Packaging loose-fill plastic

One of the first applications of biodegradable materials is based on the cooked, extruded, and expanded starch known from the food and chemical sectors (Fig. 14.23). Starch is cooked with water in the extruder and chemically modified as necessary or mixed with plasticizers, then expanded to a starch foam and dried. The extrudate is ground so that the functional properties thus created can be used in the food/chemicals sector. The foamed, cut, and dried extrudate is the end product for loose-fill packaging applications. The degree of expansion is a measure of the foam texture. It increases strongly with product temperature at the die, helped by a higher specific mechanical energy input. However, both measures increase the water-solubility of the product. 

Loose-fill packaging was one of the first successful areas of application for starch-based biodegradable polymers. Loose-fill starch-based foam is used for packaging consumer products as an alternative to polystyrene and polyethylene. While, biodegradable plastics have made some inroads into these markets, the future prospects for their growth in loose-fill are not so exciting as they are in some other areas of packaging. 

If starch is modified by partially fermenting it, or esterifying or etherification, the resulting material can be extruded by adding plasticizers. Starch-based plastics are readily biodegraded. In most cases, the polymers are also water-soluble. Several suppliers now offer thermoplastic starch. Major markets include soluble films for industrial packaging, films for bags and sacks, and loose fill. 

Mechanical testing on the foam is performed to measure the compressive stress and the resiliency. The results from diese tests are shown in table 2, in which the properties of extruded polystyrene foam (XPS) and commercial starch-based loose-frll foams (Eco-foam and Mater-Bi) together with EPS loose-fill foam (Pelaspan Pac) are added for conq>arison. The values of XPS are obtained from tests on typical XPS retail packaging trays. The table shows that the compressive stress reached with potato starch foam is comparable with that of XPS. Through the cell structure of the potato starch foam (high cell density, very small cells) a good resiliency can be obtained, although pure starch plastics exhibit brittle fracture behavior. This brittle fracture still is present on the microscopic scale of the individual cells but due to the cell density, the foam exhibits resiliency on macroscopic scale. 

The largest share in terms of volume corresponds to the starch-based plastic market. The main applications are compost bags, shopping bags, loose-fill packaging and mulch films. 

Green plastics comprise only a very small part (less than 1%) of today s plastics. They do, however, make up a significant part of some specialty, niche markets starch-based loose-fill packaging now constitutes 30% of the loose-fill packaging market. The plastics described here are those currently commercially available, and are limited mainly to those available in the United States. Manufacturers are named only for illustrative purposes the list is not intended to be comprehensive. The plastics materials are described generically, with respect to the major polymer constituent(s) for each generic type there are likely to be many specific formulations. Brief mention is made, at the end, of some materials that have been studied in the laboratory. Biomedical applications are described separately (see Biodegradable Polymers, Medical Applications). 

Note Transportation energy generally does not play any major role, neither for the production of plastics (including biodegradable ones) nor for final products made thereof. Particularly light products, e.g., loose fill packaging material, are exempted from this general rule. 

The types of end products covered are primary plastic materials (mainly pellets, i.e. granules not to be confused with transportation pallets), loose-fill packaging material (packaging chips), films, bags, mulch films, printed wiring boards (for electronics), thickener for lacquer, two different panels for passenger cars, and transport pallets. These products are compared with equivalent products made from petrochemical polymers - in many cases polyethylene, polypropylene or polystyrene. 

The loose-fill packaging growth rate is mainly attributable to two factors lack of an effective infrastructure for disposal, and the popularity of air-filled plastics and... 

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