Biopolymers present new

market opportunities for

additives in packaging
Biopolymers are produced from renewable resources, such as
corn or starch, and are being touted as sustainable alternatives to
petroleum-based polymers.The biopolymer industry is emerging,
with new products being introduced and commercial plants
starting up, although supply is currently still limited. Jennifer
Markarian reports on the current state on the biopolymer
market and the increasingly important role of additives.

Current interest in biopolymers looking to recycling rather than composting and expects the share of bio-based and non-
is driven diversely by government as an end-of-life option. European Bioplastics biodegradable resins to increase (see Figure 1).
commitments to reduced energy use estimates that global production capacities “This trend brings biopolymers into more
and carbon dioxide emissions, corporate of bioplastics will increase from about 260 direct competition with resins such as PET,
environmental responsibility goals, and to 1500 kilotonnes from 2007 to 2011, ABS, and polystyrene, and opens up more
public sentiment for ‘going green’. In
packaging, biopolymers are a piece of
the sustainability picture, which also
includes reducing material use through
light-weighting and using alternatives
to landfilling, such as recycling or
composting.
“Sustainability is the buzz-word
throughout the packaging industry, and
people are looking for new materials to
meet sustainability goals,” says Suzanne
Carroll, Rohm and Haas packaging
marketing manager. Commercial
biopolymer use is growing in packaging,
where their ‘environmentally friendly’
image is being used by retailers to
differentiate their product.
Biopolymers were originally pushed as
biodegradable and compostable, which has
led to confusion, because while most are
degradable in industrial composting facilities,
not all are degradable in home composting.
The fact that some biodegradable polymers
are produced from petroleum-based
resins adds to the confusion. However, the
industry trend is now to emphasize ‘bio’
as in biologically-produced, renewable
Figure 1: Global production capacities of bioplastics 2007-2011. (Source: European
raw materials. Although many note that
Bioplastics)
biodegradability is still important, some are

Plastics Additives & Compounding May/June 2008 ISSN1464-391X/08 © 2008 Elsevier Ltd. All rights reserved.
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opportunities for additives to increase the been targeted primarily for PLA, since it is the polymer matrix, the mineral additive absorbs
functionality of biopolymers and to enter most widely used biopolymer, but suppliers energy and slows crack propagation, thus
new markets,” says Thomas Weigl, managing are currently testing their additives in other toughening the biopolymer. Using
director at Sukano. Additives are essential for bioresins. Suppliers of bioresin compounds, 20-30% EMforce® Bio dramatically improves
improving properties as biopolymers grow like DaniMer and Cereplast, offer compounds toughness and impact resistance, the company
not only in packaging applications but also in improved through proprietary formulations found in a joint development programme with
single-use applications such as cutlery, plates, and processing. Processors using bioresins NatureWorks LLC. It also acts as a nucleating
and cups and eventually in durable goods, can dose some types of additives directly, agent, which slightly increases crystallinity.
comments Vipul Joshi, marketing manager at or use additive concentrates. Twin-screw EMforce Bio® is fully compostable. Specialty
Specialty Minerals. compounding extrusion is typically used for Minerals is currently evaluating EMforce
Biopolymers used in packaging include dispersing additives in the concentrate. Bio® in other biopolymers such as PHA and
polylactic acid (PLA), starch-based polymers, thermoplastic starch, says Mr. Joshi.
and others, with polyhydroxyalkanoates (PHA) Arkema offers Biostrength™ core-shell impact
now being commercialized. NatureWorks
Impact modifiers modifiers to improve impact strength of PLA
LLC, a business unit of Cargill, reports that PLA and other biopolymers exhibit with 4-7% additive. Translucent Biostrength™
NatureWorks® PLA resins exhibit high gloss brittleness, which results in poor impact 130 is designed for clarity applications, while
and clarity, similar to polystyrene, tensile and tear resistance (see Figure 2). Reduced Biostrength™ 150 offers higher efficiency for
strength and modulus like hydrocarbon-based brittleness is important both for end-use and opaque applications. A higher clarity impact
thermoplastics, and a high barrier to odour for manufacturing, because brittle breaks modifier is close to introduction, says Peggy
and flavour. Drawbacks of unmodified PLA during thermoforming, for example, raise the Schipper, commercial development manager
for packaging applications include brittleness, potential for small, shattered pieces of sheet to for Arkema’s functional additives. She notes
low melt strength, and low heat deflection contaminate the packaging. PLA brittleness that although the current impact modifiers
temperature. Unmodified starch-based can be reduced by combining with starch, may not meet ASTM compostability standards
polymers have relatively good melt strength, plasticizers such as glycerol or sorbitol, or other at higher use levels, most customers seem
but can be brittle. These limitations present an degradable polyesters. For instance, BASF’s more concerned about getting the properties
opportunity for additives. Ecovio resins are a combination of PLA with they need from a renewable-resourced resin.
Ecoflex, a petroleum-based, biodegradable, In the long-term, as more polymer types
aliphatic-aromatic copolyester. Mineral and are produced from renewable resources,
Additives for biopolymers polymeric additives are also being used to polymeric impact modifier technology will
In addition to some of the traditional polymer improve impact properties. likely become renewable-resource based
additives that are being used in biopolymers, Specialty Minerals’ EMforce® Bio is a high and completely biodegradable, predicts Ms.
first-generation additives developed specifically aspect ratio, carbonate-based engineered Schipper. These impact modifiers typically do
for improving processing and properties of mineral designed to improve impact toughness not have a significant effect on heat distortion
biopolymers have been introduced, with more of amorphous and semi-crystalline PLA for characteristics.
in development. To date, new additives have opaque applications. When dispersed in the Rohm and Haas’ Paraloid™ BPM-500 impact
modifier is designed to improve impact strength
and tear resistance of PLA while maintaining
clarity. The additive uses nanoparticles that
do not scatter light, achieving less than 10%
haze at a 5% loading, reports the company.
Compostability tests are in progress, but it
is thought that the additive will not affect
compostability when used at low levels.
DuPont™ Biomax® Strong 100 for non-food
contact applications and 120 for food contact
applications are ethylene copolymers that
improve impact strength and toughness of both
amorphous and crystalline PLA with addition
of 1-5 wt.% additive. Cast sheets containing
Biomax Strong exhibit improved cutting and
trimming, can withstand repeated flexing
and exhibit increased elongation at break,
says the company. Biomax Strong also acts as
a processing aid by stabilizing PLA viscosity
Figure 2: Polylactic acid (PLA) is more brittle than other polymers.
against thermal degradation and reducing

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line breaks, says Mr. Jacobs. In foam, greater

melt strength allows development of smaller,
more resilient foam cells. “Cesa-Extend opens
up applications which have been difficult
for PLA” says Mr. Jacobs. Cesa-Extend is a
synthetic molecule supplied in a PLA carrier,
and does not affect degradability at typical use
levels of less than 2%, reports Clariant.
Arkema’s Biostrength™ 700 acrylic
copolymer improves melt strength and
enhances processability at levels of 1-4%. In
clear, thermoformed packaging applications,
the additive improves melt strength for
quicker line start-up, allows increased wall
uniformity which improves package strength,
Brittle web fracture (left) and brittle fracture of a container: Sukano's impact modifier
and maintains properties of regrind so that it
concentrate Sukano PLA im S550 can improve the impact characteristics of PLA.
can be used at higher levels. In the emerging
market of foamed PLA, Biostrength 700 allows
torque. The additive marginally reduces clarity, strength, such as blown film extrusion and production of uniform, closed cells. Because
and can be dosed directly during processing. foaming. PLA has inherently low melt viscosity, it is a non-reactive product, it offers very
Biomax Strong is not biodegradable, but and is also vulnerable to thermal, oxidative, consistent processing improvement, leading to
at low loading levels should not affect the and hydrolytic degradation, which causes lower material waste, says Ms. Schipper.
compostability of articles made with it. chain scission and a further loss of molecular Rohm and Haas is currently working on
Sukano’s patented, FDA-approved impact- weight and lower viscosity, explains Kirk Jacobs, acrylic-based melt strength enhancers for PLA
modifier concentrate, Sukano® PLA im head of Clariant Masterbatches’ additive to improve fabrication performance.
S550, improves the impact characteristics of masterbatches for North America. Clariant’s
PLA without reducing clarity, heat stability, Cesa®-Extend reconnects the polymer chains
or compostability. Using a bioresin carrier is and creates a branched network that improves
Slip, antiblocks, optical
essential for obtaining homogeneity and clarity melt strength and increases tensile strength brighteners, and others
when the concentrate is let down into the resin, properties. In film applications, a robust melt
as well as for guaranteeing compostability, says strength gives the potential for increased film PLA has high gloss and clarity, similar to
Mr. Weigl. line speed and greater productivity due to fewer that of polystyrene. However, PLA resins are
Novamont’s Mater-Bi® nanostarches,
introduced at K2007, significantly increase
impact and tensile strength while remaining
biodegradable even in household composting
environments, reports the company, which
produces a range of Mater-Bi® biopolymers
modified to suit different applications. Because
starch-based polymers are hydrophilic and
typically absorb water that acts as a plasticizer,
the polymers can become more brittle in
low-humidity environments. Nanostarch
overcomes this problem and is effective even
in low-humidity. The 100-200 nm starch
particles are functionalized to be compatible
with different matrices, pre-dispersed in various
carriers, and supplied in pelletized form for use
in various biopolymers.

Melt strength modifiers

While PLA has adequate melt strength for
sheet, its relatively low melt strength limits its PLA film with (left) and without (right) Cesa-Extend from Clariant Masterbatches.
capability in processes that require higher melt

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also inherently sticky and require slip and masterbatches and Cesa®-light UV stabilizer at ways to improve temperature resistance.
antiblock additives to improve handling, such masterbatches. Mr. Jacobs reports that Clariant NatureWorks reports that cellulose fibres
as easing de-nesting of thermoformed parts is researching Cesa®-natur masterbatches can increase the heat resistance of PLA, and
or preventing blocking in thin films. “One of that would feature not only a bioresin carrier, compatibilized starch particles added to PLA
the challenges of PLA is finding additives that but additives from natural sources. Among can reduce cost and enhance modulus and heat
do not decrease clarity. Effectiveness at low use the products being evaluated are slip additive resistance. Additives such as nucleating agents
levels is critical for maintaining clarity as well masterbatches, based on naturally occurring can give slight increases in heat resistance.
as compostability,” notes Mr. Jacobs. waxes that can produce a coefficient of friction Researchers are also looking further at fibre
Suppliers are beginning to introduce additive (CoF) in PLA films similar to that achieved reinforcement. Industry experts note that,
masterbatches with bioresin carriers to cover with synthetic waxes. Natural aromatic while additive approaches give incremental
a range of additives that bioresins can use to molecules are being studied as light-stabilizing improvements, development of polymers with
enhance performance just as traditional resins masterbatches for biopolymers or as a UV filter increased crystallinity or alloys of biopolymers
do. For example, PolyOne’s OnCap™ Bio to protect the contents inside of packaging with synthetic polymers are more likely to
Additives product line for bioresins includes made of bioplastics such as PLA. “The more we enable significant gains in heat resistance.
antistat, slip, antiblock, UV protection, and can do from natural sources, the better,” says “The biopolymer industry has a
blue-tone additive masterbatches. Sukano Mr. Jacobs, who notes that while, in general, continued need to provide a full range of
offers a portfolio of functional and optical natural materials tend to have more limitations products that meet different performance
additive masterbatches for PLA. Sukano® than synthetic materials, Clariant continues requirements. There is much space for
PLA dc S511 highly-loaded concentrate research and development efforts to obtain growth of polymers and additives of
includes slip and antiblock additives the best possible performance from natural different kinds,” concludes Catia Bastioli,
that maintain clarity, as well as an optical materials. chief executive officer of Novamont.
brightener, which is a blue-tone used to Contacts:
correct the yellowish tone of PLA. Variations Arkema
include slightly blue for Europe, strongly blue
Increasing heat resistance Tel: +1 215 419 5257
for the US, and a natural tone for packaging Improving heat distortion or heat deflection Website: www.arkema.com
products such as strawberries or for those temperatures to withstand higher processing Clariant Masterbatches Division
who want the yellowish tone of PLA. Viba and use temperatures for PLA is an area of Tel: +1 540 665 2917
introduced Vibatan PLA Blue Antiox 97838 continuing development. PLA’s low heat Website: www.clariant.masterbatches.com
masterbatch, which increases polymer thermal deflection temperature, around 50-60°C, DuPont
stability during processing and controls can cause PLA packages or bottles to deform Tel: +1 302 774 1161
yellowing caused by thermal exposure, says the during storage, as well as cause sticky pellets Website: www.biomax.dupont.com
company. in transportation and handling. PLA has European Bioplastics
Clariant also offers masterbatches using grown so far in applications that don’t require Website: www.european-bioplastics.org
conventional synthetic additives in a PLA high use temperatures, such as refrigerated NatureWorks LLC
carrier, including Cesa®-bloc antiblock food packaging, but researchers are looking Tel: +1 800 664 6436 (US)/
+31 35 699 1344 (Europe)
Website: www.natureworksllc.com
Novamont
Tel: +39 0321 6996 11
Website: www.novamont.com
PolyOne Corporation
Tel: +1 440 930 1000
Website: www.polyone.com
Rohm & Haas
Website: www.rohmhaas.com
Specialty Minerals Inc
Tel: +1 610 997 8394
Website: www.specialtyminerals.com
Sukano
Tel: +1 864 486 1478 (US)/
+41 44 786 99 37 (Europe)
Website: www.sukano.com
Viba
PLA foam tray (Photo: Clariant Masterbatches). Tel: +39 0331 816 811
Website: www.vibagroup.com

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