BIODEGRADABLE/COMPOSTABLE PLASTICS
[EIRI/EDPR/ 1407] J.C. 183
INTRODUCTION
For the last few decades, the usage of plastic increased because of its specific properties such as low cost, light weight, high strength, non-biodegradability, durability, non corrosive nature, process ability and high energy effectiveness. Hence these plastics can be used for various application which includes household articles to aeronautic sector. Now a day it’s difficult to imagine a life without plastic which are mostly derived from crude oils and natural gas. Among the various polymers, polyethylene, polypropylene and polystyrene are used greatly for food packaging, biomedical field and in agriculture. According to statistics, from 1950 onwards, 9% of growth can be seen globally, in the production and consumption of plastics. In 1950 the overall production of plastic was 1.5 million tones while it reached 245 million tones in 2008.
In these polyethylene is one of the most dominant packaging material, creating the real problems in the disposal of one-trip packaging. These polymers will take millions of years to degrade under natural weathering conditions. Hence careless dumping of these plastics after its usage creates severe problems to the environment. Also during combustion it produces toxic materials which eventually pollute the atmosphere. The land filling results in the contamination of water, thereby adversely affecting the soil’s biological balance. ‘Recycling’ is another solution for reducing the amount of waste polyolefin materials. But recycling has its own limitation in regard to compatibility of different polyolefins which adversely affects the processability and final properties. Subsequently the problems created by plastic wastages to the environment triggered the interest in the development of biodegradable disposable plastics. So that the onetime use items can be disposed off with the hope that they will not remain for centuries in a landfill, or as litter, which is one of the tenets driving the recent interest in “green” technologies. The current biodegradable plastics, such as PLA, PHBV, Mater-Bi etc are very costly and the processing and mechanical properties of these materials are not good enough for the production of consumer products. Hence several studies were conducted to modify the current commodity plastics such as polyethylene, polypropylene into biodegradable type. One method to achieve this goal was blending of plastics with biodegradable agricultural feed stocks to meet the requirements of responsible and ecologically sound utilization of resources. This will reduce our dependence on depleting petrochemical resources.
Biodegradation or biotic degradation is a specific property of certain plastic materials - that is, of the polymers these materials are made of. It is a process by which a polymer material decomposes under the influence of biotic components (living organisms). Microorganisms (bacteria, fungi, algae) recognize polymers as a source of organic compounds (e.g. simple monosaccharides, amino acids, etc.) and energy that sustain them. In other words, biodegradable polymers are their food. Under the influence of intracellular and extracellular enzymes (endo- and exoenzymes) the polymer undergoes chemical reactions and the polymer degrades by the process of scission of the