Thai plastic converters and the ways to develop new applications for bioplastics

Transcription

1 Thai plastic converters and the ways to develop new applications for bioplastics By Pornchai Sangrungsri Technical Service and development manager SCG Plastics Co., Ltd.

2 Thai plastics convertors have variety of processing methods and years of experience. Thai Plastic convertors categorized by processing method Profile extrusion 11% Foam 3% Calendering 3% Compression molding 3% Film 21% Rotomolding 2% Injection molding 36% Filaments 6% Blow molding 10% Thermoforming 5% Source:

3 Thailand plastics products export double value in ten years. Source:

4 Bioplastics history in Thailand

5 Why Thai bioplastics demand growth is so slow? Market Lack of awareness for sustainability. No incentive for the early adapters. Law and regulation enforcement. Non performing compost sites due to poor waste management system. A department store campaign to ban plastic bags Technology & Production Imported raw materials make the cost skyhigh (3-4 times). Narrower processing window of bioplastics VS conventional plastics. Limitation of the conventional fabrication machines. Low productivity of compounds with the existing machines. Composability of thick finished products does not comply to compostable standard. Performance of finished products is inferior than that of the conventional plastics.

6 Voice of the convertors

7 Blown film process Do the conventional machines can handle bioplastics compound? Conventional HDPE blown film machine Poor bubble stability High blow-up ratio die HDPE screw with mixing element The right air ring type? The right die head type?

8 Blown film common issues Narrow processing window, material is more prone to degrade. Unstable film bubble causes thickness variation. Film stiffness is too soft leads to wrinkle surface. Poor melt strength limits drawdown-ability for thin film. Less productivity than conventional plastics (PE) up to 50%. Suggestion for processing bioplastics + starch compound LLDPE die head and air ring Gentle shear screw without mixing element Blow up ratio 2-3 L/D depends on starch content Compression ratio depends on compressibility of compound

9 Injection molding issues PLA needs mold heating system in order to increase crystallinity. Long mold closing time up to 60 second in order to prevent part deformation. Low thermal stability of finished products, if the crystallinity is not sufficient. Low impact strength of finished products, if the part has excessive stress residual. Suggestion for processing bioplastics and compound MIN-MAX MOLD TEMPERATURE MIN-MAX INJECTION MELT TEMPERATURE HDPE PP PS PC PLA ecovio PBS 0 HDPE PP PS PC PLA ecovio PBS Min Mold temperature Max Mold temperature Min Melt temperature Max Melt temperature Sources: i-moulder, RTP, BASF, PTT MCC,

10 Extrusion coating issues Neck in and line speed balance for paper coating. Slow line speed below 100 m/min compared with LDPE coating grade. Adhesion strength on substrate is inferior than that of LDPE coating grade. Adhesion strength Poor neck in Better neck in

11 Blow molding & Thermoforming issues Heat resistant of PLA limits hot fill drink application such as green tea. Hot food tray needs CPET thermoforming machine which is rare in Thailand. Source: Kirin Suggestion for processing high heat PLA/PDLA compound Crystallization of PLA/PDLA compound Vertical silo with horizontal agitators Molded at o C Horizontal paddles screw heat exchanger Source: Corbion Purac

12 Shelf life issues Thick finished product more than 130 micron cannot pass disintegration test according to EN Premature degradation during storage or transportation before selling. Poor waste management and separation from conventional plastics. Coated cups leaked after 12 months storage PBS Straw PLA cup lids PLA Bottle Supply chain management from raw materials to finished products is the challenge for Bioplastics.

13 How to develop new applications?

14 The mechanism to create new applications from bioplastics Sustainability Idea Fabrication experts Design concept Compound and formulation experts Design functions and usages

15 Medical applications Do bioplastics limit themselves to only packaging applications? Bioplastics medical devices have been developed by Thailand Institute of Scientific and Technological Research (TISTR). PLA fiber Dialyzer Splint

16 Medical applications Tissue repair: PLA scaffolds for bone tissue engineering Source: university of Birmingham, Chulalongkorn University Network of convertors for medical devices is set up in Thailand by the effort of Plastics Institutes of Thailand. ( Thai convertors need to implement ISO13485 standard for medical devices before producing.

17 New area of applications Bioplastics reinforced with natural fiber for construction materials. Build environmental friendly community. Source: the Centre of Expertise Biobased Economy, founded by Avans College and HZ University Roof flame from natural fiber composite with water base blinder. Provide toughness and heat resistance with lighter weight than metal. Source: Kuskao Bi by Alki, France The comfortable and generously-sized Kuskoa Bi is the first chair in the market to be manufactured by bioplastics. 100% renewable resources and recyclable. Source: International Automotive Components Group (IAC)

18 New area of applications Marine applications Marine biodegradation results for PHA and PLA after 180 days Source: California Department of Resources Recycling and Recovery Ghost fishing nets and plastics litters are the burden of the sea environment. PHA can compost better in sea water but can we extrude the strong fishing net?

19 Promoting usages of Biobased plastics Lunch in the park & Green cafeteria concept SCG head office Kasetsart University PP biomass composites chairs Biobased utensils

20 Green stadium idea Compost site Biomass 96,000 ton/year Football stadium Sustainable solution for waste management of packaging in big stadium or community places Biomass power plant 9.6 MW

21 SCG Chemicals sustainable solution Compostable Compostable compounds for film and extrusion coating applications Light weight HDPE cap Petroleum base Conventional plastics Thin wall PP lunch box Biobased Composites Renewable Bio PET Source: UCL Non-Compostable

22 Conclusion 1. Thai plastics convertors have long experience in plastics fabrication but many of them are unfamiliar with bioplastics as the alternative materials for their machines. 2. Special compounds customized for each application are necessary in order to develop new applications and optimize cost VS performance. 3. Bioplastics and Biobased plastics applications are not only limited to packaging, but constructions, marine and medical applications are also applicable. Those need to be developed and promoted in Thailand with the strong collaboration among convertors, material producers and end users. 4. By developing new applications, we need three areas of expertise: design, compound & formulation, and plastics fabrication. Thailand already have enough experts. 5. Thailand should have more legislation in order to promote bioplastic usage. Moreover supporting facilities such as industrial compost sites and biomass power plants are required in order to utilize the full benefit of bioplastics.