Bioplastic

This article is about plastics made from renewable biomass. For information on plastics which are biodegradable, see biodegradable plastic.

Bioplastic utensils.

Bioplastics or organic plastics are a form of plastics derived from renewable biomass sources, such as vegetable oil, corn starch, pea starch, or microbiota, rather than fossil-fuel plastics which are derived from petroleum. Some, but not all, bioplastics are designed to biodegrade.

Applications

Biodegradable bioplastics are used for disposable items, such as packaging and catering items (crockery, cutlery, pots, bowls, straws). Biodegradable bioplastics are also often used for organic waste bags, where they can be composted together with the food or green waste. Some trays and containers for fruit, vegetables, eggs and meat, bottles for soft drinks and dairy products and blister foils for fruit and vegetables are manufactured from bioplastics.

Non-disposable applications include mobile phone casings, carpet fibres, and car interiors, fuel line and plastic pipe applications, and new electroactive bioplastics are being developed that can be used to carry electrical current. In these areas, the goal is not biodegradability, but to create items from sustainable resources.

Performance and usage

Many bioplastics lack the performance and ease of processing of traditional materials. Polylactic acid plastic is being used by a handful of small companies for water bottles. But shelf life is limited because the plastic is permeable to water - the bottles lose their contents and slowly deform. However, bioplastics are seeing some use in Europe, where they account for 60% of the biodegradable materials market. The most common end use market is for packaging materials. Japan has also been a pioneer in bioplastics, incorporating them into electronics and automobiles.

Plastic types

Starch based plastics

Constituting about 50 percent of the bioplastics market, thermoplastic starch, such as Plastarch Material, currently represents the most important and widely used bioplastic. Pure starch possesses the characteristic of being able to absorb humidity and is thus being used for the production of drug capsules in the pharmaceutical sector. Flexibiliser and plasticiser such as sorbitol and glycerine are added so that starch can also be processed thermo-plastically. By varying the amounts of these additives, the characteristic of the material can be tailored to specific needs (also called "thermo-plastical starch"). Simple starch plastic can be made at home shown by this method[2].

Polylactic acid (PLA) plastics

Main article: Polylactic acid

Polylactic acid (PLA) is a transparent plastic produced from cane sugar or glucose. It not only resembles conventional petrochemical mass plastics (like PE or PP) in its characteristics, but it can also be processed easily on standard equipment that already exists for the production of conventional plastics. PLA and PLA-Blends generally come in the form of granulates with various properties and are used in the plastic processing industry for the production of foil, moulds, tins, cups, bottles and other packaging.

Poly-3-hydroxybutyrate (PHB)

The biopolymer poly-3-hydroxybutyrate (PHB) is a polyester produced by certain bacteria processing glucose or starch. Its characteristics are similar to those of the petroplastic polypropylene. The South American sugar industry, for example, has decided to expand PHB production to an industrial scale. PHB is distinguished primarily by its physical characteristics. It produces transparent film at a melting point higher than 130 degrees Celsius, and is biodegradable without residue.

Polyamide 11 (PA 11)

PA 11 is a biopolymer derived from natural oil. It is also known under the tradename Rilsan B, commercialized by Arkema. PA 11 belongs to the technical polymers family and is not biodegradable. Its properties are similar to those of PA 12, although emissions of greenhouse gases and consumption of non-renewable resources are reduced during its production. Its thermal resistance is also superior to that of PA 12. It is used in high-performance applications like automotive fuel lines, pneumatic airbrake tubing, electrical cable anti-termite sheathing, flexible oil & gas pipes, control fluid umbilicals, sports shoes, electronic device components, and catheters.

Bio-derived polyethylene

The basic building block (monomer) of polyethylene is ethylene. This is just one small chemical step from ethanol, which can be produced by fermentation of agricultural feedstocks such as sugar cane or corn. Bio-derived polyethylene is chemically and physically identical to traditional polyethylene - it does not biodegrade but can be recycled. It can also considerably reduce greenhouse gas emissions. Brazilian chemicals group Braskem claims that using its route from sugar cane ethanol to produce one tonne of polyethylene captures (removes from the environment) 2.5 tonnes of carbon dioxide while the traditional petrochemical route results in emissions of close to 3.5 tonnes.

Braskem plans to introduce commercial quantities of its first bio-derived high density polyethylene, used in a packaging such as bottles and tubs, in 2010 and has developed a technology to produce bio-derived butene, required to make the linear low density polethylene types used in film production.

Genetically modified bioplastics

Genetic modification (GM) is also a challenge for the bioplastics industry. None of the currently available bioplastics - which can be considered first generation products - require the use of GM crops.

Looking further ahead, some of the second generation bioplastics manufacturing technologies under development employ the "plant factory" model, using genetically modified crops or genetically modified bacteria to optimise efficiency.

