This document provides a feasibility study for producing poly l-lactic acid (PLLA) bio-plastic at an industrial scale. It analyzes the market potential, technology, and process details. Corn would be hydrolyzed into dextrose and fermented into lactic acid. The lactic acid would then be processed through esterification, polycondensation, and depolymerization to produce purified l-lactide, which would undergo ring-opening polymerization to create PLLA. An economic analysis determines the process feasibility based on a 10% initial rate of return.
Chitosan nanofibers are made from chitosan, which is derived from the deacetylation of chitin found in crustacean shells. A colloidal suspension of chitin nanofibers and chitosan solution is mixed and cast onto a mold to produce a consolidated nanostructured composite film after drying. Chitosan nanofibers are light, strong, and have a large surface area. They have applications in agriculture, wastewater treatment, food packaging, medicine, and more. Potential future applications include transparent vehicles, electronics, and valuables.
In the recent years, bio-based and biodegradable products have raised great interest since sustainable development policies tend to expand with the decreasing reserve of fossil fuel and the growing concern for the environment. Bio-Polymers are a form of polymers derived from plant sources such as sweet potatoes, soya bean oil, sugarcane, hemp oil, and corn starch. These polymers are naturally degraded by the action of microorganisms such as bacteria, fungi and algae. Bio-plastics can help alleviate the energy crisis as well as reduce the dependence on fossil fuels of our society. They have some remarkable properties which make it suitable for different applications. This paper tries to give an insight about Bio-plastics, their composition, preparation, properties, special cases, advantages disadvantages, commercial viability, its life cycle, marketing and pricing of these products.
As a result, the market of these environmentally friendly materials is in rapid expansion,
10 –20 % per year.
Introduction to biopolymers,
Biocompatible and biodegradable polymers,
Applications of biopolymers,
Biopolymers used in advanced drug delivery systems-
Cellulose and its derivatives,
chitosan,
PLGA,
Polyanhydride,
polycaprolactone.
The document discusses various types of natural polymers that originate from plants, animals, and microbes. It classifies natural polymers based on their source and structure, and provides examples such as cellulose from plants, chitin from animals, and xanthan gum from bacteria. The document also describes the properties and applications of important natural polymers including polysaccharides like starch, proteins like collagen, and their uses in fields like pharmaceuticals, food, and cosmetics.
This document discusses the properties and applications of chitosan. Chitosan is a polyaminosaccharide obtained from the deacetylation of chitin from fungi and crustaceans. Its degree of acetylation and molecular weight characterize it. Chitosan has biocompatibility, is nontoxic, and can improve wound healing. It is cationic, undergoes reactions like amines, and has varying solubility based on its degree of deacetylation. The document lists applications of chitosan in biomedical uses like drug delivery, wound healing, dentistry, and bone regeneration as well as in cosmetics, nutrition, and pharmaceuticals.
Recent Advances In BioPolymers And Its ApplicationsArjun K Gopi
Biopolymers are materials that are biodegradable, derived from renewable resources, or both. Common biopolymers include polylactic acid (PLA), polyhydroxyalkanoates (PHAs), and cellulose. Biopolymers are increasingly important due to their environmentally-friendly properties and potential to replace petroleum-based plastics. However, biopolymers currently only account for about 1% of the global plastic market. The use of nanomaterials to create bionanocomposites can help improve biopolymer properties and expand their applications in areas like packaging, textiles, agriculture, and biomedicine.
Poly Lactic Acid (PLA) is a biodegradable and compostable thermoplastic polymer made from renewable resources like corn, sugar beets and wheat. PLA is produced through fermentation of carbohydrates to lactic acid, then polymerization to form polylactic acid. It has physical properties comparable to polyethylene terephthalate but requires less fossil fuels to produce. While PLA has potential applications for single-use items and packaging due to its sustainability, its production also has criticisms related to energy usage and slowed degradation with certain additives.
Chitosan nanofibers are made from chitosan, which is derived from the deacetylation of chitin found in crustacean shells. A colloidal suspension of chitin nanofibers and chitosan solution is mixed and cast onto a mold to produce a consolidated nanostructured composite film after drying. Chitosan nanofibers are light, strong, and have a large surface area. They have applications in agriculture, wastewater treatment, food packaging, medicine, and more. Potential future applications include transparent vehicles, electronics, and valuables.
In the recent years, bio-based and biodegradable products have raised great interest since sustainable development policies tend to expand with the decreasing reserve of fossil fuel and the growing concern for the environment. Bio-Polymers are a form of polymers derived from plant sources such as sweet potatoes, soya bean oil, sugarcane, hemp oil, and corn starch. These polymers are naturally degraded by the action of microorganisms such as bacteria, fungi and algae. Bio-plastics can help alleviate the energy crisis as well as reduce the dependence on fossil fuels of our society. They have some remarkable properties which make it suitable for different applications. This paper tries to give an insight about Bio-plastics, their composition, preparation, properties, special cases, advantages disadvantages, commercial viability, its life cycle, marketing and pricing of these products.
As a result, the market of these environmentally friendly materials is in rapid expansion,
10 –20 % per year.
Introduction to biopolymers,
Biocompatible and biodegradable polymers,
Applications of biopolymers,
Biopolymers used in advanced drug delivery systems-
Cellulose and its derivatives,
chitosan,
PLGA,
Polyanhydride,
polycaprolactone.
The document discusses various types of natural polymers that originate from plants, animals, and microbes. It classifies natural polymers based on their source and structure, and provides examples such as cellulose from plants, chitin from animals, and xanthan gum from bacteria. The document also describes the properties and applications of important natural polymers including polysaccharides like starch, proteins like collagen, and their uses in fields like pharmaceuticals, food, and cosmetics.
This document discusses the properties and applications of chitosan. Chitosan is a polyaminosaccharide obtained from the deacetylation of chitin from fungi and crustaceans. Its degree of acetylation and molecular weight characterize it. Chitosan has biocompatibility, is nontoxic, and can improve wound healing. It is cationic, undergoes reactions like amines, and has varying solubility based on its degree of deacetylation. The document lists applications of chitosan in biomedical uses like drug delivery, wound healing, dentistry, and bone regeneration as well as in cosmetics, nutrition, and pharmaceuticals.
Recent Advances In BioPolymers And Its ApplicationsArjun K Gopi
Biopolymers are materials that are biodegradable, derived from renewable resources, or both. Common biopolymers include polylactic acid (PLA), polyhydroxyalkanoates (PHAs), and cellulose. Biopolymers are increasingly important due to their environmentally-friendly properties and potential to replace petroleum-based plastics. However, biopolymers currently only account for about 1% of the global plastic market. The use of nanomaterials to create bionanocomposites can help improve biopolymer properties and expand their applications in areas like packaging, textiles, agriculture, and biomedicine.
Poly Lactic Acid (PLA) is a biodegradable and compostable thermoplastic polymer made from renewable resources like corn, sugar beets and wheat. PLA is produced through fermentation of carbohydrates to lactic acid, then polymerization to form polylactic acid. It has physical properties comparable to polyethylene terephthalate but requires less fossil fuels to produce. While PLA has potential applications for single-use items and packaging due to its sustainability, its production also has criticisms related to energy usage and slowed degradation with certain additives.
The document discusses biomaterials, which are materials used in medical applications that interact with biological systems. It defines biomaterials and outlines their classification as natural or synthetic. Natural biomaterials discussed include proteins, cellulose, chitin, and polynucleotides. Synthetic biomaterials include polymers like PMMA, ceramics like calcium phosphate, and metals like titanium. Common applications of biomaterials are described like implants, prosthetics, and medical devices used in the skeletal, cardiovascular, and sensory systems.
Biopolymers are polymers that can be found in or manufactured by, living organisms. These also involve polymers that are obtained from renewable resources that can be used to manufacture Bioplastics by polymerization. Bioplastics are the plastics that are created by using biodegradable polymers
The document discusses the potential uses of chicken feather fiber (CFF) as a reinforcement material in composites. It notes that the poultry industry generates a large amount of waste feathers annually. CFF has properties like low density, thermal insulation and acoustic properties that make it suitable for composites. Studies found that CFF reinforced polymer composites have increased tensile strength compared to virgin polymers. CFF has also been used successfully as reinforcement in cement composites and medium density fiberboard, utilizing an agricultural waste and improving strength. The document concludes that CFF composites could benefit the poultry industry through waste reduction while enabling applications in low-cost housing construction.
