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Biopolymers used in food packaging

Biopolymers used in food packaging

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  • 1. What are Biopolymers? Biopolymers are long chain compoundsmade up of long chain molecule subunits.e.g.: starch, cellulose, etc.These are biodegradable, ecofriendly and areobtained from natural sources.
  • 2. Biobased Vs. Biodegradable• Biobased: A renewable productengineered or composed in whole or insignificant part from plant or animalmaterial (other than food or feed).• Biodegradable: Material that left to itselfwill be decomposed by natural processes( microorganisms)
  • 3. Origin and description of biobased polymers Biobased polymers may be divided into three main categories based on their origin and production:• Category 1: Polymers directly extracted/removed from biomass. Examples are polysaccharides such as starch and cellulose and proteins like casein and gluten.• Category 2: Polymers produced by classical chemical synthesis using renewable biobased monomers. A good example is polylactic acid, a biopolyester polymerised from lactic acid monomers. The monomers themselves may be produced via fermentation of carbohydrate feedstock.• Category 3: Polymers produced by microorganisms or genetically modified bacteria. To date, this group of biobased polymers consists mainly of the polyhydroxyalkonoates, but developments with bacterial cellulose are in progress.
  • 4. COMPOSITIONBioplastics can be made from many different sources and materials:• Plant Oil• Cellulose• Corn Starch• Potato Starch• Sugarcane• Hemp etc. 6
  • 5. COMPOSITIONPlant Oil Starch CelluloseCorn Sugarcane Potato 7
  • 6. Classification of Bioplastics• Starch based plastics• Bioplastics produced from classical chemical synthesis from biobased monomers• Polylactic Acid (PLA) plastics• Bioplastics produced directly by natural or genetically modified organisms• Polyamides 11• Polycaprolactones 8
  • 7. Starch Starch is a well–known hydrocolloid biopolymer. It is a low cost polysaccharide,abundantly available and one of the cheapest biodegradable polymersStarch is produced by agricultural plants in the form of granules, which are hydrophilic. Starch ismainly extracted from potatoes, corn, wheat and rice. It is composed of amylose (poly-α-1,4-D-glucopyranoside), a linear and crystalline polymer and amylopectin (poly-α-1,4-Dglucopyranoside and α-1,6-D-glucopyranoside), a branched and amorphous polymer. Starch hasdifferent proportions of amylose and amylopectin ranging from about 10–20% amylase and 80–90% amylopectin depending on the source
  • 8. Polylactic acid PLA is usually obtained from polycondensation of D- or L-lactic acid orfrom ring opening polymerization of lactide, a cyclic dimer of lactic acid. Two opticalforms exist: D-lactide and L-lactide. The natural isomer is L-lactide and the syntheticblend is DL-lactide. Other different synthetic methods have been studied too. PLA is ahydrophobic polymer due to the presence of –CH3 side groups. It is more resistant tohydrolysis than PGA because of the steric shielding effect of the methyl side groups.PLA has disadvantages of brittleness and poor thermal stability. PLA can be plasticizedto improve the chain mobility and to favor its crystallization.
  • 9. Poly (hydroxyalkanoates) (PHAs) PHAs, of which poly (hydroxybutyrate) (PHB) is the mostcommon, are accumulated by a large number of bacteria as energy andcarbon reserves. Due to their biodegradability and biocompatibility thesebiopolyesters may easily find numerous applications. The properties ofPHAs are dependent on their monomer composition, and it is, therefore,of great interest that recent research has revealed that, in addition toPHB, a large variety of PHAs can be synthesized by microbialfermentation. The monomer composition of PHAs depends on the natureof the carbon source and microorganisms used. PHB is a typical highlycrystalline thermoplastic whereas the medium chain length PHAs areelastomers with low melting points and a relatively lower degree ofcrystallinity. A very interesting property of PHAs with respect to foodpackaging applications is their low water vapour permeability which isclose to that of LDPE
  • 10. Since 1925, PHB is produced biotechnologically and was attentively studied asbiodegradable polyester. The R alkyl substituent group is methyl. PHB is highlycrystalline with crystallinity above 50%. Its melting temperature is 180 °C. The purehomopolymer is a brittle material. Its glass transition temperature is approximately of55 °C. It has some mechanical properties comparable to synthetic degradablepolyesters, as PLA. During storage time at room temperature a secondary crystallizationof the amorphous phase occurs. As a result, stress and elongation modulus increase (E =1.7 GPa) while the polymer becomes more brittle and hard. Elongation at break is thenmuch lower (10%). Compared to conventional plastics, it suffers from a narrowprocessability window. PHB is susceptible to thermal degradation at temperatures in theregion of the melting point. To make the process easier, PHB can be plasticized, withcitrate ester.Applications that have been developed from PHB and related materials (e.g. Biopol)can be found in very different areas and cover packaging, hygienic, agricultural, andbiomedical products. Recent application developments based on medium chain lengthPHAs range from high solid alkyd-like paints to pressure sensitive adhesives,biodegradable cheese coatings and biodegradable rubbers. Technically, the prospects forPHAs are very promising. When the price of these materials can be further reduced,application of biopolyesters will also become economically attractive.