polymer chain, oxidation, etc. The result of this process that can be affected by a great number of different enzymes are increasingly smaller molecules, which enter into cellular metabolic processes (such as the Krebs cycle), generating energy and turning into water, carbon dioxide, biomass and other basic products of biotic decomposition. These products are non-toxic and occur normally in nature and in living organisms. This process turns artificial materials, such as plastics, into natural components. A process, in which an organic substance, such as a polymer, is converted to an inorganic substance, such as carbon dioxide, is called mineralization.
COST ESTIMATION
Plant Capacity 5 MT/Day
Land & Building (1500 sq.mt.) Rs. 1.52 Cr
Plant & Machinery Rs. 1.43 Cr
Working Capital for 3 Months Rs. 6.54 Cr
Total Capital Investment Rs. 9.85 Cr
Rate of Return 67%
Break Even Point 29%
CONTENTS
INTRODUCTION
BIODEGRADATION
MATERIALS
A COMMON MISUNDERSTANDING IS THAT ALL BIODEGRADABLE
POLYMERS ARE MADE FROM RENEWABLE RESOURCES
EFFECT OF BIODEGRADABLE PLASTICS
NATURAL POLYMERS
FIGURE 3 STRUCTURE OF BACTERIAL POLYESTER (R = – (CH 2 ) X – CH 3, X = 0 – 8 OR MORE)
POLYMERS WITH HYDROLYZABLE BACKBONES
FIGURE 4 STRUCTURE OF POLYGLYCOLIC ACID (PGA)
POLYMERS WITH CARBON BACKBONES
PRACTICAL APPLICATIONS OF BIODEGRADABLE POLYMERS
MEDICAL APPLICATIONS
SURGICAL SUTURES
BONE - FIXATION DEVICES
VASCULAR GRAFTS
ADHESION PREVENTION
ARTIFI CIAL SKIN
DRUG DELIVERY SYSTEMS
AGRICULTURAL APPLICATIONS
AGRICULTURAL MULCHES
CONTROLLED RELEASE OF AGRICULTURAL CHEMICALS
PACKAGING
STARCH - BASED PACKAGING MATERIALS
FIGURE 1 INGEO TM COMPOSTABLE BOTTLES (WITH PERMISSION OF BELU WATER)
PLA - BASED PACKAGING MATERIALS
CELLULOSE - BASED PACKAGING MATERIALS
PULLULAN - BASED PACKAGING MATERIALS
PVA BIODEGRADATION
POLYESTERS
POLY (Ε-CAPROLACTONE)
POLY (L-LACTIDE)
ALIPHATIC POLYALKYLENE DICARBOXYLIC ACIDS
POLYETHYLENE (PE)
NYLON
BIODEGRADATION OF POLYMER BLENDS
STARCH/POLYETHYLENE BLENDS
STARCH/POLYESTER BLENDS
STARCH/PVA BLENDS
BIODEGRADABLE POLYMERS
MIXTURES OF SYNTHETIC POLYMERS AND SUBSTANCES THAT
ARE EASY DIGESTIBLE BY MICROORGANISMS
CHEMICALLY MODIFIED STARCH
STARCH-POLYMER COMPOSITES
THERMOPLASTIC STARCH
BIODEGRADABLE PACKING MATERIALS
THE SYNTHETIC MATERIALS WITH GROUPS SUSCEPTIBLETO HYDROLYTIC MICROBIAL ATTACK
POLYCAPROLACTONE
THE BIOPOLYESTERS
POLYHYDROXYALKANOATES
POLY-Β-HYDROXYALKANOATES
POLY (HYDROXYALKANOATE)
BLENDS OF POLY (D,L) LACTIDE FAMILY
STARCH BASED POLYMERS
STRUCTURE AND PROPERTIES OF STARCH
PREPARATION OF STARCH-BASEDBIODEGRADABLE POLYMERS
FIGURE 1 MOLECULAR STRUCTURE OF STARCH
PHYSICAL BLENDS
BLEND WITH SYNTHETIC DEGRADABLE POLYMERS
BLEND WITH BIOPOLYMERS
CHEMICAL DERIVATIVES
APPLICATIONS OF STARCH-BASED BIODEGRADABLE POLYMERS
IN FOOD INDUSTRY
IN AGRICULTURE
IN MEDICAL FIELD
FIGURE 2 SEM PHOTOGRAPH OF STRACH-G-PVA/HA HYDROGEL (SCALE BAR 3 ΜM)
BIODEGRADABLE POLYMER MATERIALS BASED ON POLY-(LACTIC ACID)
FIGURE 1 THE SYNTHESIS SCHEME OF THE PLA PREPOLYMER AND
THE PLA CHAIN EXTENDED WITH MDI
EXPERIMENTAL
MATERIALS
SYNTHESIS OF POLYMER
CHARACTERIZATIONS
RESULTS AND DISCUSSION
POLYMERIZATION
THERMAL PROPERTY
CRYSTALLINITY
CONCLUSION
BIODEGRADABLE PLASTICS PRODUCED BY INJECTION MOLDING
CHARACTERISTICS OF MATERIAL
FIG. 1 MOLECULAR STRUCTURE OF POLYLACTIDE
FIG. 2 (A) POLYMERIZATION ROUTE TO POLYLACTIDE (B) SCHEMATIC
