Nature as a role model- PLA Blends for Transparent Multilayer Films

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1 Nature as a role model- PLA Blends for Transparent Multilayer Films FKuR Kunststoff GmbH Siemensring 79, Willich/Germany & FKuR Plastics Corporation 921 West New Hope Drive, Bldg. 605, Cedar Park, TX/USA Julia Dolfen Market Development Chart 1

2 Overview Introduction Plastics & Sustainability Multilayer Extrusion of Bioplastics Successful Market Placements Conclusion Chart 2

3 Overview Introduction Plastics & Sustainability Multilayer Extrusion of Bioplastics Successful Market Placements Conclusion Chart 3

4 Introduction Founded in 1992 as Forschungsinstitut Kunststoff und Recycling Since 1998 cooperation with the Fraunhofer Institute UMSICHT, Oberhausen, Germany; mutual development and material research of Bioplastics Since 2003 operating as FKuR Kunststoff GmbH, privately owned company with the commitment to produce sustainable materials Since September 2009 operating in Austin, Texas, as FKuR Plastics Corporation Produced resins (Brands): Bio-Flex ; Biograde ; Fibrolon ; Terralene Chart 4

5 Overview Introduction Plastics & Sustainability Multilayer Extrusion of Bioplastics Successful Market Placements Conclusion Chart 5

6 Plastics & Sustainability Nature is unbeatable in terms of intelligence! Informative and Protective Packaging Easy to open Residue-free disposal Chart 6

7 Plastics & Sustainability Renewable Packaging Role model Nature! Rigid Packaging Flavorsome Packaging Chart 7

8 Plastics & Sustainability Industrial Packaging = Role model Nature? Chart 8

9 Plastics & Sustainability Requirements for Packaging: Advertise and present products Protect the goods (oxygen, humidity, germs, etc.) Extend shelf life Easy to transport Carry Messages Chart 9

10 Plastics & Sustainability Sustainability Buzzword of the last years: Sustainable economic growth Sustainable increase in profits Sustainability Development that meets the needs of the present without compromising the ability of future generations to meet their own needs. (World Commission of Environment and Development, 1987) Sustainability is more than just economic growth. It is a global and overall concept! Chart 10

11 Plastics & Sustainability The use of renewable resources is a logical consequence according to this definition of sustainability! Bioplastics are partly an aspect out of this consequence! Alternative end-of-life options Reduction of CO 2 emission 2 Chart 11

12 Plastics & Sustainability Alternative end-of-life options Reduction of CO 2 emissions Bioplastics can be categorized in two classes Biodegradable plastics (either fossil or renewable carbon source) Biological process of organic matter being degraded by micro-organisms (fungi, bacteria) and ultimately converted to water, CO 2 /methane, energy and new cell biomass. Biobased plastics (only renewable carbon source) Referring to the feedstocks, being renewed in two growing seasons or less (e.g. corn, wheat, grass, bacteria). 2 Chart 12

13 Plastics & Sustainability The Variation of Biopolymers has increased! Renewable Resources Bio-PE PHA CA PLA Bio-PA Bio-Blends TPS Not biodegradable Biodegradable Conventional plastics, e. g. PE, PP, ABS PBAT PBS Petrochemical raw materials Chart 13

14 Plastics & Sustainability Producers need bioplastics that run on conventional processing machines. Bio raw materials only run with difficulties on conventional machines and need to be modified. Compounding is the key to modification and therefore be an improvement over the competition. Dry Blending of compounded bio resins and Multilayer Structures can also increase the range of applications. Chart 14

15 Overview Introduction Plastics & Sustainability Multilayer Extrusion of Bioplastics Successful Market Placements Conclusion Chart 15

16 Multilayer Extrusion of Bioplastics Co-extrusion of Bio-Flex Grades made with NW s PLA Similar processing conditions High compatibility and inter-ply strength due to their similar chemical structure Adjusting the film properties by coextrusion: Increasing content of renewable resources High transparency and flexibility Sealing strength Improved barrier properties Improving mechanical properties by combining different Bio-Flex grades 3 Layer Co-Extrusion of Bio-Flex Chart 16