This document provides an extensive literature review on Chlorella vulgaris, a species of green microalgae. It discusses C. vulgaris's composition including proteins, lipids, carbohydrates, pigments, vitamins, and minerals. It also reviews C. vulgaris's applications, such as for food, feed, biofuel production, wastewater treatment and more. The document contains 3 tables that provide details on C. vulgaris's mineral composition, effects of unfavorable growth conditions on its fatty acid profile, and applications of its biochemical components.
Bionanocomposite materials have potential applications in food packaging due to their barrier properties and sustainability. Nanoparticles can be incorporated into biopolymers through methods like polymerization, exfoliation, and intercalation to form bionanocomposites. This improves properties such as mechanical strength and gas barrier effects compared to biopolymers alone. Bionanocomposites show promise as active packaging through inclusion of antimicrobial nanoparticles. However, more research is needed to understand potential human health risks from nanoparticle migration before wide commercial use. Regulations are being developed to ensure safety of nanomaterials used in food applications.
This document discusses the synthesis of poly(lactic acid) (PLA) biomaterials. There are two main synthetic methods - direct polycondensation and ring-opening polymerization of lactide monomers. Direct polycondensation includes solution and melt polycondensation, but yields PLA with low molecular weight. Ring-opening polymerization using metal catalysts is more common and can produce high molecular weight PLA, but the metal catalysts require removal. Recent research focuses on developing non-toxic catalysts and new polymerization conditions.
Polyethylene – its properties and uses. Polyethylene is one of the most commonly used engineering plastics. Its chemical resistance properties and ease of fabrication makes
it popular in the chemical industries. Its molecular structure provides the key to its versatility.
It's about synthesis of bioplastic. specifically about PHA and bioplastic synthesis from red algae. It was completed under guidance of Mr. Abdul Shafiullah, Lecturer SSC, Shimoga
hashim salim
hashsalim@gmail.com
Whether due to illness or injury, organ failure is a worldwide problem and its only treatment is organ transplantation or tissue replacement. Although it’s the only solution in these cases, organs demand greatly surpasses the supply. Organs are usually obtained from people who recently have died (up to 24 hours past the cessation of heartbeat) or from people who are clinically brain dead and their body functions are maintained artificially, nevertheless living organ donation is becoming more frequent [1]. The increase of the organ demand has been raising ethical concerns, since this can result in offers or incentives for donation, profit on donated human organs or even exploitation of the disadvantaged. In the developed world most countries have a legal system that oversee organ transplantation, however in poorer countries a black market has been arising, enabling those who can afford to buy organs, exploiting those who are desperate enough to sell them
It provides hopefull concepts and solutions for degradation and recycling of other degradation- resistant plastic materials.
It provides hopefull concepts and solutions for degradation and recycling of other degradation- resistant plastic materials.
It provides hopefull concepts and solutions for degradation and recycling of other degradation- resistant plastic materials.
This document discusses plastic and the bacterium Ideonella sakaiensis. It introduces common types of plastics like PET and describes properties and production of PET. It then discusses the discovery of I. sakaiensis, a bacterium able to break down PET into its monomers through two enzymes. While I. sakaiensis currently breaks down PET films slowly, its discovery could improve plastic recycling by providing a more environmentally friendly degradation process compared to chemical methods.
Effect of UV Treatment on the Degradation of Biodegradable Polylactic AcidCatherine Zhang
In this study, an alternative composting method of biodegradable polylactic acid was proposed, capable of reducing the molecular weight by over 80% in 90 minutes.
Spirulina is a blue-green microalga that is commercially produced. It has high protein content and is used as a health food and dietary supplement. Commercial production systems use large shallow ponds with controlled conditions. Geothermal energy is used in some Greek production systems to increase yields. Spirulina contains phycocyanin and polysaccharides that have antioxidant and health-promoting effects.
Biomimetics involves imitating nature to address human needs. It deals with developing innovations by studying natural structures, functions, processes and systems. Nature acts as a model. Some key points of biomimetics include mimicking nature through natural or synthetic substitutes, and studying nature's solutions to problems like the lotus plant's water resistance. Biomimetics has applications in areas like energy efficient buildings, bionic vehicles, tissue engineering and more. It is a growing field with potential for developing new materials, technologies and applications.
This document discusses characterization methods for hydrogels. Hydrogels are crosslinked polymeric networks that can absorb large amounts of water due to hydrophilic functional groups. The document outlines various physical and chemical characterization techniques to determine a hydrogel's structure, mechanical properties, porosity, water content, and chemical composition. Physical techniques include stress-strain tests, microscopy, atomic force microscopy, and mercury intrusion. Chemical techniques involve Fourier transform infrared spectroscopy, nuclear magnetic resonance, and differential scanning calorimetry. These characterization methods provide insights into a hydrogel's properties and structure-property relationships.
Starch is found in corn, wheat ,potatoes and some other plant.Plastic packaging materials perform an important role in the food industry due to their durability, lightness, and flexibility which ceramics and metals cannot provide
This document provides an overview of biomaterials, including their definition, history, examples of applications, and challenges. Key points include:
- Biomaterials are nonviable materials used in medical devices and intended to interact with biological systems. Examples include implants, prosthetics, and tissue scaffolds.
- Biomaterials have evolved from common materials like metals and plastics to more advanced engineered materials. Current research aims to more closely mimic natural tissues.
- Successful biomaterials must be biocompatible, non-toxic, and able to integrate with the body over the long term without rejection or harmful reactions. Matching mechanical properties to tissues is also important.
Presentation by John Frost, University Distinguished Professor of Chemistry, Michigan State University, at the MSU Bioeconomy Institute, Holland, Mich., Feb. 10, 2016
A bacterium that degrades and assimilates poly(ethylene terephthalate)Md. Shabab Mehebub
A new bacteria that able to breakdown and assimilates PET. It was a great discovery. We made a powerpoint presentation on that research paper. It was great challenge for us...
The document discusses biomaterials, which are materials used in medical applications that interact with biological systems. It defines biomaterials and outlines their classification as natural or synthetic. Natural biomaterials discussed include proteins, cellulose, chitin, and polynucleotides. Synthetic biomaterials include polymers like PMMA, ceramics like calcium phosphate, and metals like titanium. Common applications of biomaterials are described like implants, prosthetics, and medical devices used in the skeletal, cardiovascular, and sensory systems.
Biopolymers are polymers that can be found in or manufactured by, living organisms. These also involve polymers that are obtained from renewable resources that can be used to manufacture Bioplastics by polymerization. Bioplastics are the plastics that are created by using biodegradable polymers
The document discusses the potential uses of chicken feather fiber (CFF) as a reinforcement material in composites. It notes that the poultry industry generates a large amount of waste feathers annually. CFF has properties like low density, thermal insulation and acoustic properties that make it suitable for composites. Studies found that CFF reinforced polymer composites have increased tensile strength compared to virgin polymers. CFF has also been used successfully as reinforcement in cement composites and medium density fiberboard, utilizing an agricultural waste and improving strength. The document concludes that CFF composites could benefit the poultry industry through waste reduction while enabling applications in low-cost housing construction.
This document provides an extensive literature review on Chlorella vulgaris, a species of green microalgae. It discusses C. vulgaris's composition including proteins, lipids, carbohydrates, pigments, vitamins, and minerals. It also reviews C. vulgaris's applications, such as for food, feed, biofuel production, wastewater treatment and more. The document contains 3 tables that provide details on C. vulgaris's mineral composition, effects of unfavorable growth conditions on its fatty acid profile, and applications of its biochemical components.
Bionanocomposite materials have potential applications in food packaging due to their barrier properties and sustainability. Nanoparticles can be incorporated into biopolymers through methods like polymerization, exfoliation, and intercalation to form bionanocomposites. This improves properties such as mechanical strength and gas barrier effects compared to biopolymers alone. Bionanocomposites show promise as active packaging through inclusion of antimicrobial nanoparticles. However, more research is needed to understand potential human health risks from nanoparticle migration before wide commercial use. Regulations are being developed to ensure safety of nanomaterials used in food applications.