  • 11. Polycaprolactone (PCL): Poly- ε-caprolactone is a relatively cheap cyclic monomer. Asemi-crystalline linear polymer is obtained from ring-openingpolymerization of ε-caprolactone in presence of tin octoate catalyst. PCLis soluble in a wide range of solvents. Its glass transition temperature islow, around -60 °C, and its melting point is 60 – 65 °C. PCL is a semi-rigid material at room temperature,has a modulus in the range of low-density polyethylene and high-density polyethylene, a low tensilestrength of 23 MPa and a high elongation to break (more than 700%).Thanks to its low Tg, PCL is often used as a compatibilizer or as a softblock in polyurethane formulations. Enzymes and fungi easilybiodegrade PCL. To improve the degradation rate, several copolymerswith lactide or glycolide have been prepared. PCL is commerciallyavailable under the trade names CAPA® (from Solvay, Belgium), Tone®(from Union Carbide, USA) or Celgreen® (from Daicel, Japan) andmany others. Possible applications in packaging have been investigated.
  • 12. Cellulose and derivativesCellulose is the most abundantly occurring natural polymer on earth and is an almostlinear polymer of anhydroglucose. It is a linear polymer with very long macromolecularchains of one repeating unit, cellobiose. Cellulose is crystalline, infusible and insolublein all organic solvents.Because of its regular structure and array of hydroxyl groups, ittends to form strongly hydrogen bonded crystalline microfibrils and fibres and is mostfamiliar in the form of paper or cardboard in the packaging context. Waxed orpolyethylene coated paper is used in some areas of primary food packaging, howeverthe bulk of paper is used for secondary packaging. Cellulose is a cheap raw material, but difficult to use because of itshydrophilic nature, insolubility and crystalline structure. The cellophane produced isvery hydrophilic and, therefore, moisture sensitive, but it has good mechanicalproperties. It is, however, not thermoplastic owing to the fact that the theoretical melttemperature is above the degradation temperature, and therefore cannot be heat-sealed.Tenite® (Eastman, USA), Bioceta® (Mazzucchelli, Italy), Fasal® (IFA, Austria) andNatureflex® (UCB, Germany) are some of the trade names of cellulose-basedpolymers.
  • 13. BlendsStarch-polyvinyl alcohol: TPS and PVOH have excellent compatibility and their blends are ofparticular interest. TPS and starch can be blended at various ratios to tailor the mechanicalproperties of the final material. Compared to pure TPS materials, blends present improved tensilestrength, elongation and processability. Their biodegradability has been recently investigated. ThePVOH content has an important impact on the rate of starch degradation: increasing the amountof PVOH will decrease this rate.Starch-PLA: The mechanical properties of blends of starch with PLA using conventionalprocesses are poor due to incompatibility. An elongation increase can be achieved by usingplasticizers or reacting agents during the extrusion process. Coupling agents like isocyanates havebeen used. The hydroxyl groups of starch could react with the isocyanate group resulting inurethane linkages and compatibilization of these systems. The effect of gelatinization of starchwas also investigated. It has been shown that in PLA/gelatinized starch blends, starch could beconsidered as a nucleating agent, resulting in an improvement of crystallinity in PLA blends anda greater superiority of mechanical properties. Another way to improve compatibilization is touse a compatibilizer. Maleic anhydride can be used for this purpose. An initiator was used tocreate free radicals on PLA and improved the reaction between maleic acid and PLA. Theanhydride group on maleic acid could react with the hydroxyl groups present in starch. Interfacialadhesion between starch and PLA was then significantly improved. The mechanical propertiesobtained for PLA/starch blends compatibilized with maleic acid are higher than those obtainedfor virgin PLA/starch blends. A biodegradable PLA-grafted amylose copolymer has beensynthesized, to be used as compatibilizer agent in starch/PLA blends.