17 Multilayer Extrusion of Bioplastics New development: 3-layer-film made from Bio-Flex A 4100 CL / F 2201 CL / A 4100 CL (20/60/20 %) Processing on conventional LDPE 3- Layer blown-film extruders High transparency High amount of renewable resources: 60 80% Tough and flexible film with high puncture resistance Adjustment of mechanical properties by variation of layer ratios Chart 17

18 Multilayer Extrusion of Bio-Flex A- and F-Series Bio-Flex Multilayers Modulus of Elasticity Modulus of elasticity MD [MPa] Bio-Flex A 4100 CL / F 2201 CL / A 4100 CL (20 / 60 / 20 [%], 20µm) Bio-Flex F 2201 CL Bio-Flex A 4100 CL / F 2201 CL / A 4100 CL (15 / 70 / 15 [%], 20µm) Bio-Flex A 4100 CL Modulus of elasticity TD [MPa] Chart 18

19 Multilayer Extrusion of Bioplastics Bio-Flex Multilayers Elongation at Break Bio-Flex F 2201 CL Elongation at break MD [%] Bio-Flex A 4100 CL Bio-Flex A 4100 CL / F 2201 CL / A 4100 CL (15 / 70 / 15 [%], 20µm) Bio-Flex A 4100 CL / F 2201 CL / A 4100 CL (20 / 60 / 20 [%], 20µm) Elongation at break TD [%] Chart 19

20 Metallization of Bio-Flex Multilayers Metallization and lamination of 3-layer-film made from Bio-Flex A / F / A (20/60/20 %) Metallization and lamination of co-ex structure Excellent barrier properties High amount of renewable resources ( 70 %) Tough and flexible Chart 20

21 Barrier-properties of Bioplastics MVTR at 23 C; 100 % RH g/m²/day per 25µm PP APET CL/2201/CL metallised F2110 F1130 A4100CL CL/2201/CL S1100 PLA 4042D EVAP PVOH (HWS) PVOH (CWS) Chart 21

22 Barrier-properties of Bioplastics Oxygen transmission at 23 C; 0 % RH cm³ /m²/day per 25µm , PVOH (HWS) PVOH (CWS) EVAP CL/2201/CL metallised APET A4100CL S1100 PLA 4042D CL/2201/CL F2110 PP Chart 22

23 Industrial Composting of Bio-Flex Multilayers Degradation process at 65 C 0 days 10 days 18 days Chart 23

24 Overview Introduction Plastics & Sustainability Multilayer Extrusion of Bioplastics Successful Market Placements Conclusion Chart 24

25 Successful Market Placements Deep-Freeze Packaging Multilayer structure of different types of Bio- Flex High amount of renewable resources >70% is needed Composting is possible, but not necessary Filling on vffs machines has to be possible Further requirements: High sealing strength Toughness at low temperatures Printability Chart 25

26 Successful Market Placements Cosmetics packaging Multilayer structure of different types of Bio- Flex (A / F / A - Types) High amount of renewable resources >70% is needed Compostability is advantageous Good barrier properties, printability Chart 26

27 Successful Market Placements Tissue/Napkins packaging Multilayer structure of different types of Bio- Flex (A / F / A Types) High amount of renewable resources >70% is needed Good transparency Compostability is needed Good sealing strength; printability Chart 27

28 Successful Market Placements Material: Biograde C 7500 Mechanical properties comparable to Polystyrene High Heat Distortion Temperature (Vicat A 50 = 110 C) Processing on standard injection molding lines with good processability Produced via hot runner systems Chart 28

29 Overview Introduction Plastics & Sustainability Multilayer Extrusion of Bioplastics Successful Market Placements Conclusion Chart 29

30 Conclusion Sustainability is gaining more importance as main driver for the use of bioplastics Nature offers a variety of possibilities concerning sustainability and functionality which we included in our formulations Currently short life products are by far the largest market segment, durable market segments will follow, because of green attitude Content of renewable resources becomes more important The combination of nature based content and compostability will be important for short term applications Combining our Bio-Flex resins by co-extrusion will increase the range of applications Chart 30

31 Thank you very much for your attention! Chart 31

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