OF PLA PRODUCED VIA PREPOLYMER AND LACTIDE
METHODS
PROCESSING OF PLA
INJECTION MOLDING
FIG. 3 MAJOR COMPONENTS OF AN INJECTION MOLDING MACHINE
SHOWING THE EXTRUDER (RECIPROCAL SCREW) AND CLAMP UNITS
RESULTS
MARKET POSITION
MANUFACTURE OF BIODEGRADABLE PLASTICS
FLOW DIAGRAM
MANUFACTURERS/SUPPLIERS OF BIODEGRADABLE PLASTIC
OTHER RELATED INFORMATIONS
STARCH-BASED THERMOPLASTIC COMPOSITES
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
ALIPHATIC-AROMATIC POLYESTER
THE PRESENT METHOD PROVIDES AN ALIPHATIC AROMATIC
POLYESTER COMPRISING:
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
EXAMPLE 5
THE POLYESTERS OF THE PRESENT METHOD HAVE NUMEROUS ADVANTAGES:
TABLE 2
CELLULOSE ACETATE AND STARCH BASED BIODEGRADABLE
INJECTION MOLDED PLASTICS COMPOSITIONS
CELLULOSE ACETATES
FLOUR & STARCH ACETATES
NATURAL FIBER ACETATES
PAPER ACETATES
STARCH:
GLYCERIN:
GLYCEROL ACETATES:
ETHYLENE/PROPYLENE GLYCOL:
GELATIN & GELLING AGENTS:
SHELLAC
BORIC ACID:
FILLERS:
CRAB & LOBSTER SHELL:
NUT SHELL:
SHRIMP SHELL:
EXAMPLES
1. CELLULOSE ACETATE, STARCH & TRIACETIN:
2. CELLULOSE ACETATE, STARCH & MONOACETIN:
3. CELLULOSE ACETATE, STARCH, SHRIMP SHELL FILLER:
4. CELLULOSE ACETATE, STARCH. PROPYLENE GLYCOL
5. CELLULOSE ACETATE, STARCH, PROPYLENE GLYCOL, SHELLAC
6. CELLULOSE ACETATE, STARCH, PROPYLENE GLYCOL, BORIC ACID
7. CELLULOSE ACETATE, STARCH, PROPYLENE GLYCOL, BORIC ACID,
GELATIN
8. CELLULOSE ACETATE, PAPER ACETATE, TRIACETIN:
9. CELLULOSE ACETATE, FLOUR ACETATE, MONOACETIN:
10. CELLULOSE ACETATE, FIBER ACETATE, TRIACETIN:
LIGNIN BASED MATERIALS
ABBREVIATIONS
ASTM: THE AMERICAN SOCIETY FOR TESTING & MATERIALS.
EXAMPLES
MATERIALS
EXPERIMENTAL
CHARACTERIZATION
EXAMPLE 1
1. DYNAMIC MECHANICAL ANALYSIS (STORAGE MODULUS
OF COMPOSITES)
2. HEAT DEFLECTION TEMPERATURE (HDT) OF COMPOSITES
3. TENSILE STRENGTH OF COMPOSITES
4. YOUNG'S (TENSILE) MODULUS OF COMPOSITE
5. FLEXURAL STRENGTH OF COMPOSITES
6. FLEXURAL MODULUS OF COMPOSITES
7. IMPACT STRENGTH OF COMPOSITES
EXAMPLE 2
PART II-EFFECTS OF RAW LIGNIN, BIOFIBERS AND ADDITIVES IN
LIGNIN/PBS BLENDS
2.1. HEAT DEFLECTION TEMPERATURE (HDT) OF COMPOSITES
2.2. TENSILE STRENGTH OF COMPOSITES
2.3. YOUNG'S MODULUS OF COMPOSITE
2.4. FLEXURAL STRENGTH OF COMPOSITES
2.5 FLEXURAL MODULUS OF COMPOSITES
2.6. IMPACT STRENGTH OF COMPOSITES
OVERALL CONCLUSIONS
FORMULATIONS
B. FORMULATIONS FROM PART 11:
I. BEST FORMULATION:
II. FORMULATIONS WITH OVERALL GOOD PROPERTIES COMBINATION:
III. FORMULATIONS FOR APPLICATIONS WITH AVERAGE PROPERTIES
REQUIREMENT:
VI. FORMULATIONS FOR HIGH IMPACT REQUIREMENTS:
EXAMPLE 3
RECYCLABILITY OF FORMULATED COMPOSITE MATERIALS
PLASTICIZED POLYLACTIDE
EXAMPLES
MATERIALS:
PREPARATION OF OTHER PLASTICIZERS:
TEST METHODS
DSC (DIFFERENTIAL SCANNING CALORIMETRY)
TEAR STRENGTH
TENSILE STRENGTH AND MODULUS
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
COMPARATIVE EXAMPLE C1
COMPARATIVE EXAMPLE C2
CONTROL FILM
EXAMPLES 4-9 COMPARATIVE EXAMPLES C3-05
MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY
REACTION KETTLES
RAPID MIXER GRANULATOR
ELEVATORS, ESCALATORS, ROPEWAYS
STEAM BOILERS
DIESEL GENERATOR
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
STARCH POWDER
CALCIUM CARBONATE
TALCUM POWDER
POLYPROPYLENE RESIN
ALUMINATE ESTER COUPLING AGENT
POLYETHYLENE WAX
ITACONIC ACID
EPOXIDIZED SOYBEAN OIL
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