  • 14. Starch – PCL: To prepare films by using the film blowing technique, TPS was blended withPCL to adjust the rheological properties of the melt before the process. Novamont (Italy)produces a class of starch blend with different synthetic components. Its trade name isMater-Bi®. Four grades are available; one of them consists of PCL (Mater-Bi® Z). Thehighest amount of starch allows the acceleration of the degradation of PCL. The behaviourof some PCL-modified starch blends has been studied. The addition of modified starch leadsto an increase of the Young’s modulus of PCL and a decrease in tensile strength andelongation at break values. The blend becomes less ductile. Some synthetic polymers withlower biodegradabilty are used to control the rate of biodegradation according to theapplications. The modulus of blends of high-amylose corn starch (25% wt.) and PCL was50% higher than that of PCL and the tensile strength 15% lower. To increase the mechanicalproperties of PCL/starch, blends with LDPE were prepared. The biodegradation rate ofPCL, which is very low, can be significantly increased by the presence of starch.PCL/Chitin-chitosan blends: PCL blends with chitin were prepared as biodegradablecomposites by melt blending. Increasing the amount of chitin has no effect on the melting orcrystallization temperature. This was attributed to a non miscible blend. Another blendingroute is solvent casting. The degree of crystallinity of PCL decreases upon blending withchitin. Same results are obtained with PCL/chitosan blends. These blends are expected tohave good mechanical properties
  • 15. Material properties1. Gas barrier propertiesMany foods require specific atmospheric conditions to sustain their freshness and overall quality duringstorage. Hence, increasing amounts of our foods are being packed in protective atmosphere with a specificmixture of gases ensuring optimum quality and safety of the food product in question. To ensure a constantgas composition inside the package, the packaging material needs to have certain gas barriers. In mostpackaging applications the gas mixture inside the package consists of carbon dioxide, oxygen and nitrogen orcombinations hereof. The objective of this section is to describe the gas barriers of biobased materials usingmineral oil based polymer materials as benchmarks. In Figure 2.3, different biobased materials are comparedto conventional mineral-oil-based polymer materials. The figure is based on information from literature andon measurements of commercially available materials performed by ATO .
  • 16. Gas barriers and humidity As many of these biobased materials are hydrophilic, their gasbarrier properties are very much dependent on the humidity conditionsfor the measurements and the gas permeability of hydrophilic biobasedmaterials may increase manifold when humidity increases. Notably, thisis a phenomenon also seen with conventional polymers. The gaspermeability of high gas barrier materials, such as nylon and ethylvinylalcohol, is likewise affected by increasing humidity. Gas barriers basedon PLA and PHA is not expected to be dependent on humidity
  • 17. Water vapour transmittance A major challenge for the material manufacturer is the by nature hydrophilicbehaviour of many biobased polymers as a lot of food applications demand materials thatare resistant to moist conditions. However, when comparing the water vapour transmittanceof various biobased materials to materials based on mineral oil , it becomes clear that it ispossible to produce biobased materials with water vapour transmittance rates comparable tothe ones provided by some conventional plastics. However, if a high water vapour barriermaterial is required, very few biobased materials apply. Notably, developments are currentlyfocusing on this problem and future biobased materials must also be able to mimic the watervapour barriers of the conventional materials known today
