaging film
Thermoformed sheets Trays, cups
Blown films Packaging film
Injection (blow-) molding Salad pots, cutlery, drinking
Fibers and non-woven Agricultural products, diapers
Extrusion coating Laminated paper or films
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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 180million tons to 258 million tons by 2010 - definitely growing faster than thecommonly used plastics such as polyolefin.
Several factors such as soaring oil prices, worldwide interest in renewableresources, growing concern regarding greenhouse gas emissions and a newemphasis on waste management have created renewed interest in biopolymersand the efficiency with which they can be produced.
New technologies in plant breeding and processing are narrowing thebiopolymers-synthetic plastics cost differential, as well as improving materialproperties.
Implementation of the Kyoto Protocol will also bring into sharper focus therelative performance of biopolymers and synthetics in terms of their respectiveenergy use and CO 2 emissions
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Current stage of development (2007) of
thermoplastic biopolymers
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Production Data
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There are four major biopolymer groups in the market :
PHA or PHB
Polylactic acid (PLA)
Starch-based polymers
Cellulose
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PHAs
Poly hydroxy alkanoates
PHAs are linear polyesters produced in nature by bacterialfermentation of sugar or lipids.
More than 100 different monomers can be combined within this familyto 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 andmore brittle.
A PHB copolymer called PHBV (polyhydroxybutyrate-valerate) is lessstiff and tougher, and it is used as packaging material.
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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 5-6weeks. The action of some enzymes produced by microbes solubilisesPHB which is then absorbed through the cell wall and metabolized.
PHB is normally broken down to carbon dioxide and water whendegraded in aerobic conditions. In absence of oxygen the degradationis faster, and methane is also produced. PHB is not degraded inbiologically inactive systems such as sanitary landfills
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PLAPolylactic 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
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Cont
Most conventional plastic processes like:
Blow moulding, Injection moulding, Extrusion, Vacuumforming, Fiber spinning
References : Cargill Dow Polymers LLC-Natures Way
PURAC
Creation: Lactic acid can be obtained on the basis of renewable starchcontaining 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 completedegradation. The first stage of degradation (two weeks) is a hydrolysisto water soluble oligomers and lactic acid. The latter, as a naturallyoccurring substance, is a rapid metabolisation into CO2, water andbiomass by a variety of micro-organisms.
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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.
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Products : Starch-based tube
Degradable compost bags
Agricultural mulch filmThermoformed 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 candegrade completely within five days in aqueous aerobic testing andin 45 days in a controlled compost, or can even decompose in water
http://images.google.co.in/imgres?imgurl=http://www.packagingmag.com.au/Uploads/PressReleases/pack/Images-20081119/BioPak.JPG&imgrefurl=http://www.packagingmag.com.au/Article/Biopak-compostable-net-tubing-arrives/431453.aspx&usg=__EZh5qndIGtYP26964SRKBAAgehw=&h=670&w=716&sz=46&hl=en&start=58&um=1&tbnid=wFrK_jt7woTyWM:&tbnh=131&tbnw=140&prev=/images%3Fq%3Dstarch%2Bbased%2Bpackaging%2Bproducts%26ndsp%3D20%26hl%3Den%26sa%3DN%26start%3D40%26um%3D1http://images.google.co.in/imgres?imgurl=http://www.space-pak.com/Portals/0/biofill.jpg&imgrefurl=http://www.space-pak.com/OurProducts/tabid/55/Default.aspx&usg=__oeViPig79UpXlx0nQSDnIbKH3to=&h=300&w=400&sz=122&hl=en&start=3&um=1&tbnid=v5ggxkjfFXbD9M:&tbnh=93&tbnw=124&prev=/images%3Fq%3Dstarch%2Bbased%2Bpackaging%2Bproducts%26hl%3Den%26sa%3DN%26um%3D18/2/2019 Kavita Singh Presentation Pp-Biopolymer
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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 packagingcontext.
Derivatives: Carboxy methyl cellulose, Carboxy ethyl cellulose,
cellulose acetate, cellophane
Products: Toys packaging, Tapes, Food packaging, Paper, Membrane
http://images.google.co.in/imgres?imgurl=http://www.packagingdigest.com/content/images/pdx0708bioplastics3_34.jpg&imgrefurl=http://www.packagingdigest.com/article/CA6490214.html&usg=__Cd8uxSlwEsBM8vUKV6uwPuhA38s=&h=205&w=205&sz=96&hl=en&start=9&um=1&tbnid=y7g58EmllqQsSM:&tbnh=105&tbnw=105&prev=/images%3Fq%3Dcellulose%2Bbased%2Bpackaging%2Bproducts%26hl%3Den%26um%3D18/2/2019 Kavita Singh Presentation Pp-Biopolymer
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Most conventional processes like Injection moulding, Blow moulding
References: Bioceta, Nature flex, Cellophane
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Cellulose Acetate
Cellulose acetate (CA) is used for transparent, translucent and opaqueobjects
Furthermore, it is especially suitable for coatingsapplications requiring high melting-point, toughness, clarity,and good resistance to ultraviolet light, chemicals, oils, andgreases.
Cellulose acetate is an amorphous thermoplastic materialbelonging to the cellulosic resin family
t is obtained by introducing the acetyl radical of acetic acidinto cellulose (as cotton or wood fibers) to produce a toughplastic material
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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 itsinflammability and to give the material self-extinguishing properties
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Material Suppliers Trade Name Polymer
PHB/PHV (Poly hydroxy
alkanoates)
WasMonsanto
Biomer
Biopol
Biomer
Ester
Ester
Cellulose acetate Courtaulds
Mazucheli Bioceta
Acetal
Acetal/Es
ter
Polylactic acid/PLA Cargill Dow Polymers Nature Works
PLA
Mitsui
Hycail
Galactic
LACEA
Galactic
Ester
Ester
Ester
Ester
Starch National Starch
Avebe
Eco-FOAM
Paragon
Ester
Ester
Biopolymer packaging materials currently
available in the market.
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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 recyclingx. Shelf life and transportation
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End-of-life waste management modeling
Several different waste management treatment technologies weremodeled to understand how biopolymer degrade in aerobic and anaerobic
environments.
Comparative Study-Heres how long it takes for some commonly used products tobiodegrade, 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
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Life Cycle of a Biopolymer
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Biodegradation of Biopolymer
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Treatment technologies
Landfill (anaerobic environment);
Source separated green and food composting;
Municipal solid waste composting; andMunicipal solid waste anaerobic digestion.
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Challenges ahead
Acceptance of biodegradable polymers is likely to depend on fiveunknowns:
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 forfeeding people, by both direct consumption and to aide in growing
plants as compost.
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Thank You!
Questions?