Polylactic Acid A Practical Guide For The Processing Manufacturing and Applications of PLA 2nd Edition Lee Tin Sin
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Polylactic Acid
PLASTICS DESIGN LIBRARY (PDL) PDL HANDBOOK SERIES
Series Editor: Sina Ebnesajjad, PhD ([email protected]) President, FluoroConsultants Group,
LLC Chadds Ford, PA, USA
http://www.FluoroConsultants.com
The PDL Handbook Series is aimed at a wide range of engineers and other professionals working in the
plastics industry, and related sectors using plastics and adhesives.
PDL is a series of data books, reference works and practical guides covering plastics engineering, applications,
processing, and manufacturing, and applied aspects of polymer science, elastomers and adhesives.
To submit a new book proposal for the series, or place an order, please contact Edward Payne, Acquisitions
Editor at [email protected]
Polylactic Acid
xiii
Preface
In recent decades, the demand for plastics has grown tremendously. The
use of plastics is unavoidable for current society. However, inappropri-
ate plastic wastes disposal has led to serious environmental pollution.
The ocean has been seriously polluted by microplastics resulting from
nondegradable polymers. Conventional petroleum-derived plastics take
more than 100 years to degrade before they are harmless substances!
Although many education campaigns have been organized to create
awareness in society through the “reduce, reuse, and recycle” (3R) pro-
gram, the response of society remains inadequate.
The elimination of plastic is impossible and the 3R initiative for plas-
tics still needs a lot more time to change consumer practices and atti-
tudes. Hence, biodegradable polymers could be an alternative to reduce
the environmental impact of plastic waste. Although there are many bio-
degradable polymers in the market, poly(lactic acid) (PLA) seems to be
the most viable polymer to substitute nondegradable petroleum-based
polymers. This is because PLA is produced on a large industrial scale at
a competitive price. PLA can also be processed using current polymer-
processing technology such as injection molding, extrusion, blown film,
thermoforming, and the currently popular 3D printing method.
In this book, PLA characteristics and applications are discussed in
depth. As compared with other books on biodegradable polymers, this
book is written to enable readers to get basic but sufficient information
about PLA before proceeding to the high-level research and develop-
ment stage. Readers are given information on PLA, including as market
demand, grades, synthesis and production, thermal properties, chemical
properties, mechanical properties, rheological properties, degradation
and stability, processing technology, injection molding and 3D printing,
environmental assessment, international standards of polymer biodegra-
dation, and applications. The authors believe that this information will
be highly useful for industrial players, educators, researchers, postgrad-
uate students, environmentalists, etc. to obtain one-stop information
source on PLA.
Finally, the authors wish to record their special thanks to Ms. Silva
Isabella for advising and assisting throughout the writing of this second
edition. The authors sincerely believe that this book can promote the
xv
xvi PREFACE
Chapter Outline
1.1 Background to Biodegradable Polymers 1
1.2 Market Potential of Biodegradable Polymers
and Polylactic Acid 11
1.3 General Properties and Applications of Polylactic Acid 28
1.3.1 Polylactic Acid for Domestic Applications 28
1.3.2 Polylactic Acid and Copolymers for Biomedical
Applications 41
1.4 Conclusion 49
References 49
most serious of these is that the plastics take time to be fully degraded
into carbon dioxide. During the early breakdown process, fragmentation
of the plastic causes soil pollution, and it can be accidentally consumed
by organisms living off the soil. Again, this has shown that a fully bio-
degradable polymer with carbon credit is crucial for a sustainable
future.
Prior to a more detailed discussion of PLA, several biodegradable
polymers will now be examined and compared with PLA, to determine
the reasons why PLA is currently the most popular among the biode-
gradable polymers. PVOH and PLA are the most widely produced bio-
degradable polymers, while other biodegradable polymers, such as
polycaprolactone (PCL) and polyhydroxybutyrate (PHB), are produced
in small quantities on a the laboratory scale or at pilot plants. In 2006
the world production of PVOH reached over 1 million metric tons (MT)
per annum. However, PVOH is a petrochemical-type biodegradable
polymer. The major markets for PVOH are textile sizing agents, coat-
ings, and adhesives. Only a limited amount of PVOH is made for pack-
aging applications. The main reason for this is the hydrophilic behavior
of PVOH. Prolonged environmental exposure causes PVOH to absorb
moisture extensively. There are hydrolyzed and partially hydrolyzed
forms of PVOH. Both types of PVOH are soluble in water, and the sol-
ubility temperature of hydrolyzed PVOH is higher. The major producer
of PVOH is Kuraray, in the United States, which is responsible for
almost 16% of the world’s production. China still produces the most
PVOH, accounting for 45% of global output.
In the early 1800s PLA was discovered when Pelouze condensed lac-
tic acid through a distillation process of water to form low-molecular-
weight PLA. This is the early polycondensation process of lactic acid to
produce low-molecular-weight PLA and lactide. Lactide is a prepoly-
mer or an intermediate product used for the transformation to high-
molecular-weight PLA. This polycondensation process produces low-
yield and low-purity PLA. Almost a century later, the DuPont scientist
Wallace Carothers found that heating of lactide in a vacuum produced
PLA. Again, for high-purity PLA this process is not feasible on an
industrial scale due to the high cost of purification, which limits it to
the production of medical-grade products, such as sutures, implants, and
drug carriers. The ambitious company Cargill has been involved in the
research and development of PLA production technology since 1987,
and first set up a pilot plant in 1992. Late, in 1997, Cargill and Dow
Chemical formed a joint venture named Cargill Dow Polymer LLC to
further commercialize PLA. Their efforts have been fruitful, with the
1: OVERVIEW OF BIODEGRADABLE POLYMERS AND POLY(LACTIC ACID) 5
2500
2000
1500
1000
500
0
1975
1976
19 7
1978
19 9
19 1
1972
19 3
19 4
1981
1982
19 3
1984
1991
19 2
1993
20 1
2002
2003
20 0
2011
20 2
20 3
1994
19 0
19 9
1990
2000
2009
19 5
19 6
1987
1988
19 5
1996
19 7
19 8
2099
20 4
2005
20 6
20 7
2008
2014
2015
20 6
17
7
7
7
7
7
1
1
8
8
8
8
9
9
0
0
1
19
Year
Figure 1.2 Research publications on PLA for 1971 2017 (47 years).
120,000 109,437
Intellectual properties
100,000
80,000
53,051
60,000
40,000
14,753 14,683
20,000
675
0
USPTO JPO WIPO EPO UKPO
Figure 1.3 Number of patents published about PLA. EPO, European Patent
Office; JPO, Japanese Patent Office; UKPO, United Kingdom Patent Office;
USPO, United States Patent Office; WIPO, World Intellectual Property
Organization.
Chemical
Polymer Composition Producer Applications Biodegradability
PCL DURECT Corporation: Lactel Ethicon-Monocryl: Suture .12 months
Daicel Chemical Industry: Capronor: Contraceptive implant
Celgreen Agrotec:Agrothane: Paint and
Union Carbide Corporation: TONE metal protection film
Solvay Group: CAPA
Purac: Purasorb PC 12
Polyglycolide or PGA Purac: Purasorb PG 20 Dolphin: Petcryl: Sutures .3 months
Teleflex Incorporated Bondek: Sutures
Kureha Corporation Dexon: Sutures
DemeTech: Sutures
Polyhydroxyalkanoate, Metabolix/ADM: Telles Mirel Compost bags 3 12 months
PHB, and PHBV Ningbo Tianan Biologic Material: Consumer packaging
(PHB) Enmat Agriculture/horticulture film
Copersucar: Biocycle Rubbermaid, Calphalon,
Biomer: Biomer PaperMate
BioTuf
(PHV) EcoGen
PDO Ethticon DemeTech sutures ,7 months
Samyang Duracryl sutures
D-Tek sutures
Surgeasy sutures
Ethicon PDS II sutures
OrthoSorb pin
Cellulose acetate Celanese Cigarette filter ,24 months,
Rhodia Textile dependent on
Spectacle frames acetate content
Film media
Wound dressing: ADAPTIC
Bioceta Toothbrush
PCL, ε-Polycaprolactone; PGA, polyglycolic acid; PHB, polyhydroxybutyrate; PHBV, polyhydroxyvalerate; PDO, polydioxanone.
8 POLYLACTIC ACID
Biodegradable polyester
Aliphatic Aromatic
Renewable
PHB/PHV PHB/PHH
Nonrenewable
use as fast-food disposable packaging for hot food and drink. In general,
the development of biodegradable polymers is still in the preliminary
stages and it is anticipated that this will expand in the near future.
Figure 1.5 Plastics industry production in EU28 index years 1992 2017
(EuropePlastic, 2017).
12 POLYLACTIC ACID
2006 16 Compound
Annual Growth
Market Sector 2006 2016 Rate (%)
Food 42,025 71,774 5.5
Textiles 32,176 51,630 4.8
Furniture 13.687 22,993 5.3
Printing 780 1220 4.6
Plastic products 43,500 78,361 6.1
Fabricated metals 1.519 2259 4.0
Machinery 2397 3.658 4.3
Electrical/electronic 13,810 25,499 6.3
Other transportation 9330 16,181 5.7
Vehicles and parts 10,746 15.625 3.8
Other equipment 3852 6334 5.1
Other 21,238 33,569 4.7
manufacturing
Construction 45,886 72,919 4.7
Total 240,947 402,022 5.3
Source: Data from Accenture, 2008. Trends in manufacturing polymers: achieving high
performance in a multi-polar world. Accessed at ,www.accenture.com..
1.3 billion, has banned the use of plastic bags. Major supermarkets do
not provide free plastic bags to their customers. These actions have
helped to save at least 37 million barrels of oil per year. In Europe, sev-
eral regulations have driven forward organic waste management to help
reduce soil/water poisoning and the release of greenhouse gases.
Recycling of biowaste is the first measure to reduce the generation of
methane (a greenhouse gas) from landfills. Directive 1999/21/EC on the
Landfill of Waste requires European Union members to reduce
the amount of biodegradable waste to 35% of 1995 levels by 2016. The
second measure is to increase the use of compostable organic materials,
so that they become useful in helping to enrich the soil. This can help
replace the lost carbon from the soil as emphasized in Directive 2008/
98/EC on Waste (Waste Framework Directive). Following the introduc-
tion of Directive 94/62/EC on Packaging and Packaging Waste, which
imposed requirements for plastic and packaging waste, plastic and pack-
aging waste should now fulfill the European standard EN 13432, with
these materials to be declared as compostable prior to being marketed
to the public (European Bioplastics, 2009).
14 POLYLACTIC ACID
Ireland was one of the first countries to introduce a plastic bag levy.
Ireland’s Department of Environment, Heritage and Local Government
introduced a charge of 15 cents on plastic bags in 2002. This move had
an immediate effect, reducing the usage of plastic bags from 328 to 21
bags per capita. After this encouraging outcome, the Irish Government
increased the levy to 22 cents, further reducing the usage of plastic bags
(IDEHLG-Ireland Department of the Environment, Heritage and Local
Government, 2007). Although biodegradable plastic bags degrade more
quickly than standard ones, the Irish Government did not distinguish
between the two in their laws. However, reusable plastic bags sold in
the shops are exempt from the levy, with the condition that they should
not be sold for less than 70 cents.
Because the use of plastic bags is not entirely avoidable in modern
life, the production of reusable plastic bags made of a
compostable material is recommended, so that disposal will not burden
the environment. As people have become more aware about using
compostable packaging, many companies have tried to make their pro-
ducts at least appear to have such packaging. Consequently, various
types of “eco-packaging” are available in the market. Such eco-plastic
products need to undergo a series of tests to verify their biodegradabil-
ity and compostability. In the European Union, compostable packaging
must fulfill the requirements of EN 13432, while other countries have
their own standard to be met in order to allow the use of a
compostable logo (see Table 1.3). Due to the biodegradability of PLA,
the use of PLA as a packaging material was initially focused on the
market for high-value food and beverage containers and cups, rigid
thermofoams, high-cost films, etc. Although PLA is a biodegradable
polymer material which could replace nonbiodegradable polymers in
packaging applications, the application of PLA as a packaging material
is still very limited due to its higher production cost (Auras et al.,
2004).
The production of biodegradable polymers has increased tremen-
dously over the past few decades. In an overview of the products and
market of bio-based plastics by Shen et al. (2009) known as PRO-BIP
2009, the global output of bio-based plastics was 360,000 MT in 2007.
This represents only 0.3% of the total amount of plastic produced
worldwide. However, the production of bio-based plastics has grown
rapidly, at a rate of 38% annually between 2003 and 2007 (Shen et al.,
2009). Shen et al. (2009) have predicted that bio-based plastic produc-
tion will increase to 3.45 million MT in 2020, and will be primarily
made up of starch plastics (1.3 million MT), PLA (800,000 MT),
Table 1.3 Certification of Compostable Plastic for Respective Countries
By Viola Meynell
By F. Brett Young
MAKING MONEY
By Owen Johnson
L.S.D.
By Bohun Lynch
By William McFee
By Warrington Dawson
By Feodor Sologub
MARTIN SECKER
MCMXVI
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