  • 18. Thermal and mechanical propertiesNext to the barrier properties of the final packaging, the thermal and mechanical properties of thematerials are both important for processing and also during the use of the products derived fromthese materials. Most biobased polymer materials perform in a similar fashion to conventionalpolymers. This indicates that both polystyrene-like polymers (relatively stiff materials withintermediate service temperatures), polyethylene-like polymers (relatively flexible polymers withintermediate service temperatures) and PET-like materials (relatively stiff materials with higherservice temperatures) can be found among the available biobased polymers. The mechanicalproperties in terms of modulus and stiffness are not very different compared to conventionalpolymers. In figure 2.5 a comparison of the thermal properties of biobased polymers withexisting polymers is made. The modulus of biobased materials ranges from 2500-3000 MPa andlower for stiff polymers like thermoplastic starches to 50 MPa and lower for rubbery materialslike medium chain polyhydroxyalkanoatesFurthermore, the modulus of most biobased and petroleumderived polymers can betailored to meet the required mechanical properties by means of plasticizing, blendingwith other polymers or fillers, crosslinking or by the addition of fibres. A polymer likebacterial cellulose could for instance be used in materials which requires specialmechanical properties. In theory, biobased materials can be made having similarstrength to the ones we use today
  • 19. Compostability Compostability is another important property required for biopolymers used infood packaging. Figure 2.6 compares the compostability of various biobased materials.Notably, the “composting time” depicted in the figure represents the approximate periodof time required for an acceptable level of disintegration of the material to occur. Thismeans that the original material should not be recognizable anymore in the finalcompost (fraction < 10 mm) nor in the overflow (fraction > 10 mm). The compostingtime does not reflect the time required for the biodegradation of the materials to be fullycompleted. The process could subsequently be completed during the use of thecompost. The level of technology applied in the composting process highly affects thecomposting time needed for complete disintegration. Hence, it takes much longer toobtain a mature compost using low technology composting (e.g. passive windrowcomposting) than using high technology as in an intensively controlled tunnelcomposting process. The durations presented in figure 2.6 are based on an intermediatelevel of technology as observed in actively aerated and mechanically turned hallcomposting. Furthermore, the composting time needed for complete disintegration isalso affected by the particle size of the material. For example, wood is rapidlycomposted in the form of sawdust and small chips. A wooden log, however, takes morethan one year to be completely disintegrated. The durations presented in this figure arebased on dimensions regularly used for packaging applications
  • 20. Transmission of UV-light
  • 21. Manufacturing of biobased food packaging Engineering of a biobased package or packaging material requires knowledgeof the processing and material properties of the polymers. If the properties of the nativebiopolymer are not identical to the required one, or if the polymer by nature is notthermoplastic, a certain modification of the polymer must take place. For very specificrequirements (very low gas permeability or high water resistance) it is unlikely that onepolymer will be able to provide all required properties even after modifications. Hence,it is necessary to use multiple materials in a composite, a laminate or co-extrudedmaterial
  • 22. Possible products produced of biobased materials
  • 23. Blown (barrier) films Blown films comprise one of the first product categories to be developedbased on mineral oil derived biodegradable polyesters. They have successfully beenapplied as garbage bags and related applications. Film blowing grades of renewablepolymers have been developed based on PLA. Blown films based on thesebiopolyesters exhibit excellent transparency and cellophane-like mechanical properties.The sealability depends on the degree of crystallinity and good printability can also beachieved. The possibilities of film blowing PHB/V materials are at this time limited dueto their slow crystallization and low melt strength. In many food packagingapplications, a water vapour barrier as well as gas barriers are required. No singlebiobased polymer can fulfil both these demands. In this case, the use of co-extrusioncan lead to laminates which meet the objectives. Paragon materials which are based onthermoplastic starch can be film blown in a co-extrusion set-up with polymers like PLAand PHB/V as coating materials, resulting in a barrier coating which, for example,proved to be successful in the packaging of cheese . The use of Paragon tie-layersprovides the adhesion between the coating and the base layer. In this way, starch-basedmaterials could provide cheap alternatives to presently available gas barrier materialslike EVOH and PA6