Environmental impact

The production and use of bioplastics is generally regarded as a more sustainable activity when compared with plastic production from petroleum (petroplastic), because it relies less on fossil fuel as a carbon source and also introduces fewer, net-new greenhouse emissions if it biodegrades. They significantly reduce hazardous waste caused by oil-derived plastics, which remain solid for hundreds of years, and open a new era in packing technology and industry .

However, manufacturing of bioplastic materials is often still reliant upon petroleum as an energy and materials source. This comes in the form of energy required to power farm machinery and irrigate growing crops, to produce fertilisers and pesticides, to transport crops and crop products to processing plants, to process raw materials, and ultimately to produce the bioplastic, although renewable energy can be used to obtain petroleum independence.

Italian bioplastic manufacturer Novamont states in its own environmental audit that producing one kilogram of its starch-based product uses 500g of petroleum and consumes almost 80% of the energy required to produce a traditional polyethylene polymer. Environmental data from NatureWorks, the only commercial manufacturer of PLA (polylactic acid) bioplastic, says that making its plastic material delivers a fossil fuel saving of between 25 and 68 per cent compared with polyethylene, in part due to its purchasing of renewable energy certificates for its manufacturing plant.

A detailed study examining the process of manufacturing a number of common packaging items in several traditional plastics and polylactic acid carried out by US-group and published by the Athena Institute shows the bioplastic to be less environmentally damaging for some products, but more environmentally damaging for others.

While production of most bioplastics results in reduced carbon dioxide emissions compared to traditional alternatives, there are some real concerns that the creation of a global bioeconomy could contribute to an accelerated rate of deforestation if not managed effectively. There are associated concerns over the impact on water supply and soil erosion.

Other studies showed that bioplastics represent a 42% reduction in carbon footprint .

On the other hand, bioplastic can be made from agricultural byproducts and also from used plastic bottles and other containers using microorganisms .

Bioplastics and biodegradation

Further information: [[:Biodegradable plastic]]

The terminology used in the bioplastics sector is sometimes misleading. Most in the industry use the term bioplastic to mean a plastic produced from a biological source. One of the oldest plastics, cellulose film, is made from wood cellulose. All (bio- and petroleum-based) plastics are technically biodegradable, meaning they can be degraded by microbes under suitable conditions. However many degrade at such slow rates as to be considered non-biodegradable.PLA plastics can take 100 to 1,000 years to completely biodegrade. Some petrochemical-based plastics are considered biodegradable, and may be used as an additive to improve the performance of many commercial bioplastics. Non-biodegradable bioplastics are referred to as durable. The degree of biodegradation varies with temperature, polymer stability, and available oxygen content. Consequently, most bioplastics will only degrade in the tightly controlled conditions of industrial composting units. In compost piles or simply in the soil/water, most bioplastics will not degrade (eg PH), starch-based bioplastics will, however. An internationally agreed standard, EN13432, defines how quickly and to what extent a plastic must be degraded under commercial composting conditions for it to be called biodegradable. This is published by the International Organization for Standardization ISO and is recognised in many countries, including all of Europe, Japan and the US. However, it is designed only for the aggressive conditions of commercial composting units. There is no standard applicable to home composting conditions.

The term "biodegradable plastic" is often also used by producers of specially modified petrochemical-based plastics which appear to biodegrade. Traditional plastics such as polyethylene are degraded by ultra-violet (UV) light and oxygen. To prevent this process manufacturers add stabilising chemicals. However with the addition of a degradation initiator to the plastic, it is possible to achieve a controlled UV/oxidation disintegration process. This type of plastic may be referred to as degradable plastic or oxy-degradable plastic or photodegradable plastic because the process is not initiated by microbial action. While some degradable plastics manufacturers argue that degraded plastic residue will be attacked by microbes, these degradable materials do not meet the requirements of the EN13432 commercial composting standard.

Recycling

There are also fears that bioplastics will damage existing recycling projects. Packaging such as HDPE milk bottles and PET water and soft drinks bottles is easily identified and hence setting up a recycling infrastructure has been quite successful in many parts of the world. Polylactic acid and PET do not mix - as bottles made from polylactic acid cannot be distinguished from PET bottles by the consumer there is a risk that recycled PET could be rendered unusable. This could be overcome by ensuring distinctive bottle types or by investing in suitable sorting technology. However, the first route is unreliable as not everyone might actually separate the plastics manually and mistakes in separation might easily be made, and the second costly. However, the cost of automated machine separation could be offset by the use of renewable electricity resources such as solar and wind power.

Market

Because of the fragmentation in the market it is difficult to estimate the total market size for bioplastics, but estimates put global consumption in 2006 at around 85,000 tonnes. In contrast, global consumption of all flexible packaging is estimated at around 12.3 million tonnes.