This document discusses the synthesis of poly(lactic acid) (PLA) biomaterials. There are two main synthetic methods - direct polycondensation and ring-opening polymerization of lactide monomers. Direct polycondensation includes solution and melt polycondensation, but yields PLA with low molecular weight. Ring-opening polymerization using metal catalysts is more common and can produce high molecular weight PLA, but the metal catalysts require removal. Recent research focuses on developing non-toxic catalysts and new polymerization conditions.
Polyethylene – its properties and uses. Polyethylene is one of the most commonly used engineering plastics. Its chemical resistance properties and ease of fabrication makes
it popular in the chemical industries. Its molecular structure provides the key to its versatility.
It's about synthesis of bioplastic. specifically about PHA and bioplastic synthesis from red algae. It was completed under guidance of Mr. Abdul Shafiullah, Lecturer SSC, Shimoga
hashim salim
hashsalim@gmail.com
Whether due to illness or injury, organ failure is a worldwide problem and its only treatment is organ transplantation or tissue replacement. Although it’s the only solution in these cases, organs demand greatly surpasses the supply. Organs are usually obtained from people who recently have died (up to 24 hours past the cessation of heartbeat) or from people who are clinically brain dead and their body functions are maintained artificially, nevertheless living organ donation is becoming more frequent [1]. The increase of the organ demand has been raising ethical concerns, since this can result in offers or incentives for donation, profit on donated human organs or even exploitation of the disadvantaged. In the developed world most countries have a legal system that oversee organ transplantation, however in poorer countries a black market has been arising, enabling those who can afford to buy organs, exploiting those who are desperate enough to sell them
It provides hopefull concepts and solutions for degradation and recycling of other degradation- resistant plastic materials.
It provides hopefull concepts and solutions for degradation and recycling of other degradation- resistant plastic materials.
It provides hopefull concepts and solutions for degradation and recycling of other degradation- resistant plastic materials.
This document discusses plastic and the bacterium Ideonella sakaiensis. It introduces common types of plastics like PET and describes properties and production of PET. It then discusses the discovery of I. sakaiensis, a bacterium able to break down PET into its monomers through two enzymes. While I. sakaiensis currently breaks down PET films slowly, its discovery could improve plastic recycling by providing a more environmentally friendly degradation process compared to chemical methods.
Effect of UV Treatment on the Degradation of Biodegradable Polylactic AcidCatherine Zhang
In this study, an alternative composting method of biodegradable polylactic acid was proposed, capable of reducing the molecular weight by over 80% in 90 minutes.
Spirulina is a blue-green microalga that is commercially produced. It has high protein content and is used as a health food and dietary supplement. Commercial production systems use large shallow ponds with controlled conditions. Geothermal energy is used in some Greek production systems to increase yields. Spirulina contains phycocyanin and polysaccharides that have antioxidant and health-promoting effects.
Biomimetics involves imitating nature to address human needs. It deals with developing innovations by studying natural structures, functions, processes and systems. Nature acts as a model. Some key points of biomimetics include mimicking nature through natural or synthetic substitutes, and studying nature's solutions to problems like the lotus plant's water resistance. Biomimetics has applications in areas like energy efficient buildings, bionic vehicles, tissue engineering and more. It is a growing field with potential for developing new materials, technologies and applications.
This document discusses characterization methods for hydrogels. Hydrogels are crosslinked polymeric networks that can absorb large amounts of water due to hydrophilic functional groups. The document outlines various physical and chemical characterization techniques to determine a hydrogel's structure, mechanical properties, porosity, water content, and chemical composition. Physical techniques include stress-strain tests, microscopy, atomic force microscopy, and mercury intrusion. Chemical techniques involve Fourier transform infrared spectroscopy, nuclear magnetic resonance, and differential scanning calorimetry. These characterization methods provide insights into a hydrogel's properties and structure-property relationships.
Starch is found in corn, wheat ,potatoes and some other plant.Plastic packaging materials perform an important role in the food industry due to their durability, lightness, and flexibility which ceramics and metals cannot provide
This document provides an overview of biomaterials, including their definition, history, examples of applications, and challenges. Key points include:
- Biomaterials are nonviable materials used in medical devices and intended to interact with biological systems. Examples include implants, prosthetics, and tissue scaffolds.
- Biomaterials have evolved from common materials like metals and plastics to more advanced engineered materials. Current research aims to more closely mimic natural tissues.
- Successful biomaterials must be biocompatible, non-toxic, and able to integrate with the body over the long term without rejection or harmful reactions. Matching mechanical properties to tissues is also important.
Presentation by John Frost, University Distinguished Professor of Chemistry, Michigan State University, at the MSU Bioeconomy Institute, Holland, Mich., Feb. 10, 2016
A bacterium that degrades and assimilates poly(ethylene terephthalate)Md. Shabab Mehebub
A new bacteria that able to breakdown and assimilates PET. It was a great discovery. We made a powerpoint presentation on that research paper. It was great challenge for us...
APPLICATIONS OF PLA - POLY (LACTIC ACID) IN TISSUE ENGINEERING AND DELIVERY S...Ana Rita Ramos
Poly (lactic acid) is a thermoplastic derived from renewable resources and is at present, one of the most promising biodegradable and nontoxic biopolymers. In addition to its versatility and consequent large-scale production, PLA can be processed with a large number of techniques.
Due to its excellent mechanical properties and biocompatibility, this polymer is becoming largely applied in the biomedical field such as in tissue engineering for scaffolds and in delivery systems in the form of micro and nanoparticles. Furthermore, because it’s relatively cheap and an eco-friend, it has been considered as one of the solutions to lessen the dependence on petroleum-based plastics and solid waste problems.
In order to maximize the knowledge and development of this polymer, it is necessary to understand the material synthesis, proprieties, manufacturing processes, main applications, commercialization and its market state, which will be presented in this review.
1. Introduction
2. Poly (lactic acid)
2.1. Precursors
2.2. Synthesis
2.3. Proprieties
2.4. Processing
2.5. Biomedical Applications
2.6. Other Applications
3. Economic Potential of PLA
4. Conclusions
Biodegradable polymers break down in the body through natural biological processes. They degrade into non-toxic molecules that are metabolized and removed. Common mechanisms of biodegradation include enzymatic degradation, hydrolysis, and bulk or surface erosion. Some polymers suitable for drug delivery systems include poly(lactic acid), poly(glycolic acid), poly(caprolactone), albumin, collagen, chitosan, and dextran. These polymers can be engineered to control drug release kinetics and degradation rates.
Production of lactic acid and acidic acidTHILAKAR MANI
This document discusses the production of acetic acid and lactic acid. It provides details on:
- Acetic acid production through chemical reactions, fossil fuels, and biological processes using acetic acid bacteria. The biological process can be aerobic or anaerobic.
- Anaerobic acetic acid production is a two-step fermentation process using yeast and Acetobacter bacteria. Clostridium bacteria can also be used in anaerobic processes.
- Lactic acid is a product of carbohydrate fermentation and is produced by microbes and higher organisms during metabolism. It has various uses including in dairy and cheese production.
Plastic bottles are most commonly made from PET, HDPE, or polypropylene. The manufacturing process begins with plastic pellets being melted down and injected or blown into a mold to form preforms. These preforms are then placed in a blow mold and air is injected to expand the preform into the final bottle shape. Plastic bottles are versatile, durable, lightweight and easily recyclable. Common applications include packaging of drinks, oils, soaps and more. During recycling, bottles are sorted, shredded, melted and reprocessed into new plastic products.
Biopolymers can be divided into three categories based on their origin and production:
1) Polymers directly extracted from biomass like starch and cellulose
2) Polymers produced from biobased monomers through chemical synthesis like polylactic acid
3) Polymers produced by microorganisms or genetically modified bacteria like polyhydroxyalkanoates
Common biopolymers include starch, polylactic acid, polyhydroxyalkanoates, and polycaprolactone. These materials have properties similar to conventional plastics but are biodegradable. Their gas barrier and thermal properties depend on material and humidity conditions. Biopolymers can be composted within weeks to months depending on
This document provides a pre-feasibility report for a proposed biodegradable plastic bag manufacturing plant using PLA. Key points:
1) The report outlines the market potential and growing demand for biodegradable plastics due to bans on single-use plastics. The global biodegradable plastics market is expected to reach $6.12 billion by 2023.
2) PLA is described as the most common biodegradable plastic polymer used in bags and packaging. The report provides details on raw material requirements, manufacturing process, expected production capacity, and machinery needed.
3) Licensing requirements, project components, costs, and SWOT analysis are discussed to help potential entrepreneurs evaluate
Production of Bioplastic Film using Biodegradable Resin, PLA (Polylactic Acid)Ajjay Kumar Gupta
Production of Bioplastic Film using Biodegradable Resin, PLA (Polylactic Acid). Biodegradable Film Manufacturing Business - Sustainable Alternative to Plastics
Bioplastic is a biodegradable material that come from renewable sources and can be used to reduce the problem of plastic waste that is suffocating the planet and polluting the environment.
These are 100% degradable, equally resistant and versatile, already used in agriculture, textile industry, medicine and, over all, in the container and packaging market, and biopolymers are already becoming popular in cities throughout Europe and the United States for ecological reasons: they are known as PHA.
Advantages of Bioplastics:
• They reduce carbon footprint
• They providing energy savings in production
• They do not involve the consumption of non-renewable raw materials
• Their production reduces non-biodegradable waste that contaminates the environment
• They do not contain additives that are harmful to health, such as phthalates or Bisphenol A
• They do not change the flavor or scent of the food contained
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Contact us:
Niir Project Consultancy Services
An ISO 9001:2015 Company
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
Production of Biodegradable Plastic Films, Production of Biodegradable Plastic Packaging Film, Production of Bioplastic Products, Bioplastic Production, Bioplastic Film for Food Packaging, Production of Bioplastic, Bioplastic Manufacturing Process Pdf, Bioplastic Production Process, Bioplastic Production PPT, Bioplastic Manufacturing Plant, Biodegradable Plastic Manufacturing Process, Film Production from Bioplastics, Bioplastic Film Production, Bio Plastic Films, 100% Recyclable & Biodegradable Plastic Film, Bioplastics Film, Bioplastics Industry, Bioplastics Industry, How to Start a Biodegradable Plastic Manufacturing Company? Applications of Bioplastics, Compostable Bioplastic Manufacturing, Biodegradable and Compostable Alternatives to Conventional Plastics, Biodegradable Plastic, Bioplastic Production, Project Report on Compostable Bioplastic Manufacturing Industry, Detailed Project Report on Compostable Bioplastic Manufacturing, Project Report on Bioplastic Film Production, Pre-Investment Feasibility Study on Bioplastic Film Production, Techno-Economic feasibility study on Bioplastic Film Production, Feasibility report on Compostable Bioplastic Manufacturing, Free Project Profile on Bioplastic Film Production, Project profile on Bio plastic Film Production, Download free project profile on Compostable Bioplastic Manufacturing, Corn Starch Bioplastic Film, Bioplastic film compounds, Bioplastic Films Replacing Conventional Plastic Films
The bioplastics market in the Netherlands is growing rapidly, though it still accounts for only 1% of the total plastics market. Analysts predict the bioplastics market will grow 400% from 2012-2017. Bioplastics growth is highest in packaging and consumer electronics. Major companies like Coca-Cola and Ford are increasingly using bioplastics due to social pressure to use more sustainable materials. While bioplastics production costs remain higher than petroleum plastics currently, the gap is decreasing and bioplastics are projected to capture up to 4% of the total plastics market by 2030 as production shifts to Asia and South America.
Bioplastic Carry Bags and Garbage Bags Production. Biodegradable, Compostable and Eco-Friendly Carry Bags and Trash Bags Manufacturing Business
Polyethylene is one of the most common forms of plastics used in protective packaging materials. As biodegradable bags are introduced onto the market, polyethylene can soon be completely replaced. Biodegradable bags are typically made out of cornstarch and other natural materials.
The use of biodegradable plastic could come in easily for the use of carrying goods rather than as a primary package. A wider use of such bio degradable materials will make them commercially viable.
Compostable plastic bags dominate the market for biodegradable plastics in Europe. They not only carry goods and biowaste but also the hopes of the bioplastics industry for huge markets in years to come.
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https://goo.gl/YCz7Bu
https://goo.gl/EaPVp1
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Contact us:
Niir Project Consultancy Services
An ISO 9001:2015 Company
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
Production of Bioplastic Products, Bioplastic Carrier Bags, Biodegradable Bags, Production of Bioplastic Bag, Bio plastic Carrying Bag, Production Process of a Bioplastic Carrying Bag, Biodegradable and Eco-Friendly Bioplastic Bags, Biodegradable Carry Bags, Biodegradable Plastic Bags Manufacturing Process, Bioplastic Bags, Bioplastic Bags Production, Biodegradable Plastic Manufacturing Process, Biodegradable Plastic Bag Manufacturing Unit, Manufacturing Process of Biodegradable Plastic Bag, Bio plastics and Biodegradable Plastics, Bio-Plastic Production, Biodegradable Plastic Bag Making Business, Biodegradable Plastic Bags Manufacturing Process Pdf, Biodegradable Plastic Bags Project Report, Biodegradable Plastic Bags Manufacture in India, How to Make Biodegradable Plastic Bags, Bioplastic Bags Manufacture, Biodegradable Plastic Production, Project Report on Biodegradable Plastic Bag Manufacturing Industry, Detailed Project Report on Biodegradable Plastic Bag Manufacturing, Project Report on Bio plastic Bags Production, Pre-Investment Feasibility Study on Bioplastic Bags Production, Techno-Economic feasibility study on Biodegradable Plastic Bag Manufacturing, Feasibility report on Biodegradable Plastic Bag Manufacturing, Free Project Profile on Bioplastic Bags Production, Project profile on Biodegradable Plastic Bag Manufacturing, Download free project profile on Biodegradable Plastic Bag Manufacturing, Production of biodegradable plastic, Production of Biodegradable and Compostable Bags, Eco Friendly Bag Making Business, 100% Organic, Biodegradable and Eco-Friendly Bags, Compostable and Biodegradable Bags Manufacturing, Eco-Friendly Sustainable Trash Bags
Bioplastics technologies & global marketslinda3395
This document provides a summary and market analysis of the bioplastics industry from 2010 to 2015. It finds that the use of bioplastics grew significantly over this period, reaching 571,712 metric tons in 2010, and is expected to increase at a 41.4% compound annual growth rate to 3,230,660 metric tons in 2015. North American usage is projected to increase at a 41.4% rate to 1,459,040 metric tons in 2015. European usage is estimated to grow at a 33.9% rate to 753,760 metric tons in 2015. The report analyzes the bioplastics market by resin type and application, and profiles major industry suppliers.
Occams Business Research has done an in-depth study on the Global Polylactic Acid Market outlining opportunities across the globe and a forecast of the revenues in the PLA Market through 2021.
In this report NanoMarkets analyzes and quantifies the business opportunities available for bio-plastics in the polymer industry and along with it, discusses their applications. We also discuss the major players in the bio-plastic space and also identify the latest trends in bio-plastics. Apart from examining the market share region wise, we have highlighted the market share based on the major types of bio-plastics.
Bioplastics from Biogas - A View of Current CapabilitiesPack2Sustain, LLC
Anaerobic digestion is emerging as a way to generate sustainable energy from food waste while also addressing the issue of food waste. The global market for anaerobic digesters was nearly $4.5 billion in 2013 and is projected to reach $7 billion by 2018. Research is exploring using biogas from anaerobic digestion as a feedstock for producing bioplastics in a closed resource loop. Studies have shown the technical feasibility of generating bioplastic resins from biogas and current companies are implementing this approach.
Global and china biodegradable plastics industry report, 2010ResearchInChina
This report analyzes the global and Chinese biodegradable plastics industries. It focuses on market segments like starch-based plastics, PLA, PHA and PBS, projecting the starch industry will increase production capacity by 212.6% by 2013. It also highlights the operations and development strategies of 10 major companies in these industries.
NNFCC Market Review bio based products issue thirteen april 2013NNFCC
The document is an issue of the NNFCC Market Review from April 2013. It provides highlights and summaries of recent news and developments in the bio-based products industry. Specifically, it discusses Pirelli signing an agreement to research guayule-based rubber as an alternative to existing rubber sources. It also summarizes several companies working with tyre makers to develop rubber from bio-based isoprene. Additionally, it provides updates on capacity projections for various bio-based polymers increasing significantly by 2020 and a commercial-scale lignin plant opening in the US.
This document summarizes recent developments in the biopolymers industry. Major points include:
- Procter & Gamble plans to use sugar cane-based plastics for packaging of brands like Pantene and Covergirl starting in 2011.
- OPXBIO has accelerated development of a commercial process for producing bioacrylic from renewable resources, reducing production costs by 85% toward a target of $0.50 per pound.
- PolyOne's colorants and additives have received OK Compost certification, making them the first in the industry to receive this certification for a full range of products.
- A new flame-resistant polylactic acid profile has been added by Keller Plast
Production of Bioplastic Products. Biodegradable and Bio-Plastics Products Ma...Ajjay Kumar Gupta
Production of Bioplastic Products. Biodegradable and Bio-Plastics Products Manufacturing Business. Glasses, Plates and Bags Manufacturing Project.
India is the third largest plastic consumer in the world, with a total consumption of plastics of about four million tons and a resulting waste production of about two million tons. Bioplastics are those plastic materials that are manufactured by using natural resources. There are two categories of these plastics available in the market — biodegrable bioplastics and non-biodegradable bioplastics.
Demand for bioplastics is increasing since past decade due to growing awareness concerning environmental conservation, use of bio-based or natural resources for manufacturing materials and formulation of various regulations across countries for effective use of natural resources and waste management.
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Biodegradable Plastic Pellets Manufacturing Industry. Bioplastics Production Business
Biodegradable plastics are plastics that can be decomposed by the action of living organisms, usually microbes, into water, carbon dioxide, and biomass. Biodegradable plastics are commonly produced with renewable raw materials, micro-organisms, petrochemicals, or combinations of all three. But it turns out that the promise of biodegradable plastic may be too good to be true.
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Each month we review the latest news and select key announcements and commentary from across the biobased chemicals and materials sector including biodegradable and compostable plastic
Production of Polypropylene (PP) and their Products. Polypropylene Multifilam...Ajjay Kumar Gupta
Polypropylene is a thermoplastic polymer that is used in a variety of applications. It is made from propylene monomers and can be processed using various thermoplastic methods like extrusion, injection molding, and blow molding. The document discusses the properties and manufacturing of polypropylene, as well as providing an outlook on the market and demand for polypropylene in India. It analyzes factors driving demand and provides a feasibility analysis for starting a polypropylene manufacturing business.
What are the underlying biases and preconceived notions that we have about the products labelled "bio" or "green"? Are there other “bio”s that we need to be wary of?
Dr Jem's talk will cover bioplastics from a holistic perspective, with a focus on: types of bioplastics, pro's and con's of PLA, how is PLA 'industrially' recycled or composted, innovations in the bioplastics world, other plant-based packaging alternatives, etc.
Dr. Jem received his Ph.D. and 2 Masters degrees in biochemical engineering, and numerous awards in the USA, and worked 15 years in engineering, biotech, and pharmaceutical companies such as Ratheon, Serono, Diversa, with excellent track record with multiple awards. In 2000, he moved back to China to work for biotech and bioplastic companies such as Cargill and NatureWorks PLA. He has served as the China General Manager for Total Corbion PLA JV and previously for Corbion Purac since 2007, and serves as a Visiting Professor for several local Universities.
NNFCC market review bio based products issue one april 2012NNFCC
This document provides a summary of the latest news and announcements from the global bio-based chemicals and materials sector for April 2012. Key highlights include: the bioplastics market is expected to triple by 2015; major bioplastics companies are investing in developing Asian markets; and a number of partnerships have been announced to develop new bio-based polymers, chemicals, and materials. Commodity prices for crops and crude oil increased significantly compared to the previous year.
The document provides details about a business plan submission for a startup called Plastaro in the healthcare sector. Plastaro aims to manufacture biodegradable plastics as alternatives to traditional plastics which are used for medical disposables. Their products include a water-soluble and biodegradable bioplastic, PLA, and PHA, which can be used for items like surgical sutures and food packaging. The startup will require Rs. 33.6 lakhs in funding which will cover operational costs for one year. Key areas of expenditure include raw materials, R&D, marketing and distribution. The business model involves direct marketing and sales to healthcare facilities to promote sustainable waste management solutions.
The document discusses polyhydroxybutyrate (PHB), a type of bioplastic polymer produced by bacteria as energy storage. It provides background on the discovery of PHB, describes the bacterial production process using excess carbon sources, and lists some common PHB-producing bacteria. The document also outlines the physical and chemical properties of PHB, compares it to other bioplastics and conventional plastics, and discusses current and potential applications. In conclusion, it addresses that while bioplastics are generally more expensive than regular plastics, the environmental benefits and developing technologies could make their costs more competitive over time.
4. 3
Design Problem
Plastics are an integral part of society in that they are used in a variety of things such as
packaging, water bottles, machinery, and a lot more. Traditionally, plastics have been made
from refining crude oil. The production of plastics from this route accounts for over 99% of
plastic production in industry [1]. With the availability of crude oil, we have had the resources
to produce plastics at such a high level that society depends on the use of plastics. Since there is
a finite amount of crude oil available to us now and the price of crude oil has increased
significantly since we started producing plastics, it is important that we can find a way to keep
making plastics sustainably without tapping out the crude oil supply.
People nowadays are becoming more aware of the deteriorating environment, and the fact that
plastics are currently not really biodegradable doesn’t help with this situation. According to
CNN.com, it is projected that there will be more plastics than fish in the ocean by the year 2050
[2]. This has become alarming to people and it is clear that we need to find another way to
produce plastics that is not only sustainable, but also better for the environment.
The goal here at Orange Polymers is to develop a process to create bio-plastics at a large scale
and to determine the feasibility of this process. The process is determined as feasible if a 10%
initial rate of return can be achieved. The research team has decided to use polylactic acid,
commonly known as PLA, to use in the bio-plastic production process and will do so using ring-
opening polymerization. More specifically, poly L-Lactic acid was chosen due to its high
melting point which will allow it to be used in the production of several different plastic
production processes without melting. Polylactic acid can be produced from lactic acid which
can be fermented from raw materials such as corn, wheat, and barley. Our team is going to
evaluate this process using corn as a raw material while keeping in mind the risks of doing so.
5. 4
Market Analysis
The US market for bio-plastics seems to be growing over the next few years as can be seen in
Figure 1 below.
The revenue for the bio-plastics market has been increasing at a rate of 6.6% since 2005 and is
predicted to reach revenues of around 179.2 million USD [3].
There are several factors that drive the growth of this market. These factors also ensure that the
market will continue to grow over the next few years. In the past, the abundance of crude oil led
us to manufacture plastics that are used in many products. But as the supply of crude oil
diminishes, new sources are needed to match the demand for plastics. Also, with the decrease in
crude oil, the price per barrel has increased causing industries to lose profits. In order to increase
profits, these industries must find cheaper raw material, which can be satisfied by biomass.
80
100
120
140
160
180
2005 2007 2009 2011 2013 2015 2017 2019
Revenue(million$)
Year
Figure 1. Bio-plastics annual Revenue (graph derived using data from
www.ibisworld.com)
6. 5
A rise in environmental awareness has also helped in the growth of the market. Many
companies have switched to using packaging made from bio-plastics in order to be more
environmentally friendly. Since these plastics are biodegradable, there will be less waste and
less space needed to dispose of these plastics. Large Companies like Coca Cola and PepsiCo
have also begun using bio-plastics bottles to hold beverages. This helps companies look more
environmentally friendly and attract more customers.
Stronger economic conditions also help grow the market. As more products are sold, more
packaging is needed; hence more plastics will tend to sell as well.
Research and Development expenditure is predicted to increase slowly as well which will help
introduce new technologies and produce better products.
Figure 2 shows the 2014 usage of bio-plastics. Most of it is used in packaging and bottling of
beverages. These trends will depend on beverage companies and the strength of the economy.
The ‘other’ section includes agriculture, catering, consumer products, pharmaceutical and
Figure 2. Usage of Bio-plastics (2014) (from
www.ibisworld.com)
7. 6
construction markets. The transport sector includes plastics needed for automotive
manufacturing.
The major competitors of polylactic acid in the US are the Dow Chemical Company, and
NatureWorks LLC. NatureWorks is a company that primarily deals in products manufactured
using biopolymers and holds an 11.2% market share (2014). They produce serviceware, textiles,
bottles, packaging, films and apparel from bio-plastics. Dow Chemical is a multinational
company that deals with chemicals, plastics, agriculture and several other fields. They have also
entered the bio-plastic market [3].
For polylactic acid, in 2013 NatureWorks had a 45.2% market share which accounted for all
polylactic acid production, which comes out to an annual capacity of 150,000 tons. Based on
these values, the total polylactic acid production was 320,000 tons. Six major manufacturers
account for 90% of the global total production of polylactic acid [4]. We find it realistic to be
able to make approximately 20,000 tons of PLA each year. Based on 2013’s values, once we
add in our share of the market to the 320,000 tons produced globally, our production would
account for 5.9% of the market.
Corn will be used as a raw material in this process to produce lactic acid, which will further be
processed into polylactic acid. Due to a surplus in corn yield, the price of corn has reduced to
around 3.20 USD per bushel, the lowest in the past 9 years [5].
8. 7
Thus we can conclude that corn will be a cheap raw material to use in the production of
polylactic acid to maximize profits.
If we are to tap into the bio-plastic market, it must be done as soon as possible. There is a low
concentration of companies that deal with bio-plastics, as it is a fairly young market. But with
time, more companies are realizing the potential of bio-plastics and will try to enter the market.
The main barrier to enter the market is the high costs of hiring appropriately skilled personnel to
conduct the production. Producers must also spend large sums on processing equipment and
storage tanks. Currently there is also high competition in the market. Firms compete over
pricing, quality and skilled personnel.
Figure 3. Price of corn per bushel (2015) [3].
9. 8
Currently 44.0% of corn is used in biofuel and biopolymers. If the usage of bio-plastics
becomes popular, then more corn will be required to meet this demand. This demand may not be
able to be satisfied, as most of the corn is needed for livestock or food. Hence if the market
expands too much, there might be a sharp decrease in supply of raw materials. However, if the
production of plastics can transfer completely to bio-plastics, then the amount of corn that is
currently used in the production of polymers can be reallocated towards bioplastics, which
would help save some of the corn supply.
Polylactic Acid Processing Technology
Polyactic acid or more commonly known as PLA is a polymer with a broad range of
applications. Due to PLA’s ability to be crystallized, modified and processed in a vast range of
processing equipment it is a widely used plastic. Uses for PLA range from transparent films,
injection molding and food packaging. This polymer also has many environmentally friendly
properties. One of the materials used to make this polymer, lactic acid, is a renewable resource
[6].
Figure 4. Corn usage in percentage of revenue.
10. 9
Polylactic acid can be produced through the condensation of lactic acid and the polymerization
of the cyclic lactide dimer shown in Figure 5.
Figure 5. Polymerization to polylactic acid [6].
With the formation of Cargill Dow LLC, a low cost continuous process had been developed in
the 90’s. This process allows for the production of PLA through lactide and a prepolymer.
Firstly, lactic acid is fermented from dextrose and condensed to produce the PLA prepolymer.
Then, the prepolymer is converted into lactide isomers through the use of a catalyst to increase
reaction rate. Finally, the lactide is purified through distillation and the PLA is produced
through a ring-opening in a melt as seen in Figure 6.
11. 10
Figure 6. Process to prepare polylactic acid [6].
The above method is called ring-opening polymerization (ROP) and is used to create PLA to be
used in a wide variety of applications from biomedical to food industries. The ROP method can
be better visualized using Figure 7 showing the organic chemistry involved in ring-opening
polymerization [7]. PLA provides great properties at a low price it can be produced more using
this method with a given amount of fossil fuel then petrochemical plastics [6].
12. 11
Figure 7. PLA synthesis methods [7].
An alternative method to producing PLA is through the condensation of lactic acid. However,
this allows for an equilibrium reaction, which creates trace amounts of water, causing problems
with the desired molecular weight [6]. Thus, the ROP method is the most efficient method for
the production of a high molecular weight polylactic acid polymer.
Process Description
The plan for processing poly L-lactic acid (PLLA) involves taking the starch from corn and
hydrolyzing it into dextrose, fermenting dextrose into lactic acid, polymerizing the lactic acid
into a prepolymer while removing water from the polymer, then depolymerizing the prepolymer
into L-Lactide which uses ring-opening polymerization to create PLLA. Hydrolyzing the starch
into dextrose can be done in a three step process. The starch granules can be mixed with cold
water at a mole percentage of 35% starch in water. This creates a fairly neutral compound
(pH=6.5) to make a starch slurry. The first process step is the gelatinization of the starch which
is the swelling of the starch granules through the use of heat and water at approximately 105°C
for about 5 minutes. Through this process, we create a starch gel as the starch loses its
13. 12
crystallinity. This gel can then be attacked by enzymes. The gel is a very thick solution so using
bacterial α-amylase is necessary to hydrolyze the starch into dextrin. This process step is
liquefaction that makes the dextrin solution which has a much lower viscosity than the starch
gel. This can be run at 95°C for 2 hours and not only does the solution have a lower viscosity,
but it also has a lower molecular size substrate. A smaller substrate allows glucoamylase, the
enzyme for the third process step of saccharification, to hydrolyze the dextrin into D-glucose
(Dextrose) [8]. The saccharification process takes 72 hours when run at 60°C.
Once we have Dextrose, it must be fermented using bacteria in order to make L-Lactic acid. The
bacteria that will be used is lactobacillus bulgarics as it has a high L-Lactic acid yield of 98.8%
and glucose is assimilative in this bacteria. The fermentation process will take three days to run
and will be run at approximately 30°C as fermentation bacteria survives best in a temperature
range of 5-45°C along with slightly acidic conditions (pH 5.5-6.5) [9].
After the Dextrose is fermented into L-Lactid acid, the lactic acid can be sent into a mixer with
a feed of ammonia. The purpose of this ammonia feed is to purify the L-Lactic acid into an
ammonium lactate which will be used in the next process which is esterification. During
esterification, butanol is mixed with the ammonium lactate. The products of this reaction are
ammonia, water, and a lactate ester, which in our case is butyl lactate. The ammonia can be
recycled back into the ammonia tank to be used for purification again and the water also get
recycled into a tank of water that can be recycled back to the fermentation process.
The next step of the process is to convert the butyl lactate into a prepolymer. For this process,
we are going to do so through the use of stepwise heating to polycondense the butyl lactate. The
stepwise heating will take place through five condensers. Each condenser will be run at a higher
temperature than the last with the first condenser being run at 135°C and the fifth condenser
14. 13
being run at 200°C. Within each of the five condensers, the pressure is being decreased down to
5 mmHg while the temperature is being held constant. The purpose of using more condensers at
increasing temperatures is to remove any water that may still be in solution with the butyl
lactate. The water retained from this process is recycled into a water tank and can also be
recycled back to the lactic acid fermentation process. Butanol is also removed from this process
and can be sent back into the butanol tank that was used for the esterification process of
ammonium lactate to butyl lactate. The product of the polycondensation process that we are
most concerned with getting is a low molecular weight PLLA prepolymer. A metal catalyst is
used during this process in order to reduce the reaction time and to improve the selectivity of the
prepolymer [9]. We need to use a metal catalyst that will be able to be used in reaction
conditions of 200°C and 5 mmHg as these are the conditions of the last stage of the process.
Sodium hydroxide will be used and applied at a .01 wt% with respect to the lactate entering the
condensers.
Polymerization and depolymerization occur simultaneously. The polycondensing process is a
polymerization process to create the prepolymer, but in order to produce L-Lactide from the
PLLA prepolymer, we must depolymerize it. The same catalyst, NaOH, can be used in lactide
production which will also occur at 200°C and 5 mmHg. For this reaction, there is a ring-chain
equilibrium between L-Lactide and the prepolymer. To produce the lactide, depolymerization
occurs through a back-biting mechanism that involves the –OH terminals of the prepolymer as
shown below
15. 14
Figure 8. Back biting mechanism of prepolymer to create L-Lactide [10].
After the depolymerization of the prepolymer, crude L-Lactide is produced. In order to perform
ring-opening polymerization on our lactide, we must purify the lactide first. This will be done
through the use of a distillation column. The distillation column must operate at a temperature
that will boil out the pure L-Lactide [11]. With the distillation column running at atmospheric
pressure, the temperature of the column will be set to 150°C in order to create a purified lactide
as high boiling bottoms steams to separate out of the column to use for the ring-opening
polymerization to create PLLA.
Ring-opening polymerization (ROP) is the most used and the best way to produce polylactic
acids. Direct polycondensation reaction does create PLA, but it yields low molecular weight
polymers which limits its applications [9]. The advantages to ring-opening polymerization is the
high reactivity and selectivity with low impurity levels. The typical operation temperature for
ROP is a temperature range of 180-210°C, so for this process, a temperature of 200°C will be
used. Tin (II) bis-2-ethylhexanoic acid, otherwise known as tin octoate, will be used as the
catalyst for ROP. A residence time of 2-5 hours is optimal for this process in order to achieve a
95% conversion to poly-L-lactic acid. After ring-opening polymerization, a PLLA-tin octoate
complex is formed and all of the unreacted lactide can be sent back to the ROP reactor. The
problem with this is that the tin octoate can cause processing degradation, hydrolysis, and/or
toxicity [9]. The separation of the catalyst from the PLLA can be done by reaction by sulfuric
16. 15
acid by precipitation. The sulfuric acid will break the tin octoate away from the PLLA and will
be reduced to 10 ppm or less in order to make as pure PLLA as possible. This improves the
quality for end-user applications. The PLLA, tin octoate, and sulfuric acid can be sent to a
separator and the sulfuric acid will get recycled back to the mixer where it was used on the
PLLA-tin octoate and the tin octoate can be recycled back to the ROP reactor to be used as a
catalyst again. Pure PLLA is in the final product stream.
Polylactic acid itself has some open issues. First, PLA is not a good use for mechanical
performance applications as it is a very brittle material, with not a lot of elongation. If it is easy
to break, it will not perform well in mechanical uses. Second, there is a slow rate of degradation
of PLA’s ester groups through hydrolysis, meaning the process would take a long time and
would make applications like food packaging much more difficult. Despite these drawbacks,
researchers have been looking into different ways to modify polylactic acid in a way that PLA
can be used more effectively in the bioplastics industry [12].
Health and Safety
In all chemical processes there is always the concern about health and safety. There are federal
and state regulations that govern processes and what can be produced. The team will be using
dextrose extracted from corn to run through a fermentation process to get lactic acid. According
to the Occupational Safety and Health Administration (OSHA) criteria, dextrose is not
considered to contain hazardous ingredients [13]. Eye/face protection and skin protection is
needed for dextrose while respiratory and body protection are not required unless there are very
high concentrations and amounts of dextrose. The product from our process, polylactic acid has
minimal hazards when below the melting point. The main concern for polylactic acid is at high
temperatures exceeding the melting point where fumes can cause irritation to the eyes and
17. 16
mucous membranes. Good ventilation is recommended as to not permit the accumulation of dust
that can be ignited by spontaneous combustion or other ignition sources [14]. The use of safety
glasses, body covering clothing and thermal protective gloves is recommended. In order to
ensure proper safety, all workers personal protective equipment (PPE) should fall in accordance
with OSHA laws and regulations. Other considerations to take into account for worker safety is
that a safety department should oversee that all workers know proper handling on chemicals in
the plant and should have emergency protocols in case of emergencies.
Environmental Impact
With the increase of plastics found in the ocean and concerns about global warming, an
alternative to petroleum-based plastics is needed. Plastic substitutes like polylactic acid are
more favorable than petroleum-based plastics as they could be used as a biodegradable
replacement. The process of making polylactic acid in itself reduces fossil fuel resource use as
corn uses energy from the sun and carbon dioxide compared to other polymers that derive from
hydrocarbons. An environmental concern to take into account from our process is waste
management. The most common methods for treating polylactic acid waste streams include
composting, chemical recycling and anaerobic digestion [15]. In composting, polylactic acid
goes through a two-step degradation process where moisture and heat split the polymer chains
into small fragments and lactic acid. Microorganisms like fungi and bacteria consume the small
fragments and lactic acid as an energy source and metabolize carbon dioxide, water and humus.
Polylactic acid in commercial composting conditions will compost in approximately 30-45 days
[16]. Residential composting is not recommended as the degradation process is temperature and
humidity dependent; the minimum required conditions are usually not met for polylactic acid.
Chemical recycling is another form of waste management that recycles manufacturing-waste,
converter-waste or post-consumer polylactic acid materials to produce lactic acid monomer and
18. 17
oligomers through chemical means [15]. The lactic acid monomers and oligomers can be used
in the beginning of the process to produce more polylactic acid and reduce waste production.
Chemical recycling is very beneficial for our process as it recycles waste polylactic acid into
functional lactic acid at lower economic and environmental costs than if sent to an incinerator or
composting. Unused materials should be sent to an incinerator or other thermal destruction
device if other forms of waste management are not feasible [14]. For used materials, the
disposal options are the same but must list and identify all hazardous waste in accordance to
regulations. In our process, we are extracting starch from corn which is used to make polylactic
acid. This would mean a larger demand for corn, which could raise the question of genetically
modified foods and their impact to the environment and human health.
Legal Considerations
After extensive research looking for patents related to ring-opening polymerization of PLA, we
were unable to find any patents that would restrict our team from conducting our process.
United States Patent # 5,866,677 had a method and system for producing polylactic acid but
was different from our process as in their method, “lactide vapor is discharged from a
polymerization reaction vessel in which poly(lactic acid) is produced by ring-opening
polymerization, and trapped by solidification” [17]. The only similarities between the two
processes was the use of the ring opening polymerization to produce lactic acid but the use of it
was different.
Equipment Costs
For this process, we will be constructing our equipment out of stainless steel. The purpose for
this is that stainless steel is relatively cheap compared to most other metals and with the amount
of equipment that this process has, we must find a way to cut down on the costs of this overall
process. Pricing was acquired through the use of a program called CAPCOST. The costs of the
19. 18
equipment below is based on a CEPCI of 397 and the sizing of the equipment was calculated
from doing mass balances on each piece of equipment in the process and is shown in Table 1
below.
Table 1. Equipment for the production of PLLA and their respective prices.
20. 19
Based on the share of the market that our team believed to be achievable, several pieces of
equipment are very large. Reactors R-102, R-103, and R-108 are 400 cubic meters or larger. As
a result, these pieces of equipment are going to be very expensive as one can see that R-102 and
R-103 are both greater than $30 million. It would be possible to break these reactors down into
multiple smaller reactors, but the bare module cost will still be very large as it is shown in Table
1 as $125,014,300.00. Using smaller reactors may cut down on the costs a little bit, but it will
not help us overcome the massive bare module costs. For the propellers used in this process,
their costs are mostly based on the amount of power that each of them will use. Additionally,
there will be one spare propeller for each mixer in the process.
Economic Analysis and Feasibility
For our process of producing PLLA, we are assuming a two year construction period and a 10
year project life. Before we can set up the equipment for this process, we need to estimate how
much land alone is going to cost. Using the costs of land in the New York region since that is
where the production of PLLA will take place, we believe that the cost of our land will be
approximately $1.25 million. The tax rates of New York were also used for calculating the costs
of this process. The tax rate was set at 42%. In order to determine the feasibility of this process,
a cash flow diagram was created based on fixed capital investment (FCI), working capital
(WC), revenue per year, costs of manufacturing, and raw material costs.
Table 2. Costs of raw materials and revenue from selling PLLA at $8.00/kg
Material Name Classification Price ($/kg) Flowrate (kg/h) Annual Cost
Corn Starch Raw Material $ 0.25 2951.50 $ 6,140,596
Water Raw Material $ 0.00 47667.00 $ 66,114
Ammonia Raw Material $ 0.66 18358.00 $ 33,681,347
PLLA Product $ (8.00) 2071.20 $ (137,892,211)
21. 20
Based on a selling price of $8.00/kg and the share of the polylactic acid market that we would
like Orange Polymers to achieve, annual revenue for this process is about $137.9 million.
However, annual costs of raw materials also approach $40 million which will cut out a
significant portion of this process’ annual revenue. Additionally, we must take into account the
costs of manufacturing (COM). This accounts for another massive hit into the annual revenue as
our COM came out to be approximately $128 million which is a major contributing factor to the
debt our company will face based on the cash flow diagram in Figure 9 below. The costs of
manufacturing were calculated using Tables 4-6 in the Appendix.
Figure 9. Cash flow diagram for the production of PLLA.
This cash flow diagram was created using a selling price of PLLA at $8.00/kg which is already
significantly higher than the competitive market price. As one can see, the company would be
experiencing around $280 million in debt 10 years after construction. The two biggest reasons
for this are the costs of manufacturing and the initial capital investment that would be required
22. 21
to make this exact process work. Our process uses a lot of equipment and even though it will be
made using a relatively cheap material, it does not help the company save much money. A
constraint of an internal rate of return of 10% was given to us by the company. From the
CAPCOST calculations, the annual rate of return of this process is -4.39%. Putting this value up
against the company’s standards, this process is not feasible. Based on the trendline shown after
the first two years for construction, this process would end up breaking even around 25 years;
however, by that time, the equipment has already been replaced at least twice which would lead
to an even larger capital investment for this process.
Conclusion
The research team here at Orange Polymers have decided to investigate the ring-opening
polymerization of L-Lactic acid in order to produce poly-L-lactic acid for bioplastics. In a more
environmentally conscious world that we currently live in, it is becoming necessary to find a more
environmentally friendly way to produce plastics than we currently do. Current plastics made out
of crude oil are not biodegradable so they get disposed of in multiple ways, particularly in the
ocean. Also, with a finite amount of oil, it will become necessary that we need to produce plastics
in a different way in order to preserve the amount of crude oil that we have.
We plan to produce PLLA through the use of corn starch that we will buy off of the market
where lactic acid can be produced from the dextrose that can be extruded from the starch of
corn. 44% of the corn supply is currently being used in the production of biofuels and polymers.
If we are able to reallocate the corn being used in polymer production to be used for bioplastics,
it will be possible to use corn as a sustainable resource in the production of PLLA.
Technologically, this process is possible as it is already a process that takes place. Dextrose is
extracted from corn starch and is then fermented into lactic acid. The lactic acid condenses into
23. 22
a prepolymer that is then depolymerized into crude L-Lactide. The crude L-Lactide that is
formed gets sent to a distillation column for purification. The pure lactide that comes as a result
of the distillation is then run through ring-opening polymerization to create poly L-Lactic acid.
Any monomers that aren’t converted into PLA are sent back through the process.
With regards to health, producing PLA is not very concerning because it has a very high melting
point, and when PLA is below its melting point, it is not hazardous. The biggest concern with
this process is the emission of greenhouse gases; however, the production of polylactic acid can
cut down greenhouse gas emissions in comparison to the production of current hydrocarbon
based plastics. Additionally, dextrose does not contain hazardous ingredients. PLA is also
better for the environment because it is biodegradable, and all unconverted monomers can be
reused in the ring-opening polymerization process to minimize waste. Legally, there will not be
any issues because the only patent our team could find after extensive research regarding the
production of polylactic acid was for the use of the PLA, not the ring-opening polymerization
process itself. With more research, our team at Orange Polymers will be able to determine the
feasibility of our process design.
Based on the global market from 2013, if we are able to produce 20,000 tons each year, we will
be able to achieve nearly a 6% share of the global market when it comes to PLA production. We
will only be able to have a small share of the market since we are just getting into the market
and will not be able to compete with the top PLA manufacturers yet.
Based on our team’s economic analysis using the program CAPCOST, we developed a cash
flow diagram based on equipment costs, raw material costs, fixed capital investment, working
capital, costs of manufacturing, and annual revenue. After the generation of the cash flow
diagram, it was determined that the company would face a debt of $280 million after running
24. 23
the process for 10 years. Most of this debt is due to the significantly high costs of manufacturing
and the costs of setting up the equipment. The initial capital investment is far too high for this
process to become profitable. Also, the cash flow diagram used a selling price of $8.00/kg
which is far higher than the actual market price. Even if this process were to theoretically break
even at this price, we would not be able to sell our product because our price is much higher
than competitors. This process obtained a rate of return on investment of -4.39% and we had to
determine feasibility based on an internal rate of return of 10%. Because of this and the extreme
debt that the company would face if we go through with producing poly-L-lactic acid, we have
determined that this process is not feasible and we recommend that Orange Polymers does not
explore the production of PLLA.
25. 24
References
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[2] http://money.cnn.com/2016/01/19/news/economy/davos-plastic-ocean-fish/
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[4] Tiwari, Ritesh. "Lactic Acid Market and Derivatives 2016 Forecasts." PR Newswire
Association LLC, 5 Mar. 2016. Web. 15 Oct. 2014.
[5] http://clients1.ibisworld.com/reports/us/industry/default.aspx?entid=8
[6] Henton, David. "Polylactic Acid Technology." Citeseerx. Membrane Technology, 2002.
Web. 9 Feb. 2016.
[7] Lopes, Milena S., André L. Jardini, and Rubens M. Filho. "Synthesis and Characterizations
of Poly (Lactic Acid) by Ring-Opening Polymerization for Biomedical Applications."
CHEMICAL ENGINEERING TRANSACTIONS 38 (2014): 331-36. Aidic.it. AIDIC, 2014. Web.
9 Feb. 2016.
[8] Borglum, Gerald B. Starch Hydrolysis for Ethanol Production. Web. 4 Mar. 2016.
[9] Sin, Lee Tin, Abdul Razak Rahmat, and Wan Azian Wan Abdul Rahman. Polylactic Acid:
PLA Biopolymer Technology and Applications. William Andrew. 2012. Web. 5 Mar. 2016.
[10] Kazunari Masutani and Yoshiharu Kimura, Chapter 1 : PLA Synthesis. From the Monomer
to the Polymer, in Poly(lactic acid) Science and Technology: Processing, Properties, Additives
and Applications, 2014. Web. 1 Mar. 2016
[11] “Purification Process for Lactide.” US8053584B2. Google Patents, 8 Nov. 2011. Web. 8
Mar. 2016.
26. 25
[12] Lin Xiao, Bo Wang, Guang Yang and Mario Gauthier (2012). Poly(Lactic Acid)-Based
Biomaterials: Synthesis, Modification and Applications, Biomedical Science, Engineering and
Technology, Prof. Dhanjoo N. Ghista (Ed.) Web. 9 Feb. 2016.
http://www.intechopen.com/books/biomedicalscience-engineering-and-technology/poly-lactic-
acid-based-biomaterials-synthesis-modification-andapplications
[13] "Dextrose." Safety Data Sheet. Sigma-Aldrich, 25 June 2014. Web. 9 Feb. 2016.
[14] "Technology Focus Report: Toughened PLA." NatureWorks, 1 Mar. 2007. Web. 9 Feb.
2016.
[15] Vink, Erwin T. H., Karl. R. Rábago, David A. Glassner, Bob Springs, Ryan P. O'connor,
Jeff Kolstad, and Patrick R. Gruber. "The Sustainability of NatureWorks™ Polylactide
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Macromolecular Bioscience 4.6 (2004): 551-64. Macromolecular Bioscience. Web. 28 Feb.
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[16] "Biodegradable Products FAQ." The Dalana Group of Companies Inc. N.p., 2009. Web.
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27. Appendix
Figure 10. PFD for the ring-opening polymerization process to produce poly L-Lactic acid
28. Table 3. Sizing and flows for the ring-opening polymerization to produce poly L-Lactic acid.
29. Tables 4, 5, 6. Calculations for the costs of manufacturing (COMd)
Cost of Land $ 1,250,000
Taxation Rate 42%
Annual Interest Rate 10%
Salvage Value 0
Working Capital $ 47,420,000
FCIL $ 434,200,000
Total Module Factor 1.18
Grass Roots Factor 0.50
Revenue From Sales $ 137,892,211
CRM (Raw Materials Costs) $ 39,888,056
CUT (Cost of Utilities) $ 719
CWT (Waste Treatment Costs) $ -
COL (Cost of Operating Labor) $ 158,700
Comd = 0.18*FCIL + 2.76*COL + 1.23*(CUT + CWT +
CRM)
Multiplying factor for FCIL 0.18
Multiplying factor for COL 2.76
Factors for CUT, CWT, and CRM 1.23
COMd $ 127,657,206