  • 24. Thermoformed containers A next class of products is thermoformed containers for foodpackaging. In order to be able to thermoform a polymer it should bepossible to process this material from the melt (extrusion) into sheets andconsequently thermoforming these sheets just above the Tg or Tm of thematerial. Thermoformed products can be found based on PLA andPHB/V. Again, it is possible to produce thermoformed articles fromlaminates based on Paragon as well as other thermoplasticallyprocessable biopolymers
  • 25. Foamed products Starch-based foams for loose fill applications (Novamont, (I), National Starch (USA)a.o.) have been commercially introduced with success some years ago and the market for theseproducts is still growing. Foamed products like trays and clamshells based on starch for foodpackaging have not yet been introduced commercially. Products based on a molding techniquefrom a slurry phase (Earthshell (USA), APACK (D)) are close to market introduction. Theseproducts are produced form starch base slurries with inorganic and agrofiber based fillers. Otherproposed techniques include loose-fill molding (Novamont (I), Biotec (D)), foam extrusion(Biotec (D)), and extrusion transfer molding (Standard Starch (USA)) and expandable beadmolding .Foamed products based totally on PLA are still in a developmental phase .In order to beable to use these starch-foamed products in food contact applications coatings should be appliedon the starch- based foams. Adhesion between the foam and the coating is of importance. Paraffin and otheroligomer based coatings are proposed next to PLA and PHB/V based coatings. Protein andmedium chain length PHA based coatings are close to market introduction. Other proposedtechniques include loose-fill molding (Novamont (I), Biotec (D)), foam extrusion (Biotec (D)),and extrusion transfer molding (Standard Starch (USA)) and expandable bead moulding . Foamedproducts based totally on PLA are still in a developmental phase. In order to be able to use thesestarch-foamed products in food contact applications coatings should be applied on the starch-based foams. Adhesion between the foam and the coating is of importance. Paraffin and otheroligomer based coatings are proposed next to PLA and PHB/V based coatings. Protein andmedium chain length PHA based coatings are close to market introduction
  • 26. Coated paper It is expected that paper will stay an important biobasedpackaging material. Paper and board materials have excellent mechanicalproperties, however, the gas permeabilities are too high for many foodapplications. The hydrophilic nature of the paper-based materials is amajor challenge of these materials when packaging moist foods. To date,the paper-based materials have been coated with a thin layer of syntheticplastic which has provided the materials with the required gas propertyand water resistance. Alternatively, biobased materials might be used ascoating materials thus paving the way for a 100% biobased packagingmaterial. Paper-based materials coated with PE are readily repulpable asthe hydrophobic PE is easily removed in the pulping process. Hence,paper-based materials coated with biobased, hydrophobic polymericmaterials are, likewise, going to be repulpable
  • 27. Development of the market• Capacity 2009 400.000 t worldwide• Small market, but high growth rates up to 10 %
  • 28. Conventional Plastics used in Bulk PackagingThe main fossil fuel based plastics used inthe bulk packaging are: LDPE LLDPE HDPE PP PVC Nylon Polyester 39
  • 29. Some Biodegradable Packaging materials available in the market Biopolymers Manufacturing company PHB/PHV Monsanto, UK; Biomer, UK Cellulose acetate Courtaulds, USA; Mazzucchelli, Italy PLA Cargill Dow Polymers, USA; Mitsui, Japan; Hycail, Netherlands; Galactic, USA Starch National Starch, UK; Avebe, Netherlands Starch based blends Novamont, Italy; Biotec, Germany; Earth Shell, USA; Biop, UK
  • 30. Biodegradable materials materials Biodegradable In general 4 materials commercially available • Starch-based polymers • Polylactic acid • Polyhydroxyalkanoates • Cellulose derivates Polymer blends and composites
  • 31. Plantic trays
  • 32. Starch-based polymers Mater-Bi®• Maize and/or potatoe starch in blend with polycaprolactones and other biodegradable esters• Europeas most common bioplastic
  • 33. Mater Bi
  • 34. Starch-based polymers Starch-based polymers Others Others  Plantic® Starch from maize and hydroxypropyl, Plantic Technologies (AUS)  Solanyl® Starch from potatoes, Rodenburg Biopolymers (NL)  Bioplast® Starch blend, Biotec (DE)  Biopar® Starch from potatoes and blends, Biop AG (D) Similar to PE (converting) Limited applications!Source: www.plantic.com.au 2009-04-01
  • 35. Polylactic acid  Main producer: NatureWorks (US)  Other Producers: Hycail (FI), Toyota (J) and Uhde Inventa (D)  Glucose from maize or lactose from wheySource: LIM L.-T. et al. 2008
  • 36. Poly Lactic Acid (PLA)
  • 37. Polylactic acid blends • Ecovio® 45 % PLA + Ecoflex®, BASF (D) • Ecovio® L-Foam 75 % PLA + Ecoflex®, BASF (D) • Bio-Flex® PLA + Copolyester, FKuR (D) Similar to PET and/or PS (converting) Sensitive to temperature!Source: www.basf.com 2008-09-12 YU L. et al. 2006
  • 38. Polyhydroxyalkanoates • Mirel™ Metabolix (US) • Biomer™ Biomer (D) PHB, PHV, PHBV, ... Fermentation of starch, rape, plant residues, etc. Only Injection Moulding!Source: www.metabolix.com 2008-09-12
  • 39. ECOFLEX & ECOVIOEcoflex® - a Polyester based resin which is fully biodegradable Ecovio® - 45% based on renewables and 100% biodegradable in soil and compost
  • 40. Cellulose derivates NatureFlex™ Innovia (UK) Barrier coatings!Source: www.innoviafilms.com 2008-09-12
  • 41. NatureFlex Films
  • 42. End of life End of life Compsoting?Source: ENDRES H.-J. 2009
  • 43. ADVANTAGES OF BIOPLASTICSThe need of replacement for the petroleumbased plastic with bioplastics is just because Producing conventional plastics consumes 65% more energy than producing bioplastic. Conventional plastic are mostly toxic. Plastics last a long time and do huge damage to environment. Therefore, plastic is absolutely unsustainable and bioplastic is more sustainable. Bioplastics saves 30-80% of the greenhouse gas emissions and provide longer shelf-life than normal plastic. 55
  • 44. Bioplastics have following several other important advantagesover conventional plastics in bulk packaging which are as follows Compost derived in part from bioplastics increases the soil organic content as well as water and nutrient retention, with reducing chemical inputs and suppressing plant diseases. Starch-based bioplastics have been shown to degrade 10 to 20 times quicker than conventional plastics. On burning traditional plastics, create toxic fumes which can be harmful to peoples health and the environment. If any biodegradable films are burned, there is little, if any, toxic chemicals or fumes released into the air. Safe Biodegradability Safe for Medicinal Use Compared to conventional plastics derived from petroleum, bio-based polymers have more diverse stereochemistry and architecture of side chains which enables research scientists a great number of opportunities to customize the properties of the final packaging material. 56
  • 45. The Netherlands – An example to follow? Strong growth in the packaging sector Leading retailer Albert Heijn with strong commitment to use biopackaging Government supports the development Biobin system open for certified biodegradable products (90% of households have access)
  • 46. Conclusion The food industry has seen great advances in the packaging sector since its inception inthe 18th century with most active and intelligent innovations occurring during the past century.These advances have led to improved food quality and safety. While some innovations havestemmed from unexpected sources, most have been driven by changing consumer preferences.The new advances have mostly focused on delaying oxidation and controlling moisturemigration, microbial growth, respiration rates, and volatile flavors and aromas. This focusparallels that of food packaging distribution, which has driven change in the key areas ofsustainable packaging, use of the packaging value chain relationships for competitive advantage,and the evolving role of food service packaging. Biopolymers have highly influenced thepackaging sector greatly. Environmental responsibility is constantly increasing in importance to both consumersand industry. For those who produce biodegradable plastic materials, this is a key advantage.Biopolymers limit carbon dioxide emissions during creation, and degrade to organic matter afterdisposal. Although synthetic plastics are a more economically feasible choice than biodegradableones, an increased availability of biodegradable plastics will allow many consumers to choosethem on the basis of their environmentally responsible disposal. The processes which hold themost promise for further development of biopolymer materials are those which employrenewable resource feedstock. Time is of the essence for biodegradable polymer development, associety’s current views on environmental responsibility make this an ideal time for further growthof biopolymers.