COPA (Committee of Agricultural Organisation in the European Union) and COGEGA (General Committee for the Agricultural Cooperation in the European Union) have made an assessment of the potential of bioplastics in different sectors of the European economy:

Catering products: 450,000 tonnes per year

Organic waste bags: 100,000 tonnes per year

Biodegradable mulch foils: 130,000 tonnes per year

Biodegradable foils for diapers 80,000 tonnes per year

Diapers, 100% biodegradable: 240,000 tonnes per year

Foil packaging: 400,000 tonnes per year

Vegetable packaging: 400,000 tonnes per year

Tyre components: 200,000 tonnes per year

Total 2,000,000 tonnes per year

The European Bioplastics trade group predicted annual capacity would more than triple to 1.5 million tons by 2011. BCC Research forecasts the global market for biodegradable polymers to grow at a compound average growth rate of more than 17 percent through 2012. Even so, bioplastics will encompass a small niche of the overall plastic market, which is forecast to reach 500 billion pounds (220 million tonnes) globally by 2010.

Cost

With the exception of cellulose, most bioplastic technology is relatively new and is currently not cost competitive with (petroplastics). Bioplastics do not yet reach the fossil fuel parity on fossil fuel-derived energy for their manufacturing, reducing the cost advantage over petroleum-based plastic. However, in certain, special applications bioplastics are already unbeatable because pure material costs form only a part of the entire product costs. For example, medical implants made of PLA, which dissolve in the body, save patients a second operation. Compostable mulch films for agriculture, already often produced from starch polymers, do not have to be collected after use and can be left on the fields.

Research and Development

Further information: List of bioplastic producers

• In the early 1950s, Amylomaize (>50% starch content corn) was successfully bred and commercial bioplastics applications started to be explored.
• In 2004, NEC developed a flame retardant plastic, polylactic acid, without using toxic chemicals such as halogensand phosphorus compounds [3].
• In 2005, Fujitsu became one of the first technology companies to make personal computer cases from bioplastics, which are featured in their FMV-BIBLO NB80K line.
• In 2007 Braskem of Brazil announced it had developed a route to manufacture high density polyethylene (HDPE) using ethylene derived from sugar cane.
• In 2008, a University of Warwick team created a soap free emulsion polymerization process which makes colloid particles of polymer dispersed in water and in a one step process adds nanometre sized silica-based particles to the mix. The newly developed technology might be most applicable to multi-layered biodegradable packaging which could gain more robustness and water barrier characteristics through the addition of a nano-particle coating .

Certification

Biodegradability - EN 13432, ASTM D6400

The EN 13432 industrial standard is arguably the most international in scope and compliance with this standard is required to claim that a product is compostable in the European marketplace. In summary, it requires biodegradation of 90% of the materials in a commercial composting unit within 180 days. The ASTM 6400 standard is the regulatory framework for the United States and sets a less stringent threshold of 60% biodegradation within 180 days, again within commercial composting conditions.

The "compostable" marking found on many items of packaging indicates that the package complies with either of the two standards mentioned above. However, the marking is not owned by either regulatory body but by third party trade associations representing companies making or selling biodegradable plastics. In Europe, this is European Bioplastics, in the U.S. it is the Biodegradable Products Institute.

Many starch based plastics, PLA based plastics and certain aliphatic-aromatic co-polyester compounds such as succinates and adipates, have obtained these certificates. Additivated plastics sold as fotodegradable or Oxo Biodegradable do not comply with these standards in their current form.

Biobased - ASTM D6866

The ASTM D6866 method has been developed to certify the biologically derived content of bioplastics. Cosmic rays colliding with the atmosphere mean that some of the carbon is the radioactive isotope carbon-14. CO₂ from the atmosphere is used by plants in photosynthesis, so new plant material will contain both carbon-14 and carbon-12. Under the right conditions, and over geological timescales, the remains of living organisms can be transformed into fossil fuels. After ~100,000 years all the carbon-14 present in the original organic material will have undergone radioactive decay leaving only carbon-12. A product made from biomass will have a relatively high level of carbon-14, while a product made from petrochemicals will have no carbon-14.The percentage of renewable carbon in a material (solid or liquid) can be measured with an accelerator mass spectrometer.

There is an important difference between biodegradability and biobased content. A bioplastic such as high density polyethylene (HDPE) can be 100% biobased (i.e. contain 100% renewable carbon), yet be non-biodegradable. These bioplastics such HDPE play nonetheless an important role in greenhouse gas abatement, particularly when they are combusted for energy production. The biobased component of these bioplastics is considered carbon-neutral since their origin is from biomass.

See also

• Alkane
• Angewandte Chemie
• Biofuel
• Biopolymer
• Biodegradable plastic
• Ingeo
• Mirel
• Minerv
• Organic photovoltaics
• Plantic

External links

• Agriculture and Agrifood Canada: Bioplastics page on the Canadian Government's website
• Bio-Polym Blog
• Plastics 2020 Challenge: Debate on the future role of Bioplastics
• Biopolymer.net: Startpage with links to all kinds of bioplastics producers and information
• New process for obtaining alkanes from bio-oil (in Angewandte Chemie by Johannes A. Lercher at the Technical University of